BIM-M Benchmark Projects: Lessons for Masonry Design and Construction in the Digital Age

Transcription

1 BIM-M Benchmark Projects: Lessons for Masonry Design and Construction in the Digital Age Russell Gentry, PhD, PE Georgia Institute of Technology Digital Building Laboratory Franca Trubiano, PhD, AIA Architecture, Penn Design University of Pennsylvania

2 Presentation Outline Background Approach BIM as Process Workflows and Systems Modeling Case Study Review (Gentry) Engineered Biosystems Building Drew Charter Fleming Hall Detailed Case-Study Discussion (Trubiano) Huntsman Hall New College House A View from the Profession Wrapup

3 Masonry Project Types CMU and Brick Structural Masonry Complex Masonry

4 Project Phases Schematic Design Design Development Construction Documents Contractor Coordination Subcontractor Installation

5 Project BIM States Current No-BIM Project documentation and communication are primarily Current No-BIM through 2-D drawings, by fax, PDF, sketches, Current BIM Project team is using BIM software, model exchanges and Current BIM integration to the degree possible Future BIM A collective vision of what BIM-enabled processes for masonry Future BIM design and construction might look like in the future (BIM-M)

6 BIM-M Benchmark Study Criteria

7 BIM as Process The Importance of Workflows BPMN Flow Chart Process Model Activity Diagram Value Chain Map

8 Material Supply: Cast Stone Workflow Flow of information and material in a custom cast stone masonry process (image courtesy Midwest Cast Stone, Kansas City, Kansas)

9 Design and Construction Processes

10 Case Study Projects Project GT Engineered Biosystems Building Drew Charter School, Senior Academy Emory/Oxford Fleming Hall Woodward Academy Humanities Building Breckinridge Place GCSU Ennis Hall + GT Hinman Hall Young Harris, Enotah Hall UPenn, Huntsman Hall UPenn, New College House Architect Cooper Carry Perkins + Will Cooper Carry Perkins + Will Holt Architects Lord Aeck Sargent Lord Aeck Sargent KPF Bohlin Cywinski Jackson Mason Contractor Jollay Masonry Cornerstone Masonry Pyramid Masonry Cornerstone Masonry Dave Trayer Masonry Southeastern Restorations Zebra Construction Dan Lepore and Sons Dan Lepore and Sons Building Type Concrete Frame - Brick Veneer on Steel Studs - Interior CMU Concrete Frame - Field Stone and Cast Stone over CMU Load Bearing Block - Precast Plank, Brick/Stone Exterior Steel Frame - Brick and Cast Stone on Steel Stud Backup Load Bearing Block - Precast Plank, Brick/Cast Stone Exterior Load Bearing Brick and Stone - Restoration Load Bearing Block - Precast Plank, Brick Exterior Complex Masonry, Custom Clay Units, Concrete Frame Complex Masonry, Custom Clay Units

11 11

12 Georgia Tech Engineered Biosystems Building

13 Schematic Design Phase: Masonry Unit Selection

14 Façade Mockup Is this a BIM opportunity? Virtual mockup

15 Subcontractor Installation Phase: Brick Façade

16 Current BIM Representation

17 Brick Façade Installation: Coordination Issues 1. Re-align construction joint with center of windows southeast façade. 2. Remove relief angles between three windows metal panel here not brick. 3. Relief angle drops 0.8 in. (200mm) caulk joint will increase to 1.25 in. (31mm) thick. Resolve? Stretch brick coursing or increase caulk joint width. 4. Trim projecting leg of relief angle 0.25 in. (6mm) 5. Steel stud window framing out brick will not wrap opening. 6. Steel outriggers for shade not aligned with curtain wall or brick coursing per A1102 D7. 7. Improper waterproofing for below-grade application.

18 Is this an opportunity for a future BIM state automatic geometry update in BIM before masonry installation?

19 Brick Installation: Overview Swing Stage Pump Jack Fraco Lift 2 masons 0 laborers 3 masons 2 laborers Total 9 masons 5 laborers 4 masons 3 laborers Daily Usage ~max 10 cubes ~4500 bricks ~31.5 bags of mortar Total on Wall ~80 cubes ~42,500 bricks 283 courses 18 loose lintels Daily Schedule 7 AM: 2 laborers start mortar 10 hours of work with a 15 min breaks 30 min lunch end at 5.30 p.m.

