A Ghanaian researcher based at The Hong Kong Polytechnic University has gained international recognition for research that could improve the safety and efficiency of modular construction worldwide.

Mr. Sulemana Fatoama Abdulai of Ghana, working with Dr. Ridwan Taiwo of Nigeria and international collaborators, has published a study on modular integrated construction (MiC) that was selected as an Editors’ Choice by the American Society of Civil Engineers.

The research, published in the Journal of Construction Engineering and Management, focuses on one of the industry’s biggest challenges: achieving precise alignment of prefabricated building modules during installation.

Modular construction allows buildings to be assembled faster and with less waste, but even small alignment errors of one to three millimetres can affect structural safety and performance.

“Module alignment precision is critical for structural stability,” Abdulai said. “Misalignment can lead to gaps, uneven load distribution and long-term safety risks.”

The study, titled Hybrid Statistical Analysis of Critical Alignment Factors in Modular Integrated Construction, analysed 18 factors that influence alignment accuracy.

Using expert input and advanced statistical methods, the researchers grouped these factors into four areas: module design and features, worker-related issues, equipment condition, and weather.

The condition of rigging equipment emerged as the most consistent factor affecting successful alignment across different projects.

Dr. Taiwo said the findings are especially important as governments and developers turn to modular construction to address housing shortages and climate change.

“The construction sector accounts for about 39% of global greenhouse gas emissions,” he said. “Modular construction can reduce that impact, but only if assembly is reliable and precise.”

The researchers say applying their findings could cut construction costs by up to 30%, reduce delays and limit the need for costly on-site rework.

The work has attracted interest from construction firms and researchers in Hong Kong, mainland China, Singapore and parts of Europe, where modular construction is expanding rapidly.

The research team includes Professor Tarek Zayed, Abdulai’s PhD supervisor, and Ali Hassan Ali, both of The Hong Kong Polytechnic University.

Abdulai said future studies will explore how technologies such as sensors and artificial intelligence can further improve alignment accuracy.

“This is practical research meant to solve real problems on construction sites,” he said.