With a focus on innovation, it's not uncommon for Dimension Fabricators to test new technologies. At one time, the company was plagued by the time wasted and the risk of potential errors when its deep-drawing designers produced drawings in 2D. After noticing that contractors were increasingly using 3D models, Dan Steven, the company's Assembly Product Manager, decided it was time to look into BIM solutions.
"The company I previously worked for used Tekla Structures to model concrete with great results, so I was familiar with its capabilities. I thought that if we could deliver the project along with and offer the 3D modeling of the rebar as an add-on to our client, we would kill two birds with one stone." Stevens said, "Tekla Structures not only speeds up the detailing process, but also provides a better product for our customers."
Stevens convinced the team to buy and try out Tekla Structures, Trimble's BIM software.Today, he is an expert in 3D modeling, manages the company's software licenses, and guides an in-house team of design deepening professionals to get the most out of the software.
"Tekla Structures not only speeds up the deepening of the design process, but also provides a better product for our customers." --Dan Stevens, Assembly Product Manager, Dimension Fabricators
Work faster and error-free
By using detailed Tekla Structures models, Dimension Fabricators minimizes the occurrence of unexpected errors and rework. The transition from 2D models to data-rich 3D models allows teams to visualize steel components and more easily identify potential errors. Automated clash checking also helps ensure that costly clashes are exposed to the model before moving to the shop floor.
"In 2D modeling, we are often blind." Stevens says, "By using Tekla Structures, we've easily saved thousands of dollars because applying the 3D building blocks and all the associated data to a single project reduces virtually all the potential for error." Identifying potential problems before fabrication saves Dimension Fabricators time and money.
For example, if we ship the wrong rebar, the contractor ends up placing the wrong rebar and then discovers the problem, which causes us to recut the rebar, resend it and reinstall it," Stevens says. In addition to the time wasted, we had to discard the original rebar. Today we don't have that problem because Tekla Structures adds great clarity to our drawings and allows us to identify errors in our pre-construction contract drawings. This has been a lifesaver."
Coordination of design, manufacturing and field operations
Tekla Structures increases productivity by streamlining project management, while information-rich models improve the flow of information between deepening designers and manufacturers.
"One of the things that appealed to me most about Tekla Structures was the ability to use it with our production system, so we eliminated the manual operations required for 2D." Stevens says, "It has become seamless from deepening the design to manufacturing. We can take a floor in the model, publish it, and then fabricate it, and Tekla will generate a list of rebar that needs to be fabricated." Dimension Fabricators has also found that 3D models are easier to coordinate with other project teams. "Requests for information are much more manageable with Tekla Structures," says Stevens, "We also share the 3D models back and forth with contractors who put our Tekla Structures rebar models into their concrete model. With the 3D model, everyone on the project can identify clashes and errors before construction begins."
Tekla Structures in Projects
Stevens and his team used Tekla Structures during the bidding process for the rehabilitation and restoration of a wastewater treatment plant in New York, using 3D models to demonstrate the benefits they could bring to the project. "The bidding process was competitive, but we won the contract with Tekla Structures' ability to better coordinate the team."
When the various project teams came together to collaborate, the Tekla Structures model helped everyone visualize how the structure would fit together.Stevens said, "Using the model, we were able to identify problems, suggest alternative solutions, and avoid costly rework. Without the Tekla Structures 3D model, we wouldn't have seen these constructability issues." The project's modular construction method of laying rebar on site caught the team's attention. All of the deepening of the design and delivery of prefabricated rebar to the site had to be perfectly orchestrated.
Stevens and his team used 3D Tekla Structures models to overcome their biggest challenge - building the drilled shaft cages in the shop and placing embedded couplers in the cages at the correct elevation to make contact with the beams and slabs after digging inside the structure.
"We couldn't pour concrete in a caisson with cages, so we modified the design," says Stevens, "Some design items are unbuildable and ultimately won't work, but with Tekla Structures we can ask for a change in the contract to meet the design criteria and build the structure."
Reinforcing cages were brought to the site and the contractor would place them at the desired height, which had to be accurate.Stevens said, "They had to dig out the interior structure and hope that all the pre-built pieces were in the right place, which ultimately really happened."
The team also imported Tekla Structures models into its production software.Stevens says, "On large projects, it is helpful to publish aspects of the job into the production software. Previously, we manually created color-coded diagrams and managed materials.Tekla Structures allowed us to easily publish components to the production software and provide details on release and shipment times through markings on each product so contractors could track materials in the field."
Gaining a competitive advantage
Tekla Structures has brought us increased productivity and project accuracy, and opened the door to more commercially viable opportunities.
"We use Tekla Structures because without 3D, we'd be behind the curve." Stevens says, "The entire industry is adopting 3D modeling and construction, and it gives us the edge we need to stay competitive and win more business." --Dan Stevens, Assembly Product Manager, Dimension Fabricators
关于 Dimension Fabricators:
Since opening its doors in 1984, Dimension Fabricators has never shied away from adopting and embracing new technology and precision machinery. The company has been instrumental in some of the largest and most complex engineering projects on the East Coast of the United States. The company produces a wide range of structural steel, standard rebar and wire products, and Dimension Fabricators has earned a reputation as the manufacturer of choice for difficult and challenging structural projects.
