© 2009 Bentley Systems, Incorporated

Construction Simulation
An Introduction
Tim O’Leary
Construction Solutions Europe & Africa
 Solutions

CADASTRE
CADASTRE AND
AND LAND
LAND
BRIDGES
BRIDGES BUILDINGS
BUILDINGS DEVELOPMENT
DEVELOPMENT CAMPUSES
CAMPUSES COMMUNICATION
COMMUNICATION
SS

ELECTRIC
ELECTRIC AND
AND METALS
METALS AND
AND POWER
POWER
GAS
GAS UTILITIES
UTILITIES FACTORIES MINING OIL
OIL AND
AND GAS
GAS GENERATION
GENERATION
FACTORIES MINING

© 2009 Bentley Systems, Incorporated

WATER
WATER AND
AND
RAIL
RAIL AND
AND TRANSIT
TRANSIT ROADS
ROADS WASTEWATER
WASTEWATER

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 Construction Simulation

CONSTRUCTION Best practices and the challenges

TODAY in applying them

BENTLEY’S
Proven solution to plan, process and
CONSTRUCTSIM
OVERVIEW
status construction

• VPM • Status tracking

USING
• Data Reorganisation • Work Packs
CONSTRUCTSIM
• 4D playback • Look ahead planning

© 2009 Bentley Systems, Incorporated

• Greater workforce productivity
BENEFITS • Shorter project time
• Substantial cost savings

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Overview

Construction Best
Practices

Software Technology ConstructSim

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Virtual Plant
Model

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 Current Major Issues

Engineering
1, 2
7 3, 4, 5
6, 8

Delivery + Fabrication
1, 2
7 3, 4, 5
1. Poor communications 6, 8
between
disciplines and functions Installation
2. Concurrent engineering 1, 2
9 3, 4, 5
3. Fast-track projects 6, 8
4. Limited resources
5. Ageing skilled workforce
Testing
1, 2
6. Schedule / install by area –

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9 3, 4, 5
test and turnover by systems
6, 8
7. Short time between
AFC/IFC and constructiona) Engineering deliverables Systems Turnover
8. Many revisions b) Materials availability
9. Operate in “scramble” mode
c) Allocation of materials
and work with whatever is
available d) Fabrication deliverables

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 Common Questions
Is the planned What is the exact
schedule How will engineering
progress to date? changes affect work
achievable?
content, cost and
schedule?

How will the

schedule be kept
given the changing
circumstances?

What effort is
needed to
complete?

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What will be
the project impact be if
materials are delayed?

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 Workflow Planning

Define Priority
Engineering Areas Early on in
Design

Suppliers / IFC
Constructor
Fabricators Drawings

Automate MTOs

Last Planner
Create Work
Packs

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Lean Construction

Issue work to the Validate

field that can be Constraints
done

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 Linear Definition of Priorities

Construction
Ideal Construction Sequence
Based on Turnover Systems

Drawings Materials Installation Testing Completion

Issued Delivery Complete Complete Date

Systems
Engineering Delivery Installation Testing
Turnover

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Definition of Priorities

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 Managing Work Buffers to Speed Projects

Engineering

Delivery + Fabrication

Installation

Testing

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Systems Turnover

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 Construction Simulation

CONSTRUCTION Best practices and the challenges

TODAY in applying them

BENTLEY’S
Proven solution to plan, process and
CONSTRUCTSIM
OVERVIEW
status construction

• VPM • Status tracking

USING
• Data Reorganisation • Work Packs
CONSTRUCTSIM
• 4D playback • Look ahead planning

© 2009 Bentley Systems, Incorporated

• Greater workforce productivity
BENEFITS • Shorter project time
• Substantial cost savings

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 ConstructSim Approach

• Drive priorities based on “ideal” construction

sequence based
on turnover systems
• Expedite both engineering and fabrication to
deliver against ideal plan
• Allocate materials based on priorities
• Accurately track effort for completion
• Manage work-fronts effectively
as constraints change on site

