deliveringthe gigafactoryinteslatime using hd bim

Delivering theGigafactory in Tesla Time

Using HD BIMGregory P. Luth, Ph.D., SE, SECB

Gregory P Luth & Associates, Inc.,

Santa Clara, CA

#BIMForumED© 2017 Gregory P Luth & Associates, Inc All rights reserved

o Provide motivation and rational for design practice change

o Define “High Definition BIM” (HD BIM) as opposed to “Conventional BIM”

o Provide an overview of vision for 21st century design-construct-own process

o Provide an overview of 9 case studies of illustrating the development and

evolution of structural HD BIM over the past 11 years

� Design strategies and work practice

� Shop drawing strategies and work practice

� Constructibility strategies and work practice

o Lessons Learned

o Final Thoughts

2Objectives and Outline of Presentation


We believe that the best design is one in which all the important decisions

regarding, materials, means, methods, sequences, and schedules are made

during the design when all the impacts and costs project wide can be

considered and when the design itself can be altered to optimize schedule,

quality, cost and supply chain issues

In light of the potential offered by the digital revolution, the traditional

design process is an anachronism that we can no longer afford because too

many of the critical decisions are left for the construction team to sort out

after the design has been “finalized”

3Motivation and Rationale for Change


High Definition Building Information Modeling (HD BIM)

HD BIM is a process utilizing a Building Information Model containing the

high level of detail and precision necessary to visualize, design, detail,

fabricate, and install all elements of a building with sufficient reliability

that the interaction of elements, the sequence of construction, and the

labor activities can be defined and planned to a level of granularity similar

to manufacturing.

This is currently achievable for the structural subsystems in a building,

but requires a change in the current standards of practice.

4HD BIM Definition


HD BIM Principles

• One federated BIM model, live on the cloud, with all

disciplines visible to each other during authoring,

• Incorporates final construction knowledge and details

• Handed off to Facility Management

• Used as repository of data and knowledge for the life cycle

5HD BIM Principles


20th Century Design and Construction

• Specialization produces silos of knowledge

• Litigation produces silos of responsibility

• Process produces paperwork

6


21st Century Design and Construction – Virtuous Cycle

• Knowledge creates master builder renaissance

• Integrated teams and processes lead to hyper-efficiency

• Big Data provides transparent life cycle processes

7

8Conventional BIM VS HD BIM


Case Study 1 – USC School of Cinematic Arts, 2006 -2010

USC School of Cinematic Arts – Phase I

9



USC seismic damage control system

Rocking concrete walls:

• Concrete substrate for facade

• Ductile linked shear walls

• Pivoting shear panels

• Replaceable steel fuse

10



Anchor Bolts

� 5 – 1” Anchor Bolts Embedded 40”

� Transfer Overturning Tension to Foundation Walls

� Steel and concrete in the same model for coordination

USC LOD

With design HD BIM vs construction HD BIM,

you get all the pieces in the same model for

coordination during design

11



MEP Coordination

USC Phase II Federated Model

Note that the architectural and MEP models are

overlaid on the structural model during authoring

These are screen shots of the structural design model

which is being used for steel shop drawings, rebar shop

drawings (by EOR), and light gage stud framing shop

drawings

Architectural Coordination

12


Case Study 1 – USC School of Cinematic Arts, 2006 -2010 13

Case Study 2 – California Veterans Home 2010 - 2011

2 story steel administration

building

1 story steel maintenance

building

20 one story wood residential

“neighborhoods” comprising 1

million sq ft of managed elderly

care

Prefabrication intent thwarted

by industry inertia

14

Lateral System –

Diaphragms & Collectors

Real Construction &

Virtual ConstructionGarden Entry Truss

15Case Study 3 – Casino Hollywood, Toledo, Ohio, 2010 – 2011


Case Study 3 – Casino Hollywood, Toledo, Ohio 2010 - 2011

400,000 sq ft of casino, 3100 car, 5 level, PT

parking garage. Construction document phase

started July 2010, pile driving started

September, 2010. GPLA produced all rebar shop

drawings and turned Tekla model over to steel

detailer

Design start: July 2010

Foundation start: September, 2010

Casino open: May, 2012

18 months design start to construction finish

16

Case Study 3 – Casino Hollywood, Toledo, Ohio 2010 - 2011 17


“This project has elevated our BIM experience to a new level. Our

superintendent was referring to the latest model on a daily basis. He was able to

use an IPAD to bring the web accessed model out to the field and share it with the

crew. When the field crew starts asking to view the model, it gets the attention of

everyone. Even subcontractors that have never used it before were on board.”

