Rework is Killing Your Margins : How Real-Time Monitoring Can Save You Millions

What is construction rework?

Construction rework involves repeating tasks on-site due to errors, omissions, or non-compliance—without any approved design or scope changes. It reflects a failure to meet quality or specification standards.

Rework drives construction inefficiencies, inflates the cost of construction errors, and erodes profit margins by causing delays, resource waste, and productivity loss.

Examples:

• Reinstalling misrouted plumbing

• Relocating conduits due to clashes

• Rebuilding out-of-spec walls

• Replacing substandard materials

• Correcting MEP work that violates code

Common Causes of Rework in Construction

Understanding the causes of construction rework is critical to improving construction efficiency and minimizing costly delays. Among the most significant factors are design-related issues, which, according to quality.org, account for 40–60% of all rework. These typically include:

• Incomplete or unclear design documentation

• Design omissions or late-stage changes

• Conflicts between architectural, structural, and MEP systems
  
  

  When the design intent isn’t accurately captured or communicated, errors make their way into the field, often requiring costly and time-consuming corrections.

Another major contributor is miscommunication and poor coordination. Rework frequently occurs when teams operate with outdated drawings, unclear documentation, or fragmented workflows.

Lastly, planning failures and human factors compound these challenges. Unrealistic schedules, underqualified labor, and weak supervision can all increase the likelihood of errors. Without strong construction quality control and risk management, even minor mistakes can escalate. Labor fatigue, resource misallocation, and pressure to meet deadlines often result in construction productivity loss and broader project inefficiencies. However, studies show that with proper systems in place, up to 70% of rework can be avoided—unlocking substantial construction cost savings and ensuring smoother project delivery.

How to Reduce Rework in Construction?

Kodifly helps eliminate construction rework through an integrated system of 4D Reality Capture, real-time construction monitoring, and AI-powered analytics—improving construction quality control, efficiency, and profit margins.

Real-Time Site Monitoring with 4D Reality Capture

Kodifly’s SpatialSense hardware captures high-precision spatial data across the construction site using:

• Fixed LiDAR Systems: 240K pts/sec, ±2cm accuracy, 190m range

• Aerial & Handheld Scanners: Full site coverage, including indoor and confined spaces

This enables continuous, centimeter-level monitoring to detect defects and deviations early.

AI-Driven Rework Prevention

Kodifly’s AI performs:

• Automated defect detection and dimensional verification

• Predictive analytics to flag rework risks early

• Material quality checks and tolerance management

Targeted Reduction Across Key Rework Areas

Kodifly reduces rework in all major categories:

• Design-related: Early clash detection, as-built verification

• Quality-related: Real-time monitoring, material compliance

• Process-related: Trade sequencing, environmental tracking

Project Management That Actively Prevents Rework: Kodifly’s SpatialSense

Kodifly’s SpatialSense is a purpose-built, in-house construction project management platform that directly tackles the leading causes of construction rework—from design errors and miscommunication to site coordination failures.

Unlike fragmented tools, SpatialSense combines real-time data, BIM integration, and IoT-powered tracking into one platform—giving construction teams a single, live view of site conditions, plans, and progress.

How It Helps Reduce Rework:

• BIM vs. as-built comparisons catch design deviations before they become costly errors

• Centralized document management eliminates miscommunication across teams

• Real-time asset tracking prevents trade conflicts and improves resource coordination

• Automated safety alerts reduce risks that often lead to rework

By aligning teams around live data, SpatialSense helps ensure that work gets done right the first time—boosting efficiency, reducing construction errors, and protecting project timelines and profit margins.

Kodifly offers a complete, scalable solution to reduce rework in construction, boost productivity, and ensure construction cost savings, from single buildings to billion-dollar infrastructure projects.