© 2009 Bentley Systems, Incorporated

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 Client Feedback
Increase field Save time and cost on
productivity 7 – 25% Brownfield projects
– Streamline sequencing – TIC $50M – Savings $1M
– Reduced rework – Completed 1 month
– Automated production ahead
of work packages of schedule
– Work packages are
executable

Piping Welding

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ConstructSim
2x faster 1.8x faster

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 Diesel Refinery: $2M Savings in Mechanical Sub Change Orders

Background
– New Refinery Unit - TIC $320M
– Lump Sum Contract with Mechanical Sub
– ConstructSim Pipe purchased by Owner and
utilized by Construction Management firm

ConstructSim Use Case

“ ConstructSim enabled
us to recover project – Excessive change order submitted by
schedule losses, and Mechanical Sub
complete on time - – Actual progress not in alignment with
without paying for

© 2009 Bentley Systems, Incorporated

progress reported
unwarranted change – ConstructSim used to analyze change order
orders.” and update progress reporting system
Claim: $2.5M
Settled: $0.5M

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 Offshore Platform: Saved $17M, Reduced Schedule 3 Months

Background
– Deepwater Offshore Platform - $150M
– Time and materials contract with Fab Yard
– ConstructSim Pipe purchased by Owner and
utilized by module Fab Yard contractor

ConstructSim Use Case

“ The labour efficiency
we obtained using – ConstructSim used to re-baseline
ConstructSim enabled project schedule
us to save 3 months – Development of crew-level work face
and U.S.$17M, as well

© 2009 Bentley Systems, Incorporated

plans with ConstructSim
as reduce the punch list – Project completes on time, under budget,
items by over 99%.” and sails away with only 7 punch list items
(compared to 1000’s for other projects)

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 ConstructSim Provides Measureable Savings

Reduce Impact
of Change

Reduce
Wasted Time

Minimize
Rework 1% to 5% TIC
Reduce
Lengthy

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Planning Process

Streamline
Materials
Management

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 Who Uses ConstructSim?

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Engineers and Constructors, Ltd.

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 ConstructSim Solves Complex Planning and
Execution Problems Work the Plan
ConstructSim

• Owners Reporting & Simulation

• Construction
Managers
• Constructors

CAD Databases Project Schedule

Virtual

© 2009 Bentley Systems, Incorporated

Plant Model

Materials Management Project Controls

System Database

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 Construction Simulation

CONSTRUCTION Best practices and the challenges

TODAY in applying them

BENTLEY’S
Proven solution to plan, process and
CONSTRUCTSIM
OVERVIEW
status construction

• VPM • Status tracking

USING
• Data Reorganisation • Work Packs
CONSTRUCTSIM
• 4D playback • Look ahead planning

© 2009 Bentley Systems, Incorporated

• Greater workforce productivity
BENEFITS • Shorter project time
• Substantial cost savings

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 Using Bentley’s
ConstructSim Status
Tracking

Week 1
4D Work
Playback Packs

Automatic Look
Data Ahead
Organization ConstructSim Planning

© 2009 Bentley Systems, Incorporated

Virtual
Plant Model

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 Project Schedule Integration

MTO
From CAD +
Production Information

Schedule ConstructSim

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Task Templates &
Work Steps Standard Norms

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 Project Milestones

Project Project Project Project

Milestone 1 Milestone 2 Milestone 3 Milestone N

Rules
Rules Rules Rules
Of Of Of Of
Progress Progress Progress Progress

Engineering Fabrication Installation Testing

Initial Design Drawings Install Completions
Final Design Received Test Commissioning
Check 1 In Production Hand over Etc. Etc.