– Ryan Bannister, Rudolph-Libbe, BIM Manager

“Ordinarily, the rebar shop drawings are detailed from documents that are a

month old and frequently changing. Keeping the field updated with information is

a challenge. On this project, the web model updates were available immediately,

so we looked at it every morning before we started work. The shop drawings,

coming directly from the EOR, were even better than the model – the best

information on the job.”

– Mike Keane, Rudolph-Libbe, General Superintendent

18Case Study 3 – Casino Hollywood, Toledo, Ohio, 2010 – 2011

Case Study 4 – Isle of Capri Casino, Cape Girardeau, Missouri 2011 - 2012 19

Case Study 4 – Isle of Capri Casino, Cape Girardeau, Missouri 2011 - 2012

Details:

•160,000 square foot casino

•near New Madrid fault - high seismic

•long span over independent floating barge

•complex architectural theming elements

•SEOR provided steel and rebar shop

drawings from HD BIM model

20

Case Study 4 – Isle of Capri Casino, Cape Girardeau, Missouri 2011 - 2012

Self-centering post tensioned rocking frames with fused moment trusses HiDef BIM level of detail

Slit Shear

Plate Fuse

Rocker

PT Rods

Uplift

Base

Rebar

Bond

Breaker

PT

Anchor

21

Rebar modeling and Shop Drawings by EOR accelerates the schedule and

results in higher quality end product. 2000 yd pour with 250 tons of rebar

starting at 7 pm 2 weeks after award of concrete contract. Photo at noon.

Case Study 4 – Isle of Capri Casino, Cape Girardeau, Missouri 2011 - 2012 22


- 1 million square feet of light gage walls and associated roofs

- Free-standing concession and restrooms on 5 decks, design-build by GC

- GPLA design for hurricane, customized details for prefab, and prepared shop drawings

- Design, fab, install completed in 10 months avoiding $10 million LD’s

Case Study 5 – Daytona Rising, Daytona, Beach, Florida 2013 - 2014 23


Case Study 5 – Daytona Rising, Daytona, Beach, Florida 2013 - 2014

Objectives:

- Prefabrication

- Reduce cost

- Aggressive schedule

Constraints:

- Layout had to be developed based on Tekla model of

field measured existing steel locations and slab

elevations

- Prefabricated panels had to accommodate all MEP

openings and hardwarePrefabricated Panelized Plumbing Walls

24

Case Study 6 - Yale University Residential Colleges, New Haven, Connecticut, 2014 - 2015

- 600,000 sq. ft. of new 5 story concrete construction

- Service to Owner

- HD BIM services in collaboration with the design team

Scope included:

- Rebar constructability review of contract documents

- Rebar modeling

- Quantity check

- Rebar shop drawings with bar list in format dictated by the

rebar subcontractor

Unit Price Rebar :

- CM/sub estimate 90% drawings low 3200 tons high 4800 tons

- Initial 6 week model – 2500 tons (basis for unit price)

- Final shop drawings – 2900 tons (paid at unit price)

Modeling and Shop Drawing Effort:

- Architectural changes 400 CCD’s

- Hours spent modeling and producing shop drawings - 12000

25

Case Study 6 - Yale University Residential Colleges, New Haven, Connecticut, 2014 - 2015 26

Case Study 6 - Yale University Residential Colleges, New Haven, Connecticut, 2014 - 2015

Example Issue:

- 15,000 lineal feet of 10x24 beams

- 2#10 top continuous and 2#9 bottom

continuous beams through 10x24 columns

- #3 @ 3” closed stirrups

The use of industry standard details resulted

in:

- Lap splices increased tonnage 50%

- Rebar cages had to be assembled in place

- Heavy hooked bars from both directions

were impossible to place in the corners

All of these problems were

eliminated by changing 1 typical

detail to improve constructability

while preserving structural

integrity

ORIGINAL DETAIL

GPLA DETAIL

27


July 29, 2016 Casino Complete

Case Study 7 – Hollywood Casino Jamul, San Diego, California 2014 - 2016 28


- 3-story casino above 8-story parking garage

- Partially embedded in hillside

- Rebar, stair & structural steel shop drawings

from same model by SEOR

Case Study 7 – Hollywood Casino Jamul, San Diego, California 2014 - 2016

Enabling concept: build upper 3 floors on 90

ft tall stilts first and finish casino interior

while building parking to reduce schedule by

7 months

29


Case Study 7 – Hollywood Casino Jamul, San Diego, California 2014 - 2016

January 1, 2015 Excavation complete

April 3, 2015 Early walls steel erection

HD BIM Model Early Walls & Stilts

July 10, 2015 steel erection complete July 10, 2015 PT slab level 2 in progress

30


Case Study 8 – Tesla Gigafactory, Sparks, Nevada, 2016 - 2017

5 Buildings, 3.8 million sq ft, 2 floors and roof, all composite steel & concrete on deck.

Gravity and lateral framing uncoupled to accelerate mill order and fabrication for 90% of steel.

First use of innovative fused strongback BRB seismic system

Schedule: start design April 15, 2016, order steel May 5, start steel fab June 6, start steel erection July 6,

complete steel erection November 15, release to process March 2017

31

Example: (for 3.4M sf!!)

• Model 3 Launch – Day 1…pre-orders climb to 400,00

• Steel Mill order: Day 48 (enough design was done to start…)

• Break Ground: Day 86

• First Pick (Steel Erection): Day 116

• MEP Initial Design: Day 155

• Room Turnover: Day 310 (10 months)

From John Vardaman,

Senior Construction Manager

September, 2016

Case Study 8 – Tesla Gigafactory, Sparks, Nevada, 2016 - 2017 32

How?

Integrated delivery – Electrical, Plumbing, Mechanical, and

Construction Administration all in house (Tesla). Where we don’t

have enough horsepower or expertise, we bring in great partners

like GPLA and have full transparency inside Tesla Motors, Inc

From John Vardaman,

September, 2016



Keys to Success

• Use design strategy with interleaved activities to complement construction schedule

• Focus on design critical path – order steel ASAP, complete design & shop drawings by time

steel arrives plant, use bolted field connections, develop prefab exterior wall to weather

proof fast

‾ Develop robust lateral system to accommodate changes

‾ Develop simple but robust gravity system that can be extended and modified easily (lots

of shear studs)

‾ Uncouple lateral and gravity for design and erection

• Use integrated design, detailing, and fabrication team using same cloud-based Tekla model

with detailers under the control of the structural engineer (change management)


Key Structural Engineering Objectives & Pre-requisites

1. Get steel into the fabrication shops

a) Complete steel design, complete 3D modeling of gravity system, and

extract mill order from model

2. Supply fabrication shops with shop drawings

a) Extract shop drawings from design model

3. Submit drawings and calculations for permit

a) Complete building design, including foundations, assemble

comprehensive calculation package including documentation of global

analysis for gravity and seismic forces and design calculations for each

element of the building


Key Structural Milestones (first 50 days)

� Day 1 Phone call

� Day 7 issue Building F structural model and bid set (“Frankenset” is a

combination of new and old drawings) to fulfill corporate policy of

competitive bid

� Day 21 Issue mill order for Bldg F steel to procure (from Belgium) and get in

the shop ASAP

� Day 23 Start design buildings D’ and E’ (redirection)

