Exploring Innovation in Construction Technology: A Prototyping Guide

Trying out new construction technology doesn’t have to be risky.

Virtual Design and Construction (VDC) Strategist Renzo di Furia shows us how to adopt and develop processes for new tools. Prototyping on small-scale projects first — with help from students at the University of Washington.

Renzo worked with students at the University of Washington to research how the Sydney Opera House. How could it be built with modern technology and applied those workflow learnings to new projects.

Architects envision grand designs for a sustainable future, but it’s the contractor’s responsibility to bring these ideas to life. Transitioning from concept to concrete presents a creative challenge. As architects push design boundaries, contractors face questions of structural integrity and efficient coordination. Adopting new technology workflows is a desire among construction professionals, but limited time and budget often hinder experimentation.

Despite industry constraints, Renzo di Furia, owner of RDF Consulting Services and consultant for Turner Construction, advocates for creative exploration. Utilising student resources, working in 3D across project phases, and developing technology ecosystems allow construction teams to discover innovative building methods within real-world constraints.

Prototype, Then Iterate Again and Again

Construction professionals face the challenge of adopting new technologies for time efficiency and sustainable building practices. However, the transition is often hindered by the difficulty of changing established processes.

Renzo, collaborating with University of Washington programs, addresses this by experimenting with cost-effective construction technology. This not only benefits the current project but also provides students with real-world career experience.

Renzo emphasizes the need for continual innovation to stay competitive. Furthermore, avoid negative impacts on the bottom line.

“The advancements that NASA developed to get to space created an innovative environment that has fielded a whole generation of technology. We need a similar revolution in the building industry. But it’s not just about investing in the latest technology; it’s applying technology to real problems, prototyping to create a repeatable process, and implementing adoption and learning on a larger scale.”

Renzo di Furia

Universities and Professionals Unite

Why Students

Students prove ideal for testing new construction technology, given their familiarity with smartphones and computers from an early age.

Their innate ability to adapt to new tech, coupled with a strong motivation to address the global climate crisis. This positions them to seek solutions that reduce waste and contribute to a more sustainable future.

Unlike seasoned construction professionals who may be entrenched in traditional processes. The students, unburdened by the need to unlearn outdated methods, are more inclined to embrace innovative solutions.

“Imagine a future where research and practice are seamlessly integrated into shaping our built environment.”

University of Washington Applied Research Consortium (ARC) 

A Catalyst for Change

Professor Carrie Dossick, the associate dean of research at the University of Washington, initiated the Applied Research Consortium (ARC). Professor Dossick recognised the latent potential of students.

This educational program serves the dual purpose of enhancing students’ careers and positively impacting the bottom line for construction professionals. Upon learning about the program, Renzo promptly joined as an industry member and contributor.

“ARC brings together an interdisciplinary group of built environment firms with faculty experts and graduate student researchers at the University of Washington’s College of Built Environments (CBE) to address the most vexing challenges that firms face today. The next generation of practitioners and scholars apply their creativity and knowledge of the latest practices, accelerating progress and preparing for future work at the leading edge of our fields.”

University of Washington Applied Research Consortium (ARC)

Students, Turner Construction, and the Sydney Opera House

In 2018, the hypothesis that pairing students with professionals could ignite workflow innovation underwent a practical test. Turner Construction had recently acquired a new CNC machine. They sought a team to experiment with various building methods before deploying it on a significant project with high stakes.

Renzo, then part of Turner’s virtual design and construction (VDC) department, collaborated with university students to optimize the process. Most notably of prefabricating formwork using the CNC machine. The team chose to replicate the iconic Sydney Opera House using contemporary construction methods.

The Sydney Opera House, constructed between 1959 and 1973, is globally renowned for its distinctive white ceramic tiled sails. Although the precast ribs and roof panels were innovatively manufactured on-site, the project faced numerous challenges. Notably, the podium structure, constructed years before finalising the structural design, necessitated extensive reinforcement. These structural re-enforcements to the shell-supporting columns down to bedrock, lead to significant construction delays.

“There wasn’t a how-to manual that showed us how to make what we needed with our CNC machine. It was a lot of trial and error. There are many, many complexities. We learned while tearing the machine apart and putting it back together.”

Renzo di Furia

Renzo and the students initiated their research by examining the construction process. They looked at the Opera House and devised a strategy to replicate it using the CNC machine.

Analyzing the 2D construction drawings, they translated them into a comprehensive 3D model. The team proceeded to model the rebar and formwork. Then, successfully utilizing the CNC machine to construct forms and pour multiple 1:4 scale prefabricated rib elements.

Their research project resulted in the development of a model-based, digital prefabrication workflow. The previously intricate work, requiring substantial labor investments for limited financial returns. It now became more efficient with the integration of the CNC machine and other process improvements.

These advancements garnered industry recognition, including the AGC’s Build Washington Excellence in Innovation award in 2018.

Building Momentum 

During his time at Turner Construction, Renzo collaborated with the ARC to create an ongoing education course titled “Virtual Modeling for Digital Fabrication“. This course delves deeper into modeling for digital fabrication, covering essential elements of the digital fabrication toolbox, such as laser scanning for reality capture, referencing historical documents. Additionally advanced model building, file formatting for laser cutting, CNC routing, and 3D printing.

The curriculum enables current and future students to engage in real-life, advanced model-building and problem-solving for emerging prefabrication technologies.

Using SketchUp for 3D modeling and Scan Essentials to import point clouds. Students taking the course learn how to model a historic building. This course is ideal for students who want to learn more about design-build management. Or specifically want to learn practical skills that could help them move into a related role.

SketchUp provides software for students to use and instructional videos. This program is another positive outcome of partnering with the University of Washington. It supports Renzo’s assertion that creating an authentic, research-forward environment must include both learning and teaching.

Applied Research on a Landmark Project

The insights gained from the renovation and quarter-scale casting of the Sydney Opera House ribs have found application in various projects. Most notably the extensive renovation and expansion of the Seattle Aquarium.

A prominent destination since its construction in 1977, the Seattle Aquarium. SItuatied on the central waterfront, it required expansion to meet growing demands. Turner Construction, serving as the primary contractor, successfully completed the updates. A concrete pour lasting over 23 consecutive hours for the new marine habitat in November 2022.

“Everything that we learned along the way exploring the Sydney Opera House, which was about a two-year discovery period, we applied to the Seattle Aquarium: how we modeled the structure, how we modeled the rebar, how we approached the formwork, and more.”

Renzo di Furia

The Challenge: A Complex Geometric Shape 

Building the aquarium habitat posed challenges due to its intricate, organic shape inspired by the ocean. The aim of providing visitors with captivating views of aquatic life. Given the enormity of the planned habitat, the team anticipated complexities in rebar constructability.

Turner developed an exclusive fabrication-level modeling workflow in-house to address this challenge. The structure features a two-foot-thick, curved concrete wall, 355 tons of rebar, and 680 cubic yards of concrete. This is four times the typical amount of rebar used on a standard core, as reported by Turner.

Utilising structural foam with a fiberglass coating, concrete form liners were crafted. This was achieved using industrial CNC machinery, directly carved from the 3D model. Digital fabrication methods in Turner’s fab shop produced formwork for window openings, circular stairways, and the dramatic entrance oculus.

Prior research conducted by students and Turner on parametrically modeling. Intricate, organic concrete geometry, rebar constructability, and digitally fabricating formwork using CNC machines proved invaluable. This collective knowledge significantly streamlined the unique construction process for the Seattle Aquarium. This resulted in substantial time and cost savings.

Adopting 3D from Start to Finish

Construction faces cost challenges due to large, information-intensive job teams. Siloing issues among architects, contractors, and owners are well-known, but internal silos within construction teams are often overlooked. On a job site with 50 trades, efficient coordination of material and equipment needs is crucial to avoid wasting valuable time and resources.

