成大土木 x 繽紛科技聯合 BIM 工程應用實務課程 112 學年度 下學期 BIM 技術應用於營建工程之案例分析

APPLICATION OF BIM FOR FABRICATION OF PANELS 2. Engineering Challenges

AND IRREGULAR CONCRETE STRUCTURES Construction of the Dongdaemun Design Plaza faced considerable challenges: intricate design
Dongdaemun Design Plaza, Seoul, South Korea requirements demanded innovative engineering solutions, its central urban setting posed
logistical hurdles, and the project was constrained by a tight timeline coupled with budget
limitations.
2.1 Complexity of Design
The Dongdaemun Design Plaza's unique shape meant that over 45,000 panels, including 20,000
specially curved ones, had to be made quickly and affordably. Finding a way to efficiently
customize each panel was crucial. Each time the design and fitting of the panels were adjusted,
it significantly affected the project's timeline. This was because every tiny change required
starting over with the design details, as suggested by the facade experts and Zaha Hadid
Architects.

Figure 1.1-1 Dongdaemun Design Plaza Night Facade

1. Project Introduction
The Dongdaemun Design Plaza (DDP), located in Seoul, South Korea, is an iconic urban
Quantity
development landmark known for its distinctive neo-futuristic design, featuring curvilinear Panel Type
(Piece)
Area Ratio Flat Single Curved Double Curved

forms and no straight lines or walls. Building Information Modeling (BIM) played a crucial role in
Flat 13,841 9492 m2 29%
its construction, enabling the realization of its complex architecture.
Single
1.1 Basic Information Curved
9,554 7455 m2 22%

Double
Address : 281 Eulji-ro, Jung-gu, Seoul, South Korea 21,738 16281 m2 49%
Curved
Annual Visitor Count : 13.75 Million (as of 2023)
Total 45,133 33228 m2 100% 29% 22% 49%
Projected Cost : US $ 200 Million
Actual Cost : US $ 370 Million Figure 2.1-1 Distribution of Panel Types
Project Duration : Design Competition April 2007 – August 2007
: Site Clearance December 2007 – February 2009
Initially, the plan was to use about 14,000 panels, but this number grew to more than 45,000.
: Construction March 2009 – March 2014
With every adjustment, the way panels connected and interacted had to be rethought, making
: Official Opening Date March 21, 2014
previous designs obsolete. Additionally, getting different design software to work together
Site Area : 65,000 m2
smoothly became a major challenge
Gross Floor Area : 86,574 m2

-1-
 成大土木 x 繽紛科技聯合 BIM 工程應用實務課程 112 學年度 下學期 BIM 技術應用於營建工程之案例分析

2.2 Historical Location Construction Management Consortium of :

The Dongdaemun Design Plaza is in a historic part of Seoul, near the East Gate (Dongdaemun), Kunwon Engineering
an area famous for fashion. It's built on the site of an old stadium, with some stadium lights left Global Team Space Engineering & Consulting (GTS
to honor the history. During construction, remains of ancient walls and military sites were
E&C)
found, requiring design changes by Zaha Hadid's team to incorporate these historical elements,
Heerim CM
adding to the project's complexity.
2.3 Schedule and Budget Constraints
Cladding Consortium of :
The Dongdaemun Design Plaza project was under strict time and financial constraints. It was
completed four times faster than similar exhibition spaces built in South Korea between 2012 Iljin Aluminum
and 2014, and at least 1.3 times quicker than other Zaha Hadid Architects (ZHA) projects. SteelLife
Despite the fast pace, the cost was about 132% to 177% higher than other exhibition facilities Steel E&C (ISS)
constructed during the same period. Given DDP's intricate design, the budget was considerably
tight.
Table 3.1-1 (cont.) Dongdaemun Construction Team
3. Organizational Roles
The construction of the Dongdaemun Design Plaza (DDP) was a massive undertaking that
3.1 Participants in the Project of DDP demanded a diverse and specialized team. Each participant played a critical role, from initial
design to the final construction phases. As the project's requirements grew in complexity,
Roles Participants additional experts, such as BIM consultants, were recruited to address specific challenges,

3.2 Zaha Hadid Architects (ZHA)

Owner/Client
Design Architect, Construction
Administration
Architect of Record
Construction Documentation
City of Seoul
ZHA took on the role of design architect, bringing their renowned innovative and futuristic
design concepts to the project. They were instrumental in shaping the unique architectural
Zaha Hadid Architects identity of the DDP, requiring intricate detailing and complex geometrical considerations.
3.3 Samoo Architects & Engineering
Samoo partnered with ZHA to handle construction documentation and construction
Samoo Architects & Engineering administration. Their local expertise complemented ZHA's design work, ensuring that the
project's execution adhered to South Korean construction standards and practices.