� Day 30 issue mill order for Bldg D’ & E’ steel

� Day 43 issue “structure only” permit set D’ & E’ with comprehensive design

calculation package

� Day 50 Issue D’ & E ‘ foundation rebar shops


Structural Engineering Strategies to Support Schedule

1. Concurrent editing of SAME cloud-based model by team

2. Issue construction drawings prior to permit drawings and calcs

3. Three structural teams providing HD BIM design

• Design/modeling team (GPLA) – concept & mill order

• Analysis team (Exponent Failure Analysis) – permit calcs

• Detailing team (DGI & BDS Vircon) – shop drawings

4. Uncouple gravity and lateral systems for design – issue gravity (80% of steel) ahead of

seismic system steel

5. Provide high performance gravity system with double bay at 3rd floor and robust slab

for 350 psf and fork lift traffic

6. Provide performance-based seismic design for superior performance, economy, and

repairable damage in maximum EQ field bolted for minimum erection time

7. Panelize wall system design and integrate MEP supports


Seismic Frames BRB-SB-KF on Exterior of Building F


Rocking Fused

Strongback Frame Field Bolted FrameRocking

Strongback Frame

Krawinkler Fuse


Details For Uncoupling Design with Robust Connections


Level of Detail in Design Model & Gravity Enabling Details


Federated Tekla Model - All

MEP Pipe Hangers Spot Cooler Support Structure

Federated Tekla model – MEP & S


Modular

Catwalk



September 15, 2016 Building D’ Steel Complete



Gigafactory Top Out November 7, 2016

5 Buildings

3.5 million Square Feet

32,000 tons of structural steel

2500 tons of rebar

All steel and rebar shop drawings from GPLA HD BIM model

7 months from first phone call



Building G Stamping Presses and Injection Molding

Kick-off January 26, 2017



48

Tesla Gigafactory Area G – Progress 5/31/2017

Case Study 8 – Tesla Gigafactory, Sparks, Nevada, 2016 - 2017


49Case Study 8 – Tesla Gigafactory, Sparks, Nevada, 2016 - 2017

Tesla Gigafactory Area G – Progress

6/17/2017 – 9/5/2017 Stamping Press Pit


50Case Study 8 – Tesla Gigafactory, Sparks, Nevada, 2016 - 2017

Tesla Gigafactory Area G – Progress 9/29/2017 – 11/2/2-17


51Case Study 9 – Water Wind Sky, Seattle, Washington, 2017 – 2018

4 over 2 residential podium construction. All wood

members modeled. We need an interface with panel

software like Mitek to be able to automatically generate

panel drawings from Tekla model


o Working in a live model with reference models for coordination is a HUGE

advantage, because it is so hard to coordinate by looking at the federated model

and then going back to your stand alone model to make revisions

o Copying a model is infeasible – its significantly faster to author a model from

scratch, which is why subcontractors can never “match” a design model

o Seeing something in a federated model is not the same as having the final

dimensions and location

o Working in the same cloud based model with detailers preparing shop drawings

contemporaneously in the same model is no only possible, its 10x more efficient

than servicing 2 models – redundant data is ALWAYS a problem

o Constructibility knowledge is gleaned from all levels of the construction team – the

knowledge you get from a PM, a superintendent, a foreman, and a laborer differs

significantly

52Lessons Learned


o We REALLY REALLY need a FACILITY DATABASE that is authored jointly by all. Our

authoring software should be a two way interface with the database that permits

interdisciplinary viewing and referencing of the data.

o THE MODEL IS NOT THE DATA. The model is one way to the view the data, is extremely

useful if it is dimensionally accurate, and is of limited use if it is not dimensionally

accurate

o There are overlaps in the data that should be automatically modeled using constraints.

When a duct or pipe penetrates a slab or a beam, the duct or pipe size is not the

information the structural engineer and contractor need. The information the

contractor and engineer need is the required shape, size, and location of the hole.

“Look in the model” is not an adequate response to a request for that information.

These holes should be modeled as part of the mechanical effort. The presence of a

duct shouldn’t trigger a clash, it should trigger a hole.

o We need to move beyond clash detection

53Lessons Learned


Incomplete design is the source of many of

the problems in our industry.

In light of the potential offered by the digital

revolution, the traditional design process is an

anachronism that we can no longer afford

54Conclusion


Albert Einstein,

German born American Physicist

1879-1955

”Insanity is doing the same thing over and

over again and expecting different results”

Corollary 1: If you want the same results, do the

same thing.

Corollary 2: If you want something better, do

something different.

Corollary 3: Find out the best its been done before

you invent a better way – improve on the best.

55Final Thoughts


56

Thank you!

Gregory P Luth & Associates, IncSanta Clara, California

deliveringthe gigafactoryinteslatime using hd bim

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