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Innovation in Structural Engineering Design The Complete Structural PackageTM
Douglas G. Fitzpatrick, P.E. Fitzpatrick Engineering Group, PLLC October 14, 2015
Lean Construction Institute
Outline • Current state of the industry – steel delivery
• Observations about where we are • Why it needs to be transformed
• The Complete Structural PackageTM (CSP) • Criteria to define a design solution • Transformed deliverable
• Case Studies • Liability • Working relationships
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Lean Construction Institute
Fitzpatrick Engineering Group • Doug Fitzpatrick, P.E.
– President and Founder – Structural design of buildings – Actively involved in day-to-day engineering – BIM advocate since 2006
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London, England Amsterdam, NE
Innovations in Infrastructure Conference Innovation in Structural Engineering
Lean Construction Institute
History • Process of designing and constructing (commercial)
steel buildings has remained essentially unchanged for decades.
• “Alternate construction methods” speed up process but don’t make it more efficient
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Definitions • Steel fabricator
– Physically makes the steel that gets delivered to the job site
– Traditionally hires a detailer and connection engineer as part of that process
• Most fabricators do NOT have detailing in-house • Large local fabricator only does ~25% in-house
• Steel detailer – Figures out exactly how the pieces go together
for structural plans and details, design intent. – Conveys that info to the fabricator via 2D PDF
shop drawings and CNC files for their equipment
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Workflows
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Structural Design Construction
Fabrication
Detailing
Traditional Design-Bid-Build
Structural Design Construction
Fabrication
Detailing
“Alternate Construction Methods”
May include one-time electronic hand-off of
information
All of this work is completed manually
The earlier the Detailing starts: Less information is available to transfer electronically More data has to be recreated by hand
Time savings Cost savings??
Confusion
Lean Construction Institute
Workflows
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Structural Design Construction
Fabrication
Detailing
“Alternate Construction Methods”
Fabricator selected based on GMP
Opportunities for change orders and RFIs to fuel
change orders
The earlier the Fabricator gets involved: Less accuracy in GMP More opportunities for change orders in the ensuing
confusion as design gets finished
Confusion
Lean Construction Institute
Workflows
8
Structural Design Construction
Fabrication
Detailing
“Alternate Construction Methods”
Fabricator selected based on GMP
Opportunities for change orders and RFIs to fuel
change orders
Confusion
The earlier the Fabricator gets involved: Less accuracy in GMP More opportunities for change orders in the
ensuing confusion as design gets finished
Lean Construction Institute
Workflows
9
Structural Design Construction
Fabrication
Detailing
“Alternate Construction Methods”
Fabricator selected based on GMP
Opportunities for change orders and RFIs to fuel
change orders
Confusion The earlier the Fabricator gets involved: Less accuracy in GMP More opportunities for change orders in the
ensuing confusion as design gets finished
Lean Construction Institute
Workflows
10
Structural Design Construction
Fabrication
Detailing
“Alternate Construction Methods”
Fabricator selected based on GMP
Opportunities for change orders and RFIs to fuel
change orders
Confusion The earlier the Fabricator gets involved: Less accuracy in GMP More opportunities for change orders in the
ensuing confusion as design gets finished
Lean Construction Institute
Workflows
11
Structural Design Construction
Fabrication
Detailing
“Alternate Construction Methods”
Fabricator selected based
on GMP
Opportunities for change orders and RFIs to fuel
change orders
Confusion The earlier the Fabricator gets involved:
Less accuracy in GMP
More opportunities for change orders in the ensuing confusion as design gets finished
Lean Construction Institute
Workflows
12
Design Construction
Fabrication
Detailing
“Alternate Construction Methods”
Fabricator selected based on GMP
Confusion
There is a limit!
The earlier the Fabricator gets involved:
Less accuracy in GMP
More opportunities for change orders in the ensuing confusion as design gets finished
Lean Construction Institute
The tipping point • Summer of 2012
– Fabricator selected based on Guaranteed Maximum Price (GMP) during Design Development (DD)
– Received “pitiful” set of shop drawings – Sent out incomplete / poorly checked to “maintain the
schedule” – 50% more time checking – Change order was delivered in a spreadsheet in
excruciating detail
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Reflection
• If fabricators were using technology to track (justifiable) changes…
• Why couldn’t we use technology to eliminate opportunities for change orders and make the entire process more efficient? – Transform the process from scratch
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Solution Requirements • Electronic data transfer
• Sent incrementally
• Overlap the design phase
• Reduce or eliminate change orders
• Leverage inherent efficiencies
• Be flexible to owner’s process
• Save significant time
• Reduce or eliminate RFIs
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Transfer of Information • Fall of 2012 found:
– Detailing software package that could incrementally read structural data with global IDs
– BIM that could reliably export data with global IDs – Detailing partner with same enthusiasm
– Electronic transfer of information – Incremental updates – During the design phase – Fewer opportunities for change orders
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Fabricator Preferences • East coast – typical connections • Changes (outside model) cost detailer time
– Changing in 3D = 1x – Tracking changes on paper = 3x
• Change provenance important for AISC certification
• Solution – stay in 3D as long as possible – Make modifications easily as design changed – Adapt to selected fabricator’s preferences
• Leveraging fabricator’s shop efficiencies • Flexible for bid or negotiated project
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FEG Project Data • Could we save time?