Construction Administration 3.4 Group 5F, Evolute, Ebener

These facade consultants specialized in the complex façade system of the DDP. Their expertise
was critical in realizing the ambitious designs of ZHA, particularly in engineering and fabricating
Façade Consultant Group 5F, Evolute, Ebener
the thousands of unique façade panels.

3.5 Samsung Consortium and Trade

Main Contractor Samsung Construction and Trade (Samsung C&T)
As the main contractor, Samsung C&T was responsible for the overall construction of the DDP.
Consortium
They managed the construction site, coordinated between various subcontractors, and ensured
that the construction process adhered to the planned schedule and budget.
BIM Consultant Gehry Technologies (GT) Korea

-2-
 成大土木 x 繽紛科技聯合 BIM 工程應用實務課程 112 學年度 下學期 BIM 技術應用於營建工程之案例分析

3.6 Gehry Technologies 9) Early construction phase, May 2011 10) Mid construction phase, July 2011
Brought on board as BIM consultants, GT Korea played a crucial role in developing Building Gehry Technologies (GT) Asia hired as a BIM models for low-rise buildings
Information Modeling (BIM) for the DDP. Their work facilitated the management of complex BIM consultant; GT Korea founded. developed; manual fabrication of
geometries and integration of construction processes, improving efficiency and communication concrete forms initially continued.
among teams.
3.7 Kunwon Engineering, GTS E&C, Heerim CM 11) Mid construction phase, August 12) Late construction phase, October
2011 2011
This consortium handled construction management, overseeing the construction to ensure it
Introduction of a BIM process for Data exchange and conflict resolution
met the project's quality, time, and cost requirements. Their expertise was essential in
construction; DP model established as processes implemented for BIM models.
coordinating the project's various components and stakeholders.
the master BIM model.
3.8 Iljin Aluminum, SteelLife, Steel E&C (ISS)
13) Late construction phase, Dec 2011 14) Completion phase, Mid 2012
Specializing in cladding, this consortium was responsible for the fabrication and installation of
Development and application of Successful reduction in panel fabrication
the DDP's unique façade panels. Their work was critical to achieving the architectural vision,
multipoint stretch forming (MPSF) cost and production time through BIM to
requiring precision engineering and customization.
method for façade panels. fabrication method.
4. BIM Utilization Throughout the Life Cycle Figure 4.1-1 Project Stages in Dongdaemun Design Plaza
4.1 Project Stages
4.2 Initial BIM Implementation

1) Early planning stage - January 2010
Design challenges for Dongdaemun
Design Plaza (DDP) identified, including
double-curved façade panels.
3) Planning/Design phase, April 2010
Development of a new metal processing
machine proposed, based on multipoint
forming technique.
5) Starting Construction, Late 2010
Construction phase begins; project split
into two parts: history and culture park,
and design plaza.
7) Early construction phase, March 2011
Samsung Construction & Trade
consortium wins the project; lengthy
negotiation process ensues.
2) Early planning stage, February 2010
Design challenges for Dongdaemun
Design Plaza (DDP) identified, including
double-curved façade panels.
4) Design phase interruption, June 2010
Discovery of historical remains on-site;
project redesign required.
6) Early construction phase, February
2011
Tight schedule and budget constraints
recognized; DDP construction compared
with similar projects.
8) Early construction phase, April 2011
Seoul hires ZHA + Samoo again as
construction administrators, along with a
CM team and a new BIM team.
At early construction phase, following the hiring of the Samsung Construction & Trade
consortium and the completion of the negotiation process. Gehry Technologies (GT) Asia was
hired as the BIM consultant. The initial task was to develop BIM models for the low-rise
buildings within three months.
4.3 Development of BIM Processes
After the completion of the BIM models for the low-rise buildings, leading into the further
construction phase of the DDP project. A BIM process was established, defining roles for the
BIM consultant. The process involved specifying data exchange flows and incorporating design
changes into the BIM models.
4.4 Adoption of MPSF for Façade Panel Fabrication
At Mid to late construction phase, after the BIM process had taken shape and the project faced
challenges with fabricating the double-curved façade panels. A consortium led by SteelLife
developed a new machine using the MPSF method, combining multipoint forming and stretch
forming. Detailed shape information in the BIM model enabled efficient and precise fabrication.
4.5 Integration of BIM with MPSF
Throughout the construction phase, as the BIM process matured and the MPSF method was
refined through mock-up tests and actual production. The BIM models provided detailed shape
information for the façade panels, used to control the MPSF machine. This integration allowed
for the seamless fabrication of over 45,000 panel pieces within about a year.

