2. Digital models for visualisation

The contractors on the Caulfield to Dandenong Project were seeking new ways to better understand and plan for the transportation and construction of prefabricated elements. By modelling spatial, time and cost dimensions of the design solutions, the Alliance was able to accurately detect clashes, consider the construction planning of the project, and incorporate costings.

Space

Individual models of disciplines such as architectural, structural, bridges, electrical and mechanical service models were incorporated into a single platform to appreciate the full design. This approach enabled the project team to review each model and produce a 3D visualisation to identify and address clashes between services and infrastructure before construction commenced.

The platform was vital for preparing the contractors to achieve necessary construction works during short rail shut down times, and progressing construction alongside live rail lines.

Time

Use of a virtual construction sequencing tool was critical to the success of the first major rail occupation, where contractors finished the works within a confined corridor and beside operating trains. The construction tool allowed contractors to virtually build the project in an on-site office, review their methodologies, and provide changes as required. This wouldn’t be achieved using a traditional Gantt Chart.

The construction modelling also allowed the Alliance, client and contractors to review and communicate changes in real time, enhancing collaboration between teams throughout the design phase, and prior to site activity.

Cost Impact

The cost loaded, data rich models produced for the project were used in conjunction with a cost estimating program, to simulate and manage the costs of each component of the project. This assisted the estimators to successfully manage the overall project cost.

One example was when this process was used to compare the fabrication and construction cost of reducing the main station canopy size and increasing the smaller station canopy. Rather than estimating the cost (quantity * rates), we had the ability for near instant cost capture of design changes.

3. Digitised shop drawing reviews

With the possibility of more than 25 000 drawings to be prepared for the Caulfield to Dandenong Level Crossing Removal Project, the use of a virtual collaboration tool made it possible to digitally review and approve shop models between the Alliance design teams, and the steel fabricators.

The Alliance design team’s 3D visualisation was leveraged by the steel fabricator, who produced the fabrication model. Alliance Designers inserted comments and tracked changes directly into the fabrication model, prior to the stamped formal check from the Alliance design team. This sped up the review process compared to traditional shop drawing review processes where each drawing is printed for every review stage and passed from one discipline to another for checking.

It also utilised a built-in workflow, so drawings were virtually allocated to designers swiftly. Designers logged into the digital collaboration platform and saw their task and could see which disciplines had already reviewed the drawing, and what previous changes had been made.

Digital engineering that provides the best outcomes for communities

The integration of these digital tools on this project provides an exemplar model of how we can engineer, design and plan large-scale infrastructure projects going forward to provide the best outcomes for our communities.

The project successfully challenged the status quo and created a united front to apply a variety of innovative solutions and experiences including:

Drone flyovers using photogeometry
Visualisation models for signal sighting, working closely with Geographical Information System (GIS) team
QR Codes on assets to develop a Facility Management model
4D digital design models for construction sequencing
Lightning protection of viaduct structures and stations whilst minimising electrolysis risk
Developing an accurate model to do a material/quantity take-off

The implementation and integration of digital tools were used to great effect on this large-scale complex project. As digital tools continue to evolve, they can help drive a brighter future for infrastructure design and construction.

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