20 Façade Construction Process

21 Time-lapse of Façade Installation

22 Subcontractor Installation Phase: CMU in Vivarium

23 CMU Construction: Vivarium Level LOD 300 EBB Revit Model

24 Construction Joint Placement for Vivarium Level Is this an opportunity for BIM? Jollay Masonry

25 CMU Construction: Vivarium Level LOD CADBLOX Tom Cuneio

26 Contractor Coordination Phase: Cast Stone

27 Cast Stone Construction: Window Sills The BIM model is not quite right. The brick still exists inside the placed cast stone, creating an internal masonry clash. EBB Revit Model

28 Opportunities for BIM Future State: Design Phases Mockup budget was $80,000 and multiple mockups were created. Virtual mock ups? Need better tools for inserting cast stone accents into wall system family. Masonry patterning not properly aligned to building surface. Unable to encode glazed masonry pattern onto BIM model. BIM execution plan explicitly called for no modeling of relief angles so design BIM model was not useful for façade construction planning. No automation of construction joint placement in CMU walls. Need rule-based CJ propagation.

29 Opportunities for BIM Future State: Construction Phases One person-month of mason contractor time spent on re-measuring concrete frame and relief angles. Steel stud backup required adjusting in many locations. Need to promote BIM-M design model to BIM-M construction model. Increase LOD selectively and carefully. Break wall into parts based on project schedule. Need simple interface model for mason contractors showing masonry plus its touch points. Nominal geometry and as built. BIM model not useful for cast stone detailing due to use of wall sweeps. Need wall sweep propagation tool. Cutting units in vivarium level was messy and it would have been great to cut outside unable to pull cuts from BIM model Plumbing and wiring inside of CMU were difficult to coordinate due to use of different control lines by plumbing and masonry crews need BIM-hosted control lines

30 Drew Charter Senior Academy

31 Field- and Cast Stone Locations Cast Stone Field Stone

32 Fieldstone: East Wall A-417: 8 Exterior Details (bottom, between level 1 and 2) Field Stone CMU 2 Foam-Plastic Board Insulation Cavity Drainage Material Fluid-Applied Air Barrier Grout Fill (Cavity) 4 CMU Compressive Filler Self-Adhering Sheet Waterproofing Through Wall Flashing

33 West Wall of Academic Building (Fieldstone) Sophisticated detailing required for fieldstone relief angles Architect provided very strict rules on fieldstone installation (mockup)

34 Activity Diagram: Installation Of Fieldstone 34

35 Cast Stone

36 Cast Stone

37 Opportunities for BIM Future State: Design Phases Need library of standard cast stone shapes. Need tools for maximizing use of fieldstone given a distribution map of field stone sizes in supply. Need fieldstone wall generator given a rule-set supplied by the architect.

38 Opportunities for BIM Future State: Construction Phases Need to manage production and shipment of custom masonry material. Need to manage quantity estimates for cut stone. Potential for scanning of fieldstone supply and matching to architects wall model and to mock-up.

39 Oxford College - Emory University Fleming Hall

40 Background Information Owner Architect General Contractor Subcontractors Supplier Structural Engineer Civil MEP Emory University Cooper Carry, Inc. Brasfield & Gorrie Pyramid Masonry Block USA Uzun+Case Southern Civil Engineers Nottingham, Brook, & Pennington Size 52,000 ft 2

41 Project Masonry Scope

42 CMU Block Wall Locations precast plank on block

43 Granite Rigid Insulation 4 CMU Backup Drainage Mat CMU

44 Brick Veneer Rigid Insulation CMU Damp proofing Concrete Plank Complex masonry details shown only in 2D details not in 3D BIM 44

45 One Phase Construction Two Phase Construction 45

46 Construction/Planning Phase: Procurement Process

47 Opportunities for BIM Future State: Design Phases Revit does not provide a clear path for federation of models in masonry. Architect and structural engineer duplicate modeling effort. No one source of truth. Structural engineering of this simple load-bearing building is expensive compared to structural steel buildings poor interoperability

48 Opportunities for BIM Future State: Construction Phases Need process planning tools for load-bearing masonry, tied to resource planning. Need high-fidelity BIM models for off-site cutting of masonry (and perhaps a shop drawing process).