-3-
 成大土木 x 繽紛科技聯合 BIM 工程應用實務課程 112 學年度 下學期 BIM 技術應用於營建工程之案例分析

5. Scope of BIM Application 5.4 Irregularly Shaped Interior Concrete Structures

The scope of BIM work in the Dongdaemun Design Plaza included creating detailed digital Due to the inability of traditional construction methods to meet the necessary quality standards
models, guiding the fabrication of complex aluminum panels and interior concrete structures, for exposed concrete structures needing a flawless finish, the multipoint stretch forming (MPSF)
ensuring accuracy, and facilitating efficient project execution. technique was employed. This approach enabled the production of steel concrete forms with a
finish quality that deviated by only 0.5 mm from the design models.
5.1 BIM Models for Low Rise Buildings
Gehry Technologies (GT) Asia developed Building Information Modeling (BIM) models for the
low-rise buildings within the project. These models were intricately divided into 30 cm cross-
sections to facilitate precise fabrication processes. These cross-sections directly informed the
fabrication of concrete formwork ribs, illustrating the BIM models' crucial role in bridging the
gap between digital design and physical construction, enhancing precision, and streamlining
production.
5.2 Digital Project Master
Establishment of a Digital Project (DP) master model creates a more integrated and streamlined
construction process. By designating the DP model as the master Building Information
Modeling (BIM) repository, the project facilitated seamless data exchange and collaboration
among diverse teams. This centralization not only served as the backbone for communication
but also significantly enhanced the efficiency of incorporating design changes and resolving Figure 5.3-1 Aluminum Panels installed in DDP
interdisciplinary conflicts.

The adoption of the DP master model as the authoritative source of project information led to
the implementation of a robust conflict resolution process. Through weekly and ad-hoc BIM
meetings, discrepancies between different trades’ designs could be addressed promptly,
ensuring that all modifications were accurately reflected across the project's architectural and
engineering dimensions. This approach proved instrumental in aligning the efforts of various
stakeholders, thereby mitigating the risk of delays and ensuring a coherent progression
towards project completion.

5.3 Fabrication of Aluminum Panels

A consortium led by Iljin Aluminum, SteelLife, and Steel E&C developed a machine for creating
double-curved aluminum panels using a method called multipoint stretch forming (MPSF). This
method relied on Building Information Modeling (BIM) for panel shape data. The machine,
equipped with 1,200 posts controlled by DC motors, adjusted the posts' heights based on the
BIM data.

An automatic system using a laser scanner identified the closest match to the BIM model's
panel shape on the sheet metal. A robotic arm with a laser cutter then cut out the panels,
ensuring the cut edges were smooth by adjusting the laser's angle. Finally, ribs were welded to
the panels for structural support. Figure 5.4-1 Irregular Shaped Concrete Structure in DDP

-4-
 成大土木 x 繽紛科技聯合 BIM 工程應用實務課程 112 學年度 下學期 BIM 技術應用於營建工程之案例分析

6. Software Utilization 6.4 Revit

6.1 Importance of Software Utilization in DDP Revit supported the project through 3D coordination, design authoring, and construction
documentation. It enhanced collaboration among different disciplines by managing complex
The Dongdaemun Design Plaza (DDP) required sophisticated design and construction
data and ensuring architectural and engineering components were aligned.
techniques due to its complexity. By employing programs like Rhino, Digital Project, Revit,
AutoCAD, MIDAS, and Tekla Structures, each with its own strengths, the project team crafted a 6.5 AutoCAD
comprehensive process that brought the intricate design to life. AutoCAD was utilized for creating detailed drawings and documentation. It played a key role in
the digital fabrication process and ensured accurate communication of project details.
Phase BIM Uses Software Used 6.6 MIDAS and Tekla Structures

Schematic and Design
Design Authoring
Development
Design Authoring
3D Coordination
Construction Documentation Construction Documentation Revit
Structural Analysis
3D Coordination
Structural Analysis
Construction
Digital Fabrication
Design Authoring
MIDAS and Tekla Structures were employed for structural analysis and detailing. They
Rhinoceros addressed the structural challenges of DDP, ensuring the design's integrity and safety, and
facilitated the digital fabrication of structural elements with high precision.
Rhinoceros Digital Project
7. Workflow and Process Overview
AutoCAD
In the construction of the Dongdaemun Design Plaza (DDP), several Building Information
Modeling (BIM) processes were employed, but the primary focus here is on the fabrication of
MIDAS Tekla Structures
the aluminum panels—from design inception through data manipulation to the final
Rhinoceros Digital Project fabrication stage.
7.1 Design to Data Conversion
Revit Tekla Structures
The process begins with the architectural designs crafted in Rhinoceros (Rhino), which were
MIDAS Tekla Structures then transferred to Digital Project (DP) as IGES models. This transfer marks the first critical step
in converting design concepts into actionable data. Through DP's advanced scripting and
Rhinoceros Digital Project
templates, a wireframe model was automatically generated, providing a structural blueprint for
AutoCAD space frames and further detailing. Corrections to space frame positions, panel creation, and
the subsequent subdivision of panels were all guided by this detailed digital framework,
Rhinoceros AutoCAD ensuring that each piece adhered precisely to the architectural intent.

