Zuhair Haddad - 2nd Annual BIM Conference ME September 2013

Leveraging BIM in Lean-Based Management
of Construction
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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

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


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

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

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)

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

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

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

Case Studies


Case Study 1
Earned Value Management using C3D
Midfield Terminal Building (MTB)


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

1. BIM 3D Model

18

2. Import MTO

19

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

3. Link object to baseline activity

4. Object to progress template assignment

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

4. Progress Update (Construction Act.)

4. Progress Update (Engineering Act.)
50%

25

30%

20%

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

Future: 3 Week Look Ahead Meeting
Project Engineers

Site Engineer
Work-packaging

Forman
Update Progress

All rights reserved to CCC
29

Visual Project Controls of Plant
Construction
Case study – Habshan 5
3D-based work-packaging
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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

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).

Divide Project into work
packages

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

Example Area 1601

Sub
area
160
1-a1

Subarea 1601-a1: Division into work Packages (WP)

W
P:
K
O
D

W
P:
PS
L

WP:
PR 03

W
P:
PR04

6 Units divided into 25 work
packages

6 Units divided into 25
work packages

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

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.

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

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

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

Piping FIWPs
Spools/Field Runs Assignment

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.

Defining FIWPs constraints
Intelligent Batching: Engineering

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.

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.

Evaluate – Spools Status
Colorize Spools by Actual Status

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

Equipment & Spools
Displays all the erectable spools on each nozzle.

Sample Work Order: Spool erection

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

Results and Achievements SAS

Field Inchdia

SAS Weekly Progress Field Inchdia
1400
1200
1000
800
600
400
200
0


Results and Achievements QFD
Field Inchdia

QFD Weekly Progress Field Inchdia
6000
4000
2000
0


Back to the future

Spool in site
lay down area

Spool to be
painted

Spool in Fab
shop

Erected
Spool

Conclusion
Implement C3D Planner

Thank you,
See you at our Booth
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Zuhair Haddad - 2nd Annual BIM Conference ME September 2013

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