From the outset, we recognised that conventional modelling methods would be insufficient to capture these complexities. Instead, we integrated advanced digital tools into our workflow, leveraging Grasshopper for parametric modelling, the Tekla API for automated component creation, and Solibri for comprehensive quality assurance.

Design changes, regardless of their complexity, were incorporated rapidly and accurately, ensuring the model remained fully up to date. This agility significantly reduced turnaround times, minimised costly rework and delivered substantial time and cost savings.

The result was an exceptionally precise digital model, delivered far more efficiently than would have been possible using conventional methods. The entire process was more transparent, easier to manage and enabled progress to be closely monitored throughout delivery. Rigorous automated quality control and full process oversight ensured outstanding quality at every stage.

The bridge’s double curvature and required precamber posed significant challenges for conventional modelling methods. To address this, we developed a robust parametric workflow in Grasshopper, scripting the entire bridge geometry—including the primary shell and all secondary and tertiary elements. This enabled us to quickly generate the sophisticated bridge geometry within Grasshopper to tight tolerance requirements.

This method provided full parametric control of complicated geometry to efficiently accommodate rapid design changes, which was a major modelling delivery challenge. Automating the modelling process in Grasshopper, not only accelerated geometry creation but also enhanced error control and quality assurance from the earliest stage.

Our QA procedure was implemented prior to scripting by defining, cross-checking and approving the scripting methodology together with the design team. QC procedures were applied during and post scripting using specialised tools, guaranteeing absolute compliance of the exported shell to the complicated design geometry, in less time and with very high accuracy.

Upon completion, the intricate shell was exported to Tekla as “contour plates” via an automated pipeline (remaining structural elements exported as components). Compared to conventional manual modelling, this automation resulted in substantial time and effort savings, guaranteed higher quality and provided significant cost benefits to the client.

Additionally, the automation and structured dataflow greatly improved project scheduling and progress monitoring, making the process more predictable and manageable for all stakeholders.

Building on the parametric geometry established in Grasshopper, we advanced the fabrication modelling stage in Tekla using a fully automated, API-driven workflow. Every structural member defined in Grasshopper—ranging from the primary shell, modelled as “contour plates” to all primary, secondary and tertiary elements—was seamlessly transferred into Tekla Structures. This was achieved through bespoke APIs that read relevant parametric data from Grasshopper and programmatically generated the corresponding Tekla components, ensuring perfect fidelity to the design intent.

The automation did not stop at geometric creation. We further leveraged Tekla’s API capabilities to generate all critical fabrication details, including connections, splices and diaphragm members, based entirely on the input parameters. This parametric approach meant that any design changes—no matter how complex or urgent—could be rapidly incorporated across the entire model with a single update. This eliminated the need for painstaking manual revisions, drastically reducing turnaround time and minimising the possibility of coordination errors.

A significant advantage of this technology-driven workflow was the transformation of our quality control process. Instead of manually checking thousands of individual components, our QA/QC efforts could focus on validating the API logic and outputs. Once the APIs were rigorously reviewed and approved, we achieved consistent, project-wide quality assurance—every element produced by the API met our standards, every time. This not only ensured 100% coverage but also freed up valuable resources for higher-level project oversight.

From a project management perspective, API-based automation made scheduling far more predictable and efficient. We could plan around the clear, fixed effort of API development rather than trying to estimate countless manual tasks, resulting in more accurate timelines and resource allocation.

To maximise our digital workflow, we developed a custom Tekla plugin to transfer detailed metadata from the LOD 300 design model to the fabrication model. This ensured consistent data, streamlined procurement estimation and allowed rapid, reliable metadata quality checks through automated cross-referencing with the design model.

By harnessing advanced technology throughout the project, we achieved a level of efficiency, accuracy and transparency that conventional methods could not match. This accelerated delivery while providing the client and fabricator with a highly-detailed, data-rich model, enabling a smoother transition from design through procurement and construction.

Parametric design and automation

• Utilisation of Grasshopper for fully parametric geometry modelling, allowing precise control of complex forms and rapid adaptation to design changes.
• Automated scripting and quality assurance measures established before modelling, ensuring robust error control and compliance from the outset.

Digital fabrication modelling

• Seamless export of parametric geometry from Grasshopper to Tekla Structures as “contour plates” and components, using bespoke automated pipelines.
• API-driven automation in Tekla for generating fabrication-level details, including connections, splices and diaphragm members—eliminating manual revisions and reducing turnaround time.

Quality assurance and metadata management

• Integration of Solibri for comprehