Key Challenges & Solutions

Challenges

Complex Site Constraints: The conveyor system was to be installed one inch below the bottom chord of trusses, requiring precise coordination and creative design solutions as most header steel had to reside above the truss in space typically allocated to MEP systems.

Highly Coordinated Design: Integration of heterogeneous design data enabled the creation of a unified model, drastically reducing field changes and conflicts during installation.

Compressed Timeline: We met an aggressive delivery schedule, driven by the client’s production and installation commitments.

Safety & Compliance: Structural layouts were meticulously engineered to preserve safety envelopes for moving systems and to comply with relevant building codes and standards.

Solution - Design and Engineering

We took responsibility for load calculations, member sizing, and connection design—tasks that often stall projects when left to external engineering teams. Using STAAD.Pro, we created structural models, calculated Kip loads, and validated every connection for building impact. Every beam, hanger, and connection was carefully coordinated to ensure both optimal performance and constructability.

When envelope constraints came into play, especially around conveyor turns, we handled coordination to ensure safety envelopes, tracking profiles, and equipment paths met clearance rules through the complex screen guard. While this is traditionally done in 2D, we advanced the process using 3D CAD validation to reduce risks and prevent field changes but also revealed a high number of potential clashes that would have otherwise gone unnoticed until install. Given the size, scale, and complexity of the project, using 3D made a significant difference and helped the entire effort run more smoothly for the client.

Solution - BIM Coordination

With parts of the building dating back to 1953 the existing structure was extremely complex featuring dozens of unique trusses with various modifications over the plants 70+ years of producing vehicles. Our team developed the coordination model using a complex mix of data including; Revit, SDS2, AutoCAD, Inventor, STEP, IFC, and point cloud data to validate as-built conditions. We identified hundreds of potential collisions before any steel was shipped, expertly routing support structures through overhead trusses without impacting existing assets.

Being fully integrated meant we could resolve issues in real time. Models were constantly updated to multiple sharing platforms, including Autodesk Vault, Revizto, and Autodesk Construction Cloud. When something didn’t line up, our detailers didn’t wait for answers—they walked over to engineering and worked on the fix. No handoffs. No delays.