Precast Design Flaws: A Case Study on Coordination Issues in Saudi Arabia Residential Villa Project

Abstract

This case study investigates a precast concrete residential villa project in Saudi Arabia that faced significant setbacks due to coordination failures. Although precast systems offer advantages such as faster construction timelines and enhanced quality control, the project encountered substantial delays, design inconsistencies, and cost overruns. Major issues identified included incomplete Issued-for-Construction (IFC) drawings, limited use of Building Information Modeling (BIM), inadequate communication among project teams, and the assignment of inexperienced personnel to critical design tasks.

Survey results revealed that design-related coordination issues were responsible for over 90% of the observed rework, with 48.4% of respondents estimating that more than 6% - 8% of the total project cost was lost due to rework activities. Furthermore, 80.6% of participants reported productivity losses exceeding 50%, with some cases reaching up to 300% impact on schedule. These findings were supported by document reviews and stakeholder interviews, which highlighted misaligned precast elements and uncoordinated revisions as recurring challenges.

This study reinforces the importance of clear communication, rigorous design verification, and digital integration in precast construction. It advocates for the full implementation of BIM tools, structured workflows, and proper staff training to reduce the risk of costly errors. The insights drawn from this case offer valuable guidance for future projects, stressing the need for proactive coordination and digital collaboration to ensure the success of prefabricated systems.