The Chennai Metro Rail Limited (CMRL) Phase 2 project, covering Corridor 3 (Madhavaram Milk Colony to Sholinganallur) and Corridor 5 (Madhavaram Milk Colony to CMBT, including the Madhavaram Depot)
This package PS06 involves the design, manufacturing, supply, installation, testing, training and commissioning of key systems including Receiving Substations (RSS) at Madhavaram, Thiruvanmiyur & Nadhamuni locations, 54 Nos of Auxiliary Substations (ASS), and SCADA systems, ensuring reliable and efficient power distribution across the metro network.
The Chennai Metro Rail Limited (CMRL) Phase 2 project represents a major advancement in the adoption of digital engineering practices in metro rail infrastructure.
This implementation of Building Information Modeling (BIM),in the CMRL Projects includes 3D for engineering, 4D for Project Planning and monitoring, 5D for cost quantity management, VR/AR for customer Review including integration of multidisciplinary models, adherence to ISO 19650 standards, and the use of digital tools to improve project efficiency, reduce rework, and enhance stakeholder collaboration. The results demonstrate significant improvements in project visualization, clash resolution, cost optimization, and construction monitoring.
The project team has undertaken a federated strategy to author the 3D BIM design, in coordination with various discipline models like civil, electrical, HVAC, firefighting, lighting, and others. The ASS inputs interface with various contractors in other packages of the Metro – DPT02, UG01, UG02, UG03, UG04, UG05, UG06, EV01 & EV03 – all of which have been incorporated into the 3D BIM model, collaborated through the Autodesk Construction Cloud (ACC) platform. The HVAC model has been developed from the HVAC flow diagram and cubic feet per minute (CFM) airflow calculations. Stringent approval processes, rigid work methodologies, and the client’s requirement were some of the significant operational challenges the team faced during execution. While the ACC measures were implemented to ensure quality assurance and regulatory compliance, they have positively impacted schedule adherence, workflow efficiency, and resource planning. Cable trays and light fixtures placed at their respective locations in the BIM 3D model are regularly updated as per latest inputs. Fire & gas detection and inert gas systems are also incorporated into the model from the vendors’ inputs. Engineers from all disciplines perform checks on a weekly basis and arrive at resolutions to avoid system clashes. “We extract 2D drawings for submission and then convert the developed 3D model into a video presentation for 3D walkthroughs for the client,” reveals Project BIM Manager, who adds smilingly that has helped them obtain quicker approvals, have helped in reviews too. The client reviews the project progress using the 4D construction sequence & simulation linked to the project’s L4 schedule. By leveraging 4D modelling to link construction activities with our project schedule, we plan better, detect clashes, and execute on time, integrating BIM 5D, we are tracking real-time cost impacts alongside design changes, helping us maintain budget control and improve financial forecasting.3D BIM based Bill of Quantity used for the procurement. VR Utilized for client review and walkthrough and AR for checking the deviations and alignment at the site execution.
Clash checking and resolution were carried out as a critical part of the BIM coordination process to ensure a conflict-free design before construction. Interdisciplinary models were integrated and analyzed using Navisworks to identify clashes between structural, electrical, mechanical, and other systems. Each identified issue was reviewed in coordination with the respective design teams, and necessary modifications were implemented to resolve conflicts. Regular coordination meetings and workshops with stakeholders facilitated effective decision-making, resulting in improved design accuracy, reduced rework, and smooth project execution at the site.
With tools like Revit, Navisworks, and ACC, team perform stringent weekly quality checks that include geometric & visual accuracy, standards compliance, and LOD compliance. “All technicians and discipline BIM leads are responsible to perform these checks, one of the most important being model integrity checks to ensure that elements are modelled. correctly spatially and associated to the relevant reference grids & levels,” explains Project manager. This crucial step avoids duplication of elements & overlapping and ensures that no objects are missed. Document and interface management is through Autodesk BIM Collaborate Pro for common data storage and easy design collaboration among multiple stakeholders, across the different packages. This centralized system allows all stakeholders to access the latest project files, drawings, and specifications, streamlining construction workflows such as RFIs, checklists, quality inspections, and issue tracking. With this real-time data sharing and markup, our decision-making and issue resolutions are quicker. All updates are tracked, logged, and accessible through the cloud, reducing disputes and miscommunication. The successful implementation of ACC in PT&D’s CMRL project demonstrates the tangible benefits of digital construction management.
PT&D IC is executing the design, manufacturing, supply, installation, testing & commissioning of 3 Nos of 110kV receiving substation (RSS), 54 Nos auxiliary substation (ASS) equipment, earthing & cable routing, OCC room SCADA, and viaduct cable routing.
The 3D BIM models for 3 Nos of RSS stations were developed based on the available design inputs, with continuous design collaboration carried out through the ACC platform. Package creation and submissions were managed via the ACC server, ensuring streamlined coordination. The packages were shared with the client for approval through ACC, where the client reviewed the models and provided comments directly on the platform. All comments were addressed and incorporated into the models, and the revised submissions were resubmitted for approval. Upon receiving client approval, the project proceeded to the construction phase.
For the 54 ASS stations, all interfaces were managed through the ACC server to ensure effective coordination. The civil contractor developed and shared their models via the platform, after which we reviewed and consumed the models for further development. Based on these inputs, equipment earthing and cable routing were carried out. Requirements were raised as needed, and multiple interface coordination activities were conducted through the design collaboration process. All deliverables were reviewed and formally signed off through the ACC platform. This ensured consistency, accuracy, and improved coordination across all disciplines. To maintain progress and alignment with project objectives, the client conducted monthly offline BIM review meetings, providing a structured platform to assess deliverables, address challenges, and streamline workflows.
