Zuhair Haddad - 2nd Annual BIM Conference ME September 2013

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Zuhair Haddad - 2nd Annual BIM Conference ME September 2013

  1. 1. Leveraging BIM in Lean-Based Management of Construction Powered by 1
  2. 2. Presentation Objective Presenter Introduction Our Story Case Study – Abu Dhabi Airport Project (Mid Terminal Building) Case Study – Habshan 5 Brief Demo of C3D Interactive Q&A © CCT Intl. reserves all rights including the rights of disposal such as copying and passing on to third parties
  3. 3. Objective Detail main elements needed to build a successful BIM/Lean-Based Management of Construction Showing how BIM is not only 3D but a combination of : Advanced model authoring Software Tools Data linkage and standards Methodologies Lean Work processes Where we are now with BIM © CCT Intl. reserves all rights including the rights of disposal such as copying and passing on to third parties
  4. 4. Presenter Introduction CIO CORPORATE ASSETS AND RISK MANAGEMENT, Consolidated Contractors Co. Chairman and Chief Software Architect - CCT (Software Arm of CCC Specializing in 3DBased Project Control Software) BSCE California State University Chico California MSCE Construction Management Stanford University 4 years construction experience – CCC 3 years estimation/ IT supervisor Bechtel 28 years experience developing systems and software covering commercial and construction management disciplines Represents CCC at CIFE (Center for Integrated Facility Engineering) Co-supervised PHD research on Using Neural Networks to produce a simulation (optimization) of finishing works in a complex civil/ architectural project (CMU Qatar) Member of Board of Advisors Fiatech Fiatech is an international community of passionate stakeholders working together to lead global development and adoption of innovative practices and technologies to realize the highest business value throughout the lifecycle of capital assets. Awarded Fiatech STAR Award for contribution – 2010 Member of Novel (R&D) Committee IPLOCA Member of Encord 5Di Initiative representing CCT as a software company Autodesk, Bentley, CCT, RIB and Tekla © CCT Intl. reserves all rights including the rights of disposal such as copying and passing on to third parties
  5. 5. Company Introduction Consolidated Contractors Company (CCC) was originally formed in 1952 in Lebanon CCC, based in Athens, Greece, currently employs over 110,000 people in its worldwide operations CCC annual revenue is about US$ 6 Billion CCC is a ISO 14001 and OHSAS 18001 certified company with the highest Commitment to HSE CCC is an ISO 9001:2008 certified company CCC is predominately a construction company, providing project management, engineering, procurement and construction services for Oil & Gas and Petrochemical Works Pipelines Building & Civil Engineering Works Marine Works Maintenance of Petrochemical Installations & Underwater Structures Currently ranked 17th in ENR Top International Contractors (2012) Ranked 1st in the Middle East (2012) CCT is the technology arm of CCC established in 1998 © CCT Intl. reserves all rights including the rights of disposal such as copying and passing on to third parties
  6. 6. Mechanical Projects
  7. 7. Pipeline Projects
  8. 8. Civil Projects
  9. 9. Building Projects
  10. 10. Our Story (1) NCR 1970s until mid 1980s – Introduction to IT Developed core business applications on NCR-mini computers. Included: accounting , HR, payroll, estimation, budgeting, and cost control. 1980s – PC Era and Primavera Established PC Revolution Networks Migration of applications to VAX and then to PCs 1989 to 1998 – The rise of Project Controls Paradigm DAS Island LNG Project Challenge (limited space and huge fabrication scope) Logistics and Material Management Challenge Full Talisman Issued (Project ERP System) CCC captures major fast track mechanical projects with innovative risk sharing strategy. Thus becoming the “C of EPC”. Pyramid: the need to validate progress resulted in introducing lower levels of controls than planning Established need to control progress at Object level development of shop drawing solutions extracted from 3D Models (SpoolGen and Taliso) Material Forward Planning Issued (late 1990’s) EDI Standard Established to import data from 3D mechanical design systems (PDS, PDMS)
  11. 11. Our Story (2) 1999 to 2004 – I need intelligent 3D!! Realized the need for visual systems to access multi-faceted project data CCT Established VBC & C3D development initiated in parallel with traditional applications VBC Release 1 was completed January 2002 (document management with an underlying temporal data structure) 2004 to 2007 – Stirrings of the BIM Era Major shift back to high quality buildings and civil works Establishment of BIM Centers to service high quality building segment/GIS Beta Releases of C3D; tested on project environment around 2007 KM Initiative started 2007 to-date – “The proof of the pudding is in the eating…” We started to harvest Full implementation of VBC and C3D in CCC projects Development of best practices in BIM Implementation Creation of Simulation Department Development of Earthwork simulator/ Development of Crew Optimization Simulator (CIFE) 11