Table 6.1-1 Software Utilized in DDP and their Roles
6.2 Rhino
Rhino was used for designing the DDP's complex, free-form geometries. It allowed for accurate
modeling of the building's unique shapes and was instrumental in both the design creation and
coordination processes.
6.3 Digital Project
Digital Project facilitated the integration of architectural models with structural and engineering
data. It was used to ensure precision in the construction documents and models, aligning the
intricate designs of DDP with executable construction plans.
7.2 Data Extraction and Panel Identification
Following the creation of a digital skeleton, the process advanced to data extraction for panel
subdivision and fabrication. Each panel received a unique identifier, automating the
classification and easing the subsequent fabrication phase. The data extracted was pivotal in
defining panel types for fabrication, estimating costs, and preparing for the final physical
creation. This phase underscores the seamless transition from abstract design to tangible
components, facilitated by sophisticated BIM technologies.

-5-
 成大土木 x 繽紛科技聯合 BIM 工程應用實務課程 112 學年度 下學期 BIM 技術應用於營建工程之案例分析

7.3 From Data to Fabrication

2 3
The culmination of this process is the actual fabrication of the panels, realized through a
collaboration with a consortium led by SteelLife. The introduction of the Multipoint Stretch
Forming (MPSF) method revolutionized the production of double-curved aluminum panels.
This technique, supported by a machine equipped with 1,200 posts, each individually controlled
for precision, allowed for the direct translation of BIM data into physical forms. The machine's
ability to automatically detect and match panel shapes to the BIM model, followed by precise
4 cutting and forming, exemplifies the direct link between digital data and physical fabrication.

8. Conclusion

5 6
The use of Building Information Modeling (BIM) for the Dongdaemun Design Plaza (DDP)
project epitomizes the transformative potential of digital technologies in the field of
architecture and construction. Through a seamless digital-to-physical transition, BIM facilitated
7 the management of complex geometries, ensuring the precise realization of the DDP's unique
design.

This process not only optimized the fabrication of aluminum panels, leading to a significant
reduction in both cost and production time, but also exemplified the capability of BIM to
streamline construction workflows, enhance collaboration, and improve efficiency. The success
of the DDP project serves as a compelling case study for the adoption of BIM in ambitious
8 9 10
architectural endeavors, highlighting its invaluable role in modern construction.
(1) Initial Model Transfer: Architectural models were transferred from Rhino to Digital Project as IGES files.
9. Resources and Reference
(2) Wireframe Development: Automated generation of wireframe models for spatial framing using Digital Project.
• Sacks, R., Eastman, C., Lee, G., & Teicholz, P. (2018). BIM Handbook: A Guide to Building
(3) Space-frame Adjustment: Utilized Excel and Digital Project for precise location corrections of space-frames. Information Modeling for Owners, Designers, Engineers, Contractors, and Facility Managers
(3rd ed.).
(4) Panel Creation: Detailed creation of panels and supporting rod bars.
• Engineering.com. (n.d.). Dongdaemun Design Plaza: A BIM Proof of Concept. Retrieved April
(5) Data Extraction: Subdivision data for panels were methodically extracted. 8, 2024, from https://www.engineering.com/story/dongdaemun-design-plaza-a-bim-proof-
of-concept
(6) Panel Identification: Automatic numbering of panels with unique IDs.
• Metropolis. (n.d.). Dongdaemun Design Plaza (DDP). Retrieved April 8, 2024, from
(7) Type Classification: Panels classified into types for fabrication and estimation purposes based on their shape. https://use.metropolis.org/case-studies/dongdaemun-design-plaza-ddp
• Shin, N. (2014). Territorialized urban mega-projects beyond global convergence: The case of
(8) Perforation Modeling: Generation of models for panels requiring perforations.
Dongdaemun Design Plaza Park Project, Seoul. ResearchGate. Retrieved April 8, 2024, from
(9) Final Modeling: Completion of models incorporating substructures and detailed patterns. https://www.researchgate.net/publication/261717818_Territorialized_urban_mega-
projects_beyond_global_convergence_The_case_of_Dongdaemun_Design_Plaza_Park_Project
(10) Fabrication Data: Extraction of detailed drawings and fabrication data in DXF format from the final models. _Seoul
• Inexhibit. (n.d.). Seoul, Dongdaemun Design Plaza by Zaha Hadid Architects. Retrieved April 8,
Table 7.2-1 Process of Extracting Dimension Data from Design
2024, from https://www.inexhibit.com/case-studies/seoul-dongdaemun-design-plaza-by-
zaha-hadid-architects/

-6-