The extensive utilization of rebar during the construction of the project generates immense rebar waste, leading to increased construction costs and significant greenhouse gas emissions. Various approaches have been explored focusing on the minimization of rebar-cutting waste, such as optimizing cutting patterns, lap splice position, and special-length rebar utilization. Nonetheless, reducing rebar usage by minimizing the number of splices remains uninvestigated. In response to these issues, a two-stage optimization algorithm was developed, prioritizing special-length rebar to achieve near-zero rebar-cutting waste of less than 1% and concurrently reduce rebar usage, thereby promoting sustainable construction practices. The two-stage algorithm presented in this study involves the optimization of the lap splice position for the continuous rebar with a reduction of splices number. Furthermore, it integrates a special-length minimization algorithm for the additional rebars. Applying the algorithm to beam structures in a small-sized factory building project led to a notable reduction of 29.624 tons of rebar, equivalent to 12.31% of the total purchased quantity. Greenhouse gas emissions were reduced by 102.68 tons, and associated costs decreased by USD 30,256. A rebar-cutting waste of 0.99% which is near zero was achieved. These findings highlight the significant potential of the proposed algorithm in reducing rebar waste and facilitating sustainable construction practices. In addition, the application of the proposed algorithm in reinforced concrete construction projects will amplify the associated advantages accordingly.

Reducing the construction time for large logistics buildings can result in reduced construction management costs and economic gains from early operation. A large logistic building with a heavy load and long spans was constructed as a precast concrete (PC) structure, which requires the use of a sizable crane to lift heavy PC members. A basic analytical approach is employed to resolve potential errors in the planning of PC member erection and to build a systematic erection plan. Calculation techniques for the trajectory distance, which use the crane location, are applied to select an erection plan that minimizes crane work. A crane trajectory distance calculation algorithm for sustainable PC member erection in large logistic buildings with heavy loads and long spans has been developed. The developed model aids in creating simulation and optimization models to ensure minimal usage of cranes in the future and determining cost, construction time, CO2 emissions, and energy use for each erection plan.

The construction of reinforced concrete (RC) structures inevitably consumes an excessive number of rebars, leading to significant cutting waste and carbon emissions. Extensive research has been conducted to minimize this issue and its consequences; however, these methods consistently consume a substantial number of rebars. This includes a previous study that utilizes the lap splice position optimization and special-length rebar concept without considering the lapping zone regulation. Moreover, conventional lap splices pose inherent drawbacks that could jeopardize the structural integrity of RC members. In contrast, mechanical couplers eliminate the need for rebar lapping, effectively reducing rebar consumption. This research aims to evaluate the impact of an integrated mechanical coupler and special-length-priority minimization algorithm on the reduction in rebar consumption and cutting waste in RC columns, achieving near-zero cutting waste. To validate the effectiveness of the proposed algorithm, it was applied to the column rebars of an RC building. The results revealed a significant reduction in ordered rebar consumption by 18.25%, accompanied by substantial reductions in cutting waste (8.93%), carbon emissions (12.99%), and total costs (10.81%) compared with a previous study. The outcomes provide the industry with insights into further reducing rebar consumption and its related consequences. Applying the proposed algorithm to various construction projects will further amplify the corresponding benefits.

The construction industry generates significant CO2 emissions, and rebar is a major contributor to this environmental impact. Extensive research has been conducted to address this issue. Recent advancements have introduced algorithms to reduce rebar waste and consumption, demonstrating the feasibility of achieving near-zero rebar cutting waste (N0RCW) by considering special-length rebars. However, conventional lap splices, the most common rebar joint method, consistently consume excessive rebar quantities despite extending beyond their mandated zones. Conversely, couplers eliminate rebar lengths required for lapping splices, reducing the usage of rebar. Applying special lengths and couplers in heavily loaded structures like diaphragm walls can significantly reduce rebar usage and cutting waste, consequently reducing CO2 emissions and associated costs. This study aims to optimize rebar consumption and sustainability in diaphragm wall structures by integrating mechanical couplers with a special-length rebar approach. A case study confirmed a substantial reduction in purchased rebar usage (17.95% and 5.38%) and carbon emissions (15.24% and 2.25%) compared to the original design and previous study, respectively. Broadly implementing the proposed method across various buildings and infrastructure projects could further multiply these benefits, fostering the achievement of SDGs adopted by the United Nations for sustainable construction.

In reinforced concrete (RC) structures, splicing is required owing to the length limitations of rebars, insufficient lengths, and transportation issues. In particular, splices connect the rebar of RC structures such as walls, columns, beams, slabs, and joints. Lap splices are the most commonly used method worldwide because they do not require specific equipment or skilled workers. However, lap splices incur high construction costs because of the long splice lengths required for large-diameter rebars in megastructures, as well as issues pertaining to material supply, labor costs, constructability, and project duration. Additionally, approximately 15% more rebar is required because of the overlap. Energy saving for a sustainable built environment is possible if the disadvantage of lap splices, which generate high CO2 emissions due to the excessive use of rebar, are resolved. Hence, mechanical rebar couplers (MRCs) have been developed. However, despite their advantages, they have not been widely applied in construction sites owing to concerns regarding safety, quality, and constructability. Although various MRCs have been developed, most studies focus only on their structural performance. Therefore, a data-driven approach for selecting MRCs based on the reinforcing bar shape and structural characteristics is proposed in this study. Using a data-driven MRC selection algorithm, using the T-threaded coupler for one rebar over two floors resulted in 56% more efficient labor productivity, 15% shorter assembly time, 17% lower costs, and 26% lower CO2 emission. Using a developed algorithm, the appropriate MRC can easily and rapidly be selected for frequent design changes.

Rebar quantity estimation is pivotal for determining the cost of construction projects and essential for bidding purposes. A bar bending schedule plays a crucial role by providing rebar information and bending instructions, facilitating efficient procurement. Traditional methods of bar bending schedules, which involve manual extraction from 2D (two-dimensional) drawings, are error-prone and hinder construction productivity. This study proposes a Building Information Modeling (BIM)-based algorithm that automates the generation of a Bar Bending Schedule (BBS) directly from the 3D (three-dimensional) BIM models, ensuring accuracy and eliminating manual errors. The effectiveness of the algorithm was verified by comparing the rebar quantities generated by the model against those derived from optimization calculations. The results demonstrated a mean absolute error of 0.017 and a mean absolute percentage error of 1.13%, validating the algorithm’s precision. Additionally, it achieved a remarkable 33.33% reduction in the manpower required for preparing BBSs, highlighting its potential to revolutionize construction workflow efficiency and accuracy.