The steel bar project at the Wuhan Tianhe Airport Phase III, managed by China Construction Third Engineering Bureau, showcases the advantages of using the “BIM prototype + CNC processing” model. This approach dramatically improves production efficiency, reduces material waste, and ensures cost savings.
Key Benefits of the BIM Prototype + CNC Processing Model
- High Material Utilization
- Efficiency: For every 1,506 tons of steel bars processed, only 8.9 tons of waste are generated, achieving an impressive overall utilization rate of 99.41%.
- Cost Savings: Compared to traditional labor-intensive processing, this method generates direct economic benefits amounting to 191,237 yuan.
- Six-Step Process Overview
Step 1: BIM Prototype
- Process: Open the 3D BIM model in software, input key parameters (e.g., concrete protective layer thickness, steel bar model, spacing values), and generate steel bar distribution in 30 seconds.
Step 2: Generate Original Bill of Materials
- Process: Use a customized template to export a detailed bill of materials immediately.
Step 3: Generate Processing Bill of Materials
- Process: Employ a self-developed “Material Bill Processing Program” to optimize the original bill, match steel bar lengths scientifically, minimize waste, and create processing and sorting bills.
Step 4: Distribute Tasks Digitally
- Process: Send processing task bills to operators via the “BIM Cloud Management System.”
Step 5: Import Task via Barcode
- Process: Workers scan the barcode on the processing material plate, and corresponding tasks are displayed on CNC equipment screens.
Step 6: CNC Rebar Processing
- Process: Select and start tasks on CNC equipment. Steel bars are straightened, bent, and cut with minimal manual handling required.
Advantages of the BIM Prototype + CNC Processing Model
- Simplified Prototyping
- Efficiency: Software-based copying in BIM models is fast and precise, reducing the need for extensive manual experience. The research team developed over a dozen high-efficiency reinforcement components, streamlining complex and conventional structures.
- Error Reduction: Real-time model display helps in troubleshooting issues such as conflicts between vertical and horizontal bars, which traditional methods might only reveal on-site.
- Streamlined Processing
- Performance: Data from the Tianhe Airport Phase III project indicates that 1,506 tons of steel bars were processed in 70 days by just four workers, achieving accurate cutting and bending with minimal manual labor.
- Material Cost Savings
- Waste Reduction: Accurate BIM copying and CNC processing allow for precise prediction of material waste, reducing additional losses and waste compared to traditional manual processing methods.
Field Insights
At the workshop, CNC steel bar bending machines, CNC bar shearing production lines, and two-way moving inclined plane bar bending centers operate alongside auxiliary equipment like gantry cranes and forklifts. The entire process is methodically executed in six steps:
- BIM Model Preparation: Quick setup of the project model and automatic steel bar distribution.
- Material Bills Creation: Accurate and optimized bills for processing and sorting.
- Task Distribution: Digital transmission of tasks to operators.
- Barcode Scanning: Efficient task import into CNC equipment.
- CNC Processing: Automated and precise steel bar processing with minimal manual intervention.
The “BIM Prototype + CNC Processing” model represents a significant advancement in steel bar processing, offering efficiency, accuracy, and cost-effectiveness. This modern approach demonstrates how technology can revolutionize traditional methods, providing a blueprint for future construction projects.
