Automated BIM-Integrated 3D Laser Scanning Framework for Shape Quality Control of Precast Concrete Members: Production-Scale Validation with IFC-Linked Tolerance Evaluation and Rule Engine Architecture

Precise dimensional conformity of precast concrete members is critical for structural performance and on-site assembly accuracy, yet conventional manual inspection remains labor-intensive and unable to scale with modern production-line throughput. Existing scan-vs-BIM approaches address geometric verification in principle but are constrained by manual registration dependencies, the absence of machine-readable IFC-linked tolerance criteria, and limited validation under real factory yard conditions. This study presents a production-scale automated shape quality control (SQC) framework that closes all three gaps simultaneously. A purpose-designed two-point target device enables fully automated, repeatable registration seed-point extraction. A formal IFC property-set-linked rule engine architecture—comprising entity extraction, deviation computation, rule interpretation, and pass/fail decision stages—replaces ad hoc script-based tolerance checking with an interoperable, auditable compliance pipeline. Factory-scale validation on precast arch segments (n = 10) and wall panels (n = 12) achieved registration RMSE of 1.25–1.95 mm, pass rates exceeding 91%, and a 37.1% reduction in inspection time versus manual methods (95% CI: 34.5–39.6%; p < 0.001; Cohen’s d = 3.89). Repeatability testing yielded ICC = 0.971 and Bland–Altman limits of agreement of [−0.45, +1.07] mm. The framework represents a substantive step toward fully digital, production-integrated quality management for industrialized precast construction.