iTSHOWCASE 2008 Award Winners Academy

Best use of Digital Design: Tekla UK and Littlehampton Welding

Tuesday, 7 April 2009

Fabrication and Installation: Littlehampton Welding, Concept and Design: Gerry Judah, Project Management: Peter Harris, Consultant Structural Engineering: Capita Bobrowski, Client: Land Rover UK

The task

To construct a purpose-built structure for the central feature display at the Goodwood Festival of Speed 2008. The structure was sponsored by Land Rover to celebrate their 60th anniversary and was built in layers of welded frames with single rakers between the frames. Featuring five Land Rovers, one of each model, with an unpainted finish to give it a rugged, rock like texture, the structure suspended five racing cars above the passing crowds beneath. After the three day show it was dismantled.

Designed to be an eye-catching display piece, it was important that the structure met the designers' concept and the client's brief to celebrate Land Rover's 60th anniversary. Due to the scheduling of the project and the need for the structure to be completed ahead of the festival taking place, it was also essential that it was completed to programme. It had to be fabricated as simply and efficiently as possible in order to meet the tight programme and to keep costs to a minimum. In addition, as the heavyweight structure was suspended above the crowds below, it was also vital that it was constructed accurately with no room for error as the safety of visitors to the festival was of the highest importance.

Structure specs: Height:34 metres, Drawings:2560, Parts:3415, Bolts:4890, Weight:106 tonnes

The application

Littlehampton Welding used Tekla’s 3D BIM software to create a model of the structure that could be shared with all stakeholders on the project.

Littlehampton Welding used the Tekla Structures 13.1 BIM software.  Tekla Structures allowed them to simplify a very complex 3D structure onto 2D workshop drawings that could be used to fabricate the structure. The software exceeded all expectations and allowed the structure to be completed ahead of schedule, quickly, efficiently and accurately.

The structure was modelled by a single Tekla Structures user working from a 3D analysis model in DXF file format produced by the structural engineer. Schedule:

• Littlehampton Welding received the DXF model from the engineer on the 8th April 2008.
• The first fabrication drawings were issued to the works on the 16th April 2008.
• The final drawings were issued to the works on the 6th June 2008 - these were the car support frames.
• Work on the structure started on site on Friday 13th June 2008 and finished on Friday 4th July 2008. The work was concluded in just three weeks (excluding 9 days of dismantling after the show).

The benefits

The software can streamline the entire construction process, enabling every stage to be completed more efficiently, cost-effectively and on time. It supports collaborative working between the different parties involved in a building project including architects and designers, steel and concrete detailers and manufacturers, structural engineers as well as contractors. A functional building information model in extreme detail – right down to every nut and bolt – can be shared by the whole project team, visually indicating planning and progress. All engineering, detailing and project management information is integrated into one 3D model. It models the whole process from project planning to site management, helping to plan and schedule the entire structure as well as tasks and resources.

By using the Tekla Structures software, Littlehampton Welding was able to save 6 days on site, cutting costs on staff and plant hire.  The company was originally programmed to work weekends in order to complete the structure within the desired timescale but was able to complete construction without the need for this.

The contract was completed ahead of schedule and with the absolute minimum of drawing office (DO) or fabrication errors. Littlehampton Welding is known for its work on architectural metalwork, steelwork and footbridges, as well as working in aluminium, stainless steel and glass. The structure was a great opportunity to expand and showcase Littlehampton Welding's capabilities. 

Tekla Structures gave Littlehampton Welding the ability to export parts of the structure as 3D DXF files to enable the engineer to check the model as it progressed without having to produce a lot of extra drawings. Tekla Structures also produced ‘snapshots’ for the engineers and designer so they could see at a glance if there were any particular problems that needed resolving, meaning time saved on site where it mattered most.

One of the key benefits of the software is that it gave Littlehampton Welding the ability to show the client (Land Rover UK) 3D perceptive images to give an accurate impression of what the completed structure would look like and to give an idea of what the patrons at the show would see from their position on the ground.

The goals of creating an eye-catching display piece, ready to be exhibited at the Goodwood Festival were met ahead of schedule. This is Littlehampton Welding’s fifth year of working with designer, Gerry Judah on the central feature at the Festival. It is known for its experience in creating unusual or specialised metalwork sculptures.

This project was very much a case of taking the designer’s concept and together with the structural engineer, turning it into a reality. It was very much a team effort.  As the structure was intended for display at a specific event, completion beyond the schedule was not an option.  Due to the very tight schedule, fabrication at the lower levels of the structure began while the levels above were still being drawn. The upper sections were being fabricated as the first sections were being fitted on site. Having a 3D model allowed visual decisions, such as where to place the cars, to be made sooner to enable early construction of certain parts of the structure.

Customer comments

Tekla Structures met and exceeded Littlehampton Welding’s expectations, enabling it to simplify very complex 3D structures into 2D drawings that allowed them to work more closely with its partners and suppliers involved in the project. It also allowed detailed 3D models of the finished structure to be shared with the client, Land Rover UK, to give them a realistic impression of what the feature display would look like.

The efficiencies, time and cost savings gained by Littlehampton Welding by using Tekla Structures gives it a significant competitive advantage. Increased productivity together with a decrease in potential errors means that Littlehampton Welding is perfectly positioned to capitalise on its increased efficiency in order to cultivate new business opportunities in innovative design.

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