© 2009 Bentley Systems, Incorporated

Check 2 Shipped
Check 3
Approval

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 Automatic Data
Organization Status
Tracking

Week 1
4D Work
Playback Packs

Automatic Look
Data Ahead
Organization ConstructSim Planning

© 2009 Bentley Systems, Incorporated

Virtual
Plant Model

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 ConstructSim Automatic Data Reorganization for
Construction Tasks

© 2009 Bentley Systems, Incorporated

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 4D Playback Status
Tracking

Week 1
4D Work
Playback Packs

Automatic Look
Data Ahead
Organization ConstructSim Planning

© 2009 Bentley Systems, Incorporated

Virtual
Plant Model

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 4D Playback to Optimize and Communicate the
Construction Sequence

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 Status Tracking Status
Tracking

Week 1
4D Work
Playback Packs

Automatic Look
Data Ahead
Organization ConstructSim Planning

© 2009 Bentley Systems, Incorporated

Virtual
Plant Model

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 On-Demand Status Tracking and Visualisation

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 Tracking Equipment Delivery

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 Pipe Delivery Status Visualization

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 Area 08
(Mod and
Non-Mod Pipe)

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Pipe Delivery Status Visualization
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 Pipe Delivery Status
Visualization
Area 11
 Area 15

Pipe Delivery Status Visualization

 Area 02

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Pipe Hydro Test Status Visualization
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 Area 06

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Pipe Hydro Test Status Visualization
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 © 2009 Bentley Systems, Incorporated
Area 16

Pipe Hydro Test Status Visualization

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 Work Packs Status
Tracking

Week 1
4D Work
Playback Packs

Automatic Look
Data Ahead
Organization ConstructSim Planning

© 2009 Bentley Systems, Incorporated

Virtual
Plant Model

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 Fast, Easy Work Pack Creation

© 2009 Bentley Systems, Incorporated

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 Look Ahead Planning Status
Tracking

Week 1
4D Work
Playback Packs

Automatic Look
Data Ahead
Organization ConstructSim Planning

© 2009 Bentley Systems, Incorporated

Virtual
Plant Model

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 Work Pack Reports and Look Ahead Planning
to Streamline Scheduling

© 2009 Bentley Systems, Incorporated

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 Construction Simulation

CONSTRUCTION Best practices and the challenges

TODAY in applying them

BENTLEY’S
Proven solution to plan, process and
CONSTRUCTSIM
OVERVIEW
status construction

• VPM • Status tracking

USING
• Data Reorganisation • Work Packs
CONSTRUCTSIM
• 4D playback • Look ahead planning

© 2009 Bentley Systems, Incorporated

• Greater workforce productivity
BENEFITS • Shorter project time
• Substantial cost savings

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 ConstructSim Benefits for Owner Operator

• Enables schedule date to be

met

• Reduces costs

• Provides an insight to
project progress

• Potential to shorten schedule

and achieve additional
production

© 2009 Bentley Systems, Incorporated

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 ConstructSim Benefits
for Construction Managers

• Saves 1-5% TIC or 7 – 25%

of field man-hours

• Reduced claims litigation

• Greater control and visibility

of project

• Start up date controlled /

compressed

• Know where you are at and

© 2009 Bentley Systems, Incorporated

what needs to be completed

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 ConstructSim Benefits for
Direct Hire Contractors

• Reduces wasted time on-site

• Improves field productivity by 7 -

25%

• Reduces rework and out of

sequence work

• Maximises productivity of on-site

equipment e.g. cranes / scaffold

• Improves co-ordination between

© 2009 Bentley Systems, Incorporated

disciplines

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 Cost Savings
Co-ordination between disciplines to maximise
effectiveness of resources such as scaffolding / cranes

Work pack planning man-hours

REDUCE Wasted field man-hours
Rework
“Punch list” items

REMOVE “Out of sequence” work

SAVE Between 1% - 5% of TIC

© 2009 Bentley Systems, Incorporated

ACHIEVE On-time project completion

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© 2009 Bentley Systems, Incorporated
Thank you

Sustaining Infrastructure
 Additional Information

• Streamlining Materials

• Planning Levels

• Additional Details

• Electrical / Instrumentation

© 2009 Bentley Systems, Incorporated

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