Digital design workflow using fabrication - aware configurators

Abstract

The construction industry has undergone a profound transformation in recent years, driven mainly by integrating advanced digital tools. One such tool is configurators, advanced digital platforms that enable the integration of diverse knowledge domains, allowing architects, designers, fabricators, contractors, and engineers to explore many design variations and assess them against various parameters such as sustainability, cost, and manufacturability. However, Building Information Modelling (BIM) stands out as a game-changer, revolutionising how stakeholders collaborate and execute projects. Generally, a building configurator is made for product-specific criteria involving only one stakeholder. As to developing a multi-party configurator, this research delves into the transformative role of configurators in streamlining design workflows and enhancing collaboration among stakeholders in the construction sector.

The Design-Bid-Build (DBB) system, a predominant project delivery method in construction, operates under a linear workflow where the design and construction phases are distinct and sequential. During the bidding phase of this system, once the design is finalized and approved, it is put out to bid, inviting contractors to submit their proposals. To formulate their bid, contractors review the design documents and calculate the overall cost, considering labour, materials, overhead, and profit. This phase is characterized by competitive bidding, where multiple contractors vie to offer the most cost-effective solution to secure the project. This method allows owners to select a contractor that best aligns with the project’s budgetary and quality requirements.

In a conventional design workflow, the conceptual design undergoes numerous iterations of design and detailing before advancing to the fabrication phase. This iterative cycle, albeit integral to building planning, is notably time-intensive. Given this context, integrating manufacturing insights early in the design phases has been contemplated to expedite the overall design workflow.

Given the considerations above, the project’s proposal was focused on creating a prototype tool capable of executing the competitive bidding process involving contractors and subcontractors. It also translates the manufacturer’s expertise into a digital model. The example of the curtain wall system as a prototype was chosen and modelled as a solution to the proposed workflow. As an assumption, Two curtain wall systems, stick and unitised, are built by two fabricators. This proof of concept would enable the design of a curtain wall façade to be ready for the schematic phase after the bidding.

The foundational knowledge and information for developing this tool were sourced from the literature survey. The tool entered the modelling phase after the initial study of design workflow and façade elements. The configurator aimed to highlight the tool's user and developer and their impact during the modelling. The initial step involved setting the input parameters, using the knowledge from the manufacturer needed for the bidding, enabling the designer to create a model that aligns with the manufacturer’s capabilities. Two bidding fabrication-aware configurators were formulated based on the tool's back end.

Following the development of the two configurators, the project advances to the validation phase, structured into two distinct processes. Initially, the process was tested for its feasibility and workability of the configurator by various iterations of the input parameters. The outcomes of this process ensure the critical support requirements for the proof of concept.

Subsequently, the emphasis shifts to the professional validation of the configurator, a crucial step in the practicality of the solution. Four key validations were analysed in this step with professional feedback from the demonstration. The derived results offer insights into various aspects of the design’s effectiveness, productivity, functionality and market viability, providing pivotal information that can significantly influence the refinement and finalization of the project. The validation results are instrumental in making informed adjustments and optimizations, ensuring the proposed design workflow meets the intended objectives and specifications.

Adopting configurators in the construction industry is instrumental in addressing the challenges of increasing design complexities and the demand for sustainable, high-performance buildings. By providing a platform for real-time feedback and multidisciplinary collaboration, configurators allow for informed decision-making, optimizing designs for human comfort, environmental impact, and structural integrity. The exploration of configurators in this paper underscores their significance in advancing digital design workflows and highlights their potential in shaping the future of construction, marked by innovation, sustainability, and enhanced interoperability.