• Looked at 45 of our existing steel projects – Time has been tracked in our timesheets – Knew exactly when CDs were issued – Knew about when we started receiving shop
drawings to earnest – Knew about how long to review shop drawings
• Graphed data (size of building in square feet vs. time) to see where the opportunities might be
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Preparation time
Review time
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FEG Project Data
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Shopdrawingprepara.on.meTimetorecreatedataanddeliver2Dshop
drawingsforreview
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FEG Project Data
Shop drawing review time FEG time
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• Preparation 8-9 weeks • Review by Contractor 1-2 weeks • Review by Architect 1-2 weeks • Review by Engineer 6-7 weeks • Mailing/shipping time 1-2 weeks
• Total 17-22 weeks
Fabrication package time
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• Preparation 8-9 weeks • Review by Engineer 6-7 weeks
• Total 14-16 weeks • Detailer estimate – 3D to fabrication pkg 5-6 weeks
• Difference 8 weeks
• Significant time savings
Fabrication package time
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Improved Communication • Phone calls • Screen sharing • Direct electronic review of the detailer’s live model
– Approval mode only – No paper submittals
• Could we put all of this together and make a difference
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Case Studies • Southeastern MOB
– Three story, 60,000 sf – Structural frame 320 tons – Six (6) week turnaround from
fabricator’s notice to proceed – No RFIs and no change
orders
– “This [process] was a lot better for us in the plant and the field. This [process] was by far the best experience I have had in a long time. [The elimination of the RFI process] saved a tremendous amount of time.” Greg Sain, Project Manager, CM Steel (fabricator)
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Case Studies • Otarre MOB
– Two story, 73,000 sf – Structural frame 318 tons – Five (5) week turnaround from
fabricator’s notice to proceed
– No RFIs and no change orders
– “The detailed drawings were some of the best ever. Any question we had got resolved quickly. All electronic files were excellent…. The whole process was a good experience for D & T. We saved erection time in the field.”
– Travis Crumpton, President, D&T Steel (fabricator)
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Lean Construction Institute
Case Studies • Octapharma
– Two story, 87,000 sf – Structural frame – 340 tons – Same process as the previous
two case studies – No RFIs – Change orders?
– Based on previous case studies – similar tonnage
• Saved 8 weeks = 2 months = $2,000,000 savings to owner
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Transforming Deliverables
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StructuralDesign Construc.on
Fabrica.on
Detailing
FEG Process
Detailing complete in 3D model at CDs
5-6 weeks for fabricator optimization
StructuralDesign Construc.on
Fabrica.on
Detailing
Traditional Design-Bid-Build
Time savings Dollar savings 8 weeks
8 weeks
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Risk/Liability • BIM journey started in 2006 • First BIM project – Level of Detail/Development
(LOD) 300 (beams, columns) – Shared data with fabricator/detailer
• All BIM since – LOD 350 – Only difference to detailer’s model is connections
• Electronic model review lets us focus on the important parts
• Liability Risk
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Lean Construction Institute
Working Relationships • Who works for who?
– Detailer works for FEG • This is not engineers doing shop drawings • No formal partnership • Separate entity • Most fabricators do not have in-house detailing
– FEG works for • Architect (during design) • Contractor (during or after design) • Owner (during design) • Fabricator (during or after design)
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Plus / Delta Delta • Engineers • Liability • Not perfect • Not easy • Cannot be just any detailer
Plus • Proof of concept to shorten schedules • Flexibility for owner – bid versus
negotiated • Not a proprietary solution • Improved communication • Decreased risk / liability • Trust based • Early meaningful involvement of
detailer / fabricator • Not unique to a single project • Reduced waste - no paper shop
drawings • Minimal recreation of structural data • Flexibility in working relationships • Upgraded old process into something
more efficient • FEG engineers think about end goal –
sharing data
Lean Construction Institute
Structural Steel Fabrication Package A Paradigm Shift
Thank you
Questions?
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