  12. 12. Our Story (3) 2007 to-date – “The proof of the pudding is in the eating…” We started to harvest VBC ATLAS Released - a web-based project handover system Dashboard – one stop shop for reporting and data access Released several mobile solutions (pipeline, timesheet, warehouse managements, etc…) capturing data on location Lean Based Control (C3D Planner Released – a site management tool) Foreman Tool (C3D Planner and ATLAS Integration) C3D Android beta released – the first step toward site updates Ambitious Implementation of BIM Solutions on Midfield Terminal Building (Abu Dhabi Airport Project) C3D Interactive (C3D for the masses) released – easy to use 3D data integration tool for non-techy users Moving to the Cloud 12 © CCT Intl. reserves all rights including the rights of disposal such as copying and passing on to third parties
  13. 13. The CCC Full Project Controls
  14. 14. Project Control Strategy Reliant Pull-Driven Technique optimize supply chain rather than sub optimization Assure availability of resources before start of activity. Emphasize productivity through the full work chain vs. individual activities Prevent sub-optimization Partnering Proper Project Work Breakdown Structure Project/Area/SubArea/Fragnet/Activity/Object/Operation Integrated EPC schedule with Emphasis on Handover and Construction Activities. (effective supply chain) 3D model built with WBS in mind and used as primary scope management tool. Early on Cooperation with the Partners/ EDI definition. 3 Month Look Ahead Schedule/ Material forward plan 3 weeks Look Ahead Schedule
  15. 15. Case Studies © CCT Intl. reserves all rights including the rights of disposal such as copying and passing on to third parties
  16. 16. Case Study 1 Earned Value Management using C3D Midfield Terminal Building (MTB) © CCT Intl. reserves all rights including the rights of disposal such as copying and passing on to third parties
  17. 17. C3D Implementation Steps 1 2 3 4 5 • Import BIM 3D model • Importation of MTO • Link 3D objects to baseline Activities • Assign 3D objects to related progress operation templates • Update progress 17
  18. 18. C3D Implementation Steps 1. BIM 3D Model 18
  19. 19. C3D Implementation Steps 2. Import MTO 19
  20. 20. C3D Implementation Steps Level – 1 • Work Type • Construction or Engineering Level – 2 • Building • Central Area , Piers Level – 3 • Floor • Lower Basement, Apron or Arrivals level Level – 4 • Work Discipline • Concrete, Pluming or Electrical Discipline Level – 5 • Activity • DCPB2SDV035511068 CSP - INSTALLATION OF PRECAST WALLS (AREA D) • • Level – 6 (Object Level) • MTB_BuCP_B2_STR-CON_COL-C5423 Level – 7 (Operations Level) • F/W Shuttering • Rebar • Pour Conc. • F/W Strike • Punch List
  21. 21. C3D Implementation Steps 3. Link object to baseline activity
  22. 22. C3D Implementation Steps 4. Object to progress template assignment
  23. 23. C3D Implementation Steps 4. Progress Update • Work Type • Construction or Engineering Level – 1 • Building • Central Area , Piers Level – 2 • Floor • Lower Basement, Apron or Arrivals level Level – 3 • Work Discipline • Concrete, Pluming or Electrical Discipline Level – 4 • Activity • DCPB2SDV035511068 CSP - INSTALLATION OF PRECAST WALLS (AREA D) Level – 5 • • Level – 6 (Object Level) • MTB_BuCP_B2_STR-CON_COL-C5423 Level – 7 (Operations Level) • F/W Shuttering • Rebar • Pour Conc. • F/W Strike • Punch List
  24. 24. C3D Implementation Steps 4. Progress Update (Construction Act.)
  25. 25. C3D Implementation Steps 4. Progress Update (Engineering Act.) 50% 25 30% 20%
  26. 26. EV Calculations C3d Cost loading Percentage Completion per Each Activity Total Cost & Man_Hours per Activity X Total Earned Value for Activity Activities are sorted per ADAC L6 & L7 EV per ADAC L6 & L7
  27. 27. Conclusion
  28. 28. Sample Reports
  29. 29. Future: 3 Week Look Ahead Meeting Project Engineers Site Engineer Work-packaging Forman Update Progress All rights reserved to CCC 29
  30. 30. Visual Project Controls of Plant Construction Case study – Habshan 5 3D-based work-packaging Powered by
  31. 31. C3D Visual Project Controls Work Packages Definition Aggregation What if Scenarios/Queries/Algorithms Erectibility Study 3D Model Piping Equipment Progress Data Steel WBS Objects Templates Cable trenches Pipe Detailing Spools Joints Test Packs
  32. 32. Applied Workface Planning C3D Visual Project Controls Define Field Work-packages: Create small, well defined, Field Installation Work Packages (FIWP) for the construction workforce using C3D Volumes and Aggregations. Define FIWP constraints: Each FIWP has a standard list of constraints that must be satisfied prior to the work being released (example. Use C3D Relations and Queries to fetch these constraints i.e. a list of all of the things that a Foreman will need to execute the work: drawings, materials, scaffolds, steel structure etc. Use C3D to monitor and manage FIWPs: C3D to Produce an Erectibility Study to visualize results through a 3D view of: what we should be doing next (the target schedule). what we could be doing next (information, equipment, resources and materials). what we are doing next (actuals/reality).
