Reality check

3D models are not just for architects.

The benefits of building m&e services “on screen” have been seen on a large scale in Amec’s work at the huge Heathrow Terminal 5 project.

The project team has used Navisworks modelling software to plan and schedule how the different trades interface on site. “The model allows extensive use of 3D design and visualisation; this facilitated the development of an m&e module product range,” explains George Adams, chief engineer at Amec’s Building and Facilities Services division.

Use of the model has allowed Amec to manufacture 60% of m&e components for T5 off site. Perhaps the most dramatic example of m&e prefabrication ever seen in the UK, T5’s service chimneys (EMC, Feb 2006, p23-25) could only be developed using 3D modelling. “The key drivers for the [chimney] modules are the time benefit and to give programme assurance,” explains Adams. “The business benefits from this far outweigh any capital savings.”

A virtual reality film of the m&e services was created from the 3D model to help in planning the programme of works. It also gave site workers a clear idea of the process before beginning work. This was reinforced by trials at the prefabrication plants and visits to the manufacturing facilities by on-site personnel to iron out any issues before final installation.

The key benefits for the Amec design and build team were:

The key drivers for the chimney modules are the time benefit and to give programme assurance

• trialling on screen – this assists risk identification and reduction;
• team work – this enables all members of the delivery process to understand and contribute effectively;
• planning – this significantly informs the programming process through proper understanding of the interfaces and sequence;
• training – building the m&e services within the virtual environment allowed the on-site assembly teams and the off-site production teams to understand and familiarise themselves with the modules and their co-ordination and assembly into the overall project;
• all access and maintenance issues during and after assembly have to be assessed and approved.

The process for establishing an array of virtual “products” for the T5 modularisation programme included the involvement of the supply chains in a form of a cluster management structure.

Amec has now developed a web-based tool for the management of its modularisation capability; this incorporates extensive use of virtual manufacturing.

The web tool allows a number of features to be put into an open communication format to allow all cluster members to review and participate in the delivery process. The team would look at:

• logistics management – scheduling;
• production management – production rates;
• design and detailing – information transfer;
• material requirements – equipment schedules;
• planning – use of Key Performance Indicators (KPIs) for programme delivery.

Adams is in no doubt that the use of virtual manufacturing will grow in the industry as off-site solutions become more of a common feature in the way m&e services are delivered to projects.

“Virtual processes in the future will provide opportunities for real-time, real dimensional integration between design, off-site production, site assembly, commissioning and operational training and maintenance,” predicts Adams. You heard it hear first.