HS2 JV reveals how it fast-tracked Birmingham design

Mott MacDonald and Systra are developing the scheme for the area which covers 70km around Birmingham and involves 320 primary assets such as viaducts and 550 sub-assets such as drainage systems. The design work includes 48 viaducts, 68 overbridges, 27 underbridges, 31 culverts, 74 embankments, 40 cuttings, three tunnels, and 14 retaining walls.

The challenge for the Mott Macdonald and Systra designers was to digitally  co-ordinate the huge amount of design work, accommodating 1,850 users (600 on the design side), 43,000 incoming files and 60,000 design files. In addition, the design teams were based around the world, with the project’s major engineering centres in UK, France, Poland, India and Korea. In total the work involved 35 offices in 28 cities across eight countries.

“If you have an understanding of project numbers then you realise that these are exceptionally big numbers. The trick is to deliver it (the design) in one design team,” said Mott MacDonald information manager Kristof Komeny, speaking at the Bentley Year in Infrastructure conference in Singapore, where the team is a finalist for a project delivery award.

He added: “We have to deliver HS2 through our client's building information modelling (BIM) vision, which is to create a digital twin that they will be able to use to operate and maintain their assets.”

Systra BIM manager Leïla Essemrhouni said that the challenge she faced was coming up with a digital system which gave everyone easy access to data, ensuring collaboration between different offices and giving quality assurance.

Using Bentley ProjectWise, Mott MacDonald and Systra were able to move towards a modelling system, producing 4,000 BIM models as a source of all the design information. From this a digital twin for the design has been created.

The move to BIM models and a digital twin has dramatically reduced the drawing production time and cost. Designers were able to work on the models collaboratively, and synchronise with HS2.

The project involved training 1,800 people in the wider design team so that they were using the right technology at the right time. It also required buy-in from the supply chain through training via workshops and online.

Mott MacDonald and Systra estimate the that the system saved 10,000 hours of model checking time alone, through elements such as a common checking tool rather than having different parts of the team using different systems to check designs. They say the system has captured 100% of the design risk with digital tools including one which highlights clashes between what has been designed and project standards. It also includes a register of hazards.

The technology holds data including asset information, calculations, check sheets, and CAD data, which can be individually assigned to assets. This information can give a quick view of what has been done so far on any part of the design, helping to highlight potential delays.

Komeny said the system has enabled the designers to make better decisions about, for example, where and when to do off-site manufacturing and which elements or components can be standardised.

“We have a huge amount of data so why not harness it to the best of our abilities. We know exactly how many diaphragm walls there are and how much concrete is in there. We know exactly where the beams are along the entire route. So, we can use this data to make decisions such as maybe change from insitu to precast in some areas, or put a concrete processing plant in one region over the other,” said Komeny.

It has also had a positive impact on the project’s drive to reduce carbon, as the system includes a drag-and-drop interface which allowed the team to import data from BIM models which included carbon and cost datasets. The team used the carbon portal to compare various design options – an important factor as most carbon can be saved during the design phase.

Mott MacDonald estimates that construction emissions for Phase 1 (London-Birmingham) will be in the range of 5.8-6.1M.t of carbon dioxide equivalent (MtCO₂e). However, the first 60 years of its operational phase are expected to result in a carbon saving of 3.0-3.2MtCO₂e.

The N1 package includes the Long Itchington Wood Green Tunnel to Delta Junction and the Birmingham Spur. N2 includes Delta Junction (pictured) to the West Coast Main Line tie-In.

Software used by Mott MacDonald and Systra includes iModelHub, MicroStation, OpenRail, ProjectWise and Synchro.

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