“Building a sound 3D model that you can use throughout the design and construction process takes quite a bit of practice and dedication — a little bit like learning to play a musical instrument well.”

Renzo di Furia

Renzo and Turner enhanced collaboration for the Seattle Aquarium project using data in a 3D environment, making it Turner’s first 100% model-based communication project.

They utilised a detailed SketchUp model with numerous scenes for site planning and extracted material amounts for concrete, wood, and rebar from 3D models during construction. The initial habitat mockup involved a physical foam model, carved with a large CNC machine. This evolved from the students’ process developed studying the Sydney Opera House.

“For the Seattle Aquarium, the complexities of the design pushed the site management to adopt a complete 3D workflow, which broke down information silos and allowed any puzzles to be solved by a much more unified team. The ability to problem-solve effectively with a large, disparate group is rare and demonstrates the the enormous value of a true 3D process.”

Renzo di Furia

Maintaining a continuously updated 3D model from the project’s inception to construction ensured transparent communication with all stakeholders. Turner’s team held weekly meetings with architects and other disciplines to review the 3D model and address any challenges.

An Interconnected Tech Ecosystem

Seamless interoperability among design software was as crucial as human communication on the project. The team employed Trimble Connect, a cloud-based common data environment (CDE) and collaboration platform, to ensure synchronized model versions and keep everyone connected.

In addition to Trimble Connect, they utilized SketchUp for 3D modeling, LayOut for creating 2D documents, Tekla for structural design, Trimble Total Stations, Trimble Laser Scanning Solutions for surveying, Revit for detailed construction documents, and more.

“We began our VDC journey years ago by coordinating MEP systems. We then took those lessons and applied them to our self-performed concrete operations. During that discovery process, we realized that the true critical path of any construction project is information management. I’ve since been prototyping an improved structural-centric workflow system that increases quality control dramatically and can be applied to any project, large or small.”

Renzo di Furia

Applying the appropriate technology at strategic points elevated Turner’s modeling and coordination for the Seattle Aquarium. This enhancement bolstered quality control processes and facilitated the effective management of shared information throughout the design and construction phases.

The Way Forward: Structure-Centric Systems

The construction sector is transitioning into an era of enhanced collaboration, with the adoption of new technologies and processes. Renzo envisions that transitioning to structure-centric systems will enhance coordination and consolidate model information.

“ln all the years that I’ve been doing this (VDC Management), we start with MEP coordination and then apply that to our self-performed concrete operation. I believe there’s a better way; I’ve prototyped a structure-centric workflow system to help bring data and disciplines together, following one centralized structural model.” 

Renzo di Furia

The structure-centric modeling workflow needs further fleshing out to have building teams adopt it across disciplines. Thankfully, we know some students that can help with that! 

Creativity and Construction Go Hand-in-Hand

The construction industry faces challenges with workflow disconnects, adopting new technology, and fostering its acceptance across teams. Critical hurdles for creating a better and greener future.

Construction professionals can showcase their creativity by collaborating with local universities, engaging students in innovative projects. Furthermore, integrating advanced 3D workflows and intelligent technology for more efficient construction.

This approach not only inspires a learning culture but also reduces waste, contributing to environmental sustainability. Explore SketchUp’s collaborative and user-friendly 3D modeling software to build your workflow. Try a free trial if you don’t have a subscription.

About Renzo di Furia

Renzo di Furia is a seasoned virtual construction professional with expertise in fabrication tolerance modeling, boasting over 18 years of experience with 3D modeling tools.

He has pioneered a streamlined approach to BIM (Building Information Modeling) and VDC (Virtual Design and Construction) implementation, aligning with staff roles, enhancing operational excellence, and optimising quality, productivity, and safety.

Renzo actively contributes to the development of BIM and VDC training curriculums through collaborations with the University of Washington’s Department of Built Environments, the Trimble Visiting Professionals Program, and the Carpenters’ International Training Center in Las Vegas.

Follow Renzo on LinkedIn. 

Note: This article is a re-write originally featured on the Trimble SketchUp website.

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