  33. 33. Divide Project into work packages
  34. 34. Project Division into work packages Areas and Sub areas are often very large to analyze Divide the subareas furthermore to work packages through 3D volumes and aggregations. Section of a Piperack Around equipment substations, building etc… Define Typical Fragnets for each subarea (standard sequence of work) Foundation Structural Steel Scaffolding Equipment Piping Electro-mechanical Load / Analyze each package separately
  35. 35. Example Area 1601 Sub area 160 1-a1
  36. 36. Subarea 1601-a1: Division into work Packages (WP) W P: K O D W P: PS L WP: PR 03 W P: PR04
  37. 37. 6 Units divided into 25 work packages 6 Units divided into 25 work packages
  38. 38. FIWP Steel Structure
  39. 39. FIWP Pipe Racks Definition Pipe racks in 3D are modeled as one ‘piece’. Divide Pick Racks into steel structure packages(ST). (designer, fabricator) If ST packages are not tagged: assign a tag for them. PR 004 7 PR 005 0
  40. 40. Define FIWP Constraints Loading per ST package Selecting only specific ST packages to be loaded Analyze each discipline per ST package: Piping, scaffolding, cable trail etc.
  41. 41. Steel Structure Package Progress The Steel structure package progress is linked to the 3D model Packages are assigned a color according to a legend: Not Started In Progress Done
  42. 42. Scaffolding
  43. 43. Scaffolding representation Scaffolds are represented in the 3D model as ‘blocks’. Each block is tagged and assigned attributes such as: – Scaffold type, level, tag no Scaffolding Blocks
  44. 44. Scaffolding Representation Scaffolding progress linked to each level in the package Target spools (pipes) based on their levels in case: Different crews are responsible of different pipe rack levels. Scaffolding is not yet present at particular elevations Scaffolding not yet ready Scaffolding ready
  45. 45. Piping FIWPs Spools/Field Runs Assignment
  46. 46. Spool layout Area
  47. 47. Defining FIWPs Spools & FRs assignment An isometric span relatively a large area making it difficult to identify the exact location of the spools/field runs. Assign each spool to its related package. In case the spools is located in a ST package add its level in it.
  48. 48. Defining FIWPs constraints Intelligent Batching: Engineering
  49. 49. Define Field (Site) priorities Field Prioritizes based on: Project Schedule Steel Structure availability Equipment installation Piping continuity, space constraints and connectivity. C3D Gives each Package Volume a priority tag between 1 and 6 based on above.
  50. 50. Manage FIWPs Constraints Allocate material and resources Allocate needed material to Defined Work packages On rare conditions, material is allocated to higher priority Work Package Direct Link to Stores and Site Material Management System.
  51. 51. Evaluate – Spools Status Colorize Spools by Actual Status
  52. 52. Fabrication The main purpose is to target those spools whose fabrication will lead to proceed with the line continuity and expand the work front for site engineers. Spool in site lay down area Spool to be painted Spool in Fab shop Erected Spool
  53. 53. Equipment
  54. 54. Equipment & Spools Displays all the erectable spools on each nozzle.
  55. 55. Sample Work Order: Spool erection
  56. 56. Weekly Tracking Report
  57. 57. Results and Achievements
  58. 58. Results and Achievements HAB5 Hab5 Weekly Progress Field Inchdia 1600 Field Inchdia 1400 1200 50 1000 40 30 20 800 After Applying the ES 600 Before Applying the ES 400 10 Num Of Welders 200 0 12-Mar-11 19-Mar-11 26-Mar-11 02-Apr-11 09-Apr-11 16-Apr-11 23-Apr-11 30-Apr-11 07-May-11 14-May-11 21-May-11 28-May-11 0 54 55 56 57 58 59 60 61 62 63 64 65
  59. 59. Results and Achievements SAS Field Inchdia SAS Weekly Progress Field Inchdia 1400 1200 1000 800 600 400 200 0 After Applying the ES Before Applying the ES
  60. 60. Results and Achievements QFD Field Inchdia QFD Weekly Progress Field Inchdia 6000 4000 2000 0 After Applying the ES Before Applying the ES
  61. 61. Future work
  62. 62. Back to the future Spool in site lay down area Spool to be painted Spool in Fab shop Erected Spool
  63. 63. Back to the future
  64. 64. The CCC Full Project Controls
  65. 65. Conclusion Implement C3D Planner
  66. 66. Live Demo
  67. 67. Thank you, See you at our Booth Powered by 68

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