The project

PT. Wijaya Karya (WIKA), an Indonesia-based company saved time and costs, allowing for ROI 3 years early by transitioning from a traditional 2D design method and adopting a 3D BIM methodology.

WIKA’s project team quickly realized that traditional 2D design methods would not deliver the large and complex 8.95-kilometer toll road development on time and under budget. “The total volume of the concrete is a quarter of that of the Giza pyramid,” said Fery Safaria, engineering manager at WIKA. “The total scale of the project is about four times that of Vatican City.”

Saving time using a BrIM methodology

To design such a complex road system and meet the aggressive schedule, WIKA transitioned from a traditional 2D design method and adopted a 3D BIM methodology. The project team began the conversion with image capture via unmanned aerial vehicles, using generalized predictive control to produce a reality mesh within ContextCapture, being able to photograph and process 166 hectares of land in just 15 days, six times faster than traditional surveying methods. Using BIM methodologies reduced the time needed for communication and inspection by as much as 30%, compared to previously deployed methods. OpenRoads helped WIKA review the alignment of the main road, ramps, and approaching structures, while OpenBridge allowed the team to iterate pier positions and heights based on real-world conditions. WIKA’s design iteration within OpenRoads, OpenBridge, and gINT avoided 1,600 meters of costly waterway foundation work and reduced the design process by 25 days.

Watch the project's video presentation here:

 

Meeting Government Standards while Improving Efficiency

Using RM Bridge informed the project team where to place tendons, undertake design analysis of the box girder structure, model deformation, and test work method variations on the double-decker bridge. Within LEAP Bridge, WIKA analyzed the precast girder structure within the concrete to ensure that the project met national bridge loading standards. With ProStructures, WIKA designed bar mark reinforcement, created a bill of materials, and issued reports. Since the three applications are interoperable, WIKA increased the efficiency of bridge modeling by 40% and saved up to 10% of the construction budget. Once the project team fully surveyed and modeled the design, it used LumenRT to produce a digital representation of the project to help all parties understand the current status. The digital visualizations streamlined communications and improved decision-making. WIKA’s design work included a 4D model of the construction process. The project team simulated the movement of heavy equipment in a tight area using RM Bridge to improve efficiency and minimize fuel consumption.

 

Delivering a Return on Investment Three Years Ahead of Schedule

By using a BIM methodology to visualize data, WIKA boosted the accuracy of the model, shortened build time, reduced inspection time, and improved the overall quality of the development. Strong visualization of the design and construction process improved reviews among stakeholders and accelerated decision-making. In the end, visualizations and intraoperability among the Bentley applications helped WIKA detect 85 potential clashes, which could have caused USD 60 million in cost overruns and up to four months of delays. Though WIKA projected the design of Harbour Road 2 would take seven months using traditional 2D survey and design methods, its decision to switch to a BIM methodology helped the project team complete the design in only four months. When construction is completed, an estimated 63,500 vehicles will cross the new toll road each day, which will speed economic and tourism development in the area and facilitate access to the U-20 World Cup matches. Combined with the cost savings gained through design efficiencies, the government expects Harbour Road 2 to pay for itself by 2032, or three years earlier than anticipated.

Bridge software used:

LEAP, OpenBridge, RM Bridge