The RSS Combined Coordinated Service Model and associated signoff documents, along with ASS, OCC, and BOCC signoff documentation, were successfully developed and managed through the BIM platform in coordination with other SWC and civil contractors. BIM enabled a streamlined review and approval process by ensuring all stakeholders worked on a coordinated and up-to-date model. This facilitated effective interdisciplinary collaboration, improved document accuracy, and ensured that all design and construction requirements were properly validated before final signoff.
Continuous monitoring and evaluation of BIM progress enabled effective tracking of project milestones, ensuring timely updates, improved quality control, and adherence to project standards.
The project leveraged advanced Virtual Reality (VR) technology to enhance design validation and stakeholder engagement. The CMRL client visited and reviewed their model in the PT&D VR facility at Chennai Headquarters, where they experienced an immersive review of the project in a fully virtual environment. This enabled a comprehensive understanding of spatial arrangements, system layouts, and overall project design. The VR room was also extensively utilized for Model Review purposes, including detailed clash detection reviews and site planning simulations, improving coordination among project teams. The setup incorporated the HTC Vive Pro wearable device, providing high-quality visualization and interaction capabilities. The virtual environment was developed using industry-leading platforms such as Fuzor and Stream, ensuring accurate model integration and real-time rendering for effective decision-making.
Augmented Reality (AR) was successfully implemented at the CMRL site for the Receiving Substation (RSS) and BOCC Utility Building, enhancing on-site visualization and execution. This technology enabled project teams to overlay digital BIM models onto the physical environment, facilitating accurate validation of design against actual site conditions. The use of AR improved installation accuracy, supported real-time decision-making, and minimized potential errors during construction. It also served as an effective tool for site coordination, allowing stakeholders to better understand complex systems and ensure alignment with the intended design.
Monthly construction progress reports are prepared based on Primavera P6 schedule and submitted to the client to ensure effective monitoring and control of project activities.
These reports provided a comprehensive overview of the work completed, ongoing activities, and upcoming milestones, along with key performance indicators and progress status against the planned schedule. Integrated with BIM data, the reports offered clear visual insights through model-based progress tracking and 4D simulations, enabling the client to better understand site conditions and overall project advancement. This systematic reporting approach enhanced transparency, supported informed decision-making, and ensured alignment with project timelines and objectives.
The 4D BIM plan versus actual analysis was implemented to effectively monitor and control construction progress by linking the project schedule with the 3D BIM model. The planned construction sequence (baseline schedule) was compared with the actual site progress, enabling clear visualization of delays, deviations, and ongoing activities.
This comparison provided valuable insights for project stakeholders, allowing timely corrective actions and improved decision-making. By integrating plan vs actual tracking within the BIM environment, the project team enhanced schedule management, increased transparency, and ensured better alignment with project timelines.
In the BIM environment, RFI (Request for Information) tracking was effectively integrated with construction progress to ensure seamless coordination between design and execution teams. RFI numbers were embedded within the BIM models and linked to specific elements and activities, enabling real-time updates and clear traceability.
As construction progressed, RFIs were continuously monitored and updated within the model, allowing stakeholders to visualize issues in context and take timely corrective actions. This integration improved communication, reduced response time, and ensured that project progress remained aligned with design intent and site requirements.
BEXEL Manager software was utilized to implement 5D BIM for the CMRL project at the Madhavaram Receiving Substation (RSS), enabling the integration of cost management with the 3D BIM model. This approach allowed for accurate quantity take-offs, cost estimation, and budget tracking directly from the model.
5D BIM enables the calculation and comparison of planned quantities against actual quantities for effective material procurement monitoring. Initially, quantities are extracted from the design model as planned values. During execution, actual quantities are tracked based on site consumption, purchase orders, and delivery records. By integrating cost and quantity data within the BIM environment, any deviations between planned and actual quantities can be identified in real time. This helps in optimizing material procurement, reducing wastage, avoiding shortages, and ensuring better cost control and project efficiency.
By linking project components with cost data, the team was able to monitor financial performance in alignment with construction progress, identify potential cost deviations, and optimize resource planning. The use of BEXEL Manager significantly enhanced cost control, improved transparency, and supported informed decision-making throughout the project lifecycle.
Bexel Manager for 5D BIM is utilized to validate tender quantities against actual quantities executed on site, helping in identifying variations, controlling costs, and ensuring better project planning and procurement management.
5D BIM is utilized to compare planned costs with actual costs, enabling effective monitoring and control of project expenses throughout the entire project lifecycle. By integrating cost data with the BIM model, it provides real-time insights into budget performance, helps identify deviations, and supports informed decision-making for better cost management and project efficiency.
Automated placement of cable trefoil clamps along curved viaduct alignments presents a significant challenge due to complex geometries, varying orientations, and the need for precise spacing. Automation routine was developed to address these challenges by enabling accurate and consistent placement of more than 900 trefoil clamps with minimal user intervention. The system incorporates automated detection of curved viaduct paths and applies intelligent algorithms to ensure uniform clamp positioning along the alignment. By eliminating manual placement, the approach significantly reduces human error and improves modeling reliability. The implementation of this method has resulted in a reduction of modeling time by over 95%, while simultaneously enhancing model accuracy, coordination, and overall constructability.
The implementation of automation in the BIM workflow has significantly improved efficiency by reducing model creation time. In addition to time savings, BIM has enabled a much higher level of accuracy in model development, minimizing errors and enhancing overall design quality. This improvement has contributed to faster project delivery, reduced rework, and more reliable outputs for construction and coordination activities.
“Digital technologies like 3D BIM, 4D BIM, 5D BIM & VR/AR can coalesce to generate business value and improve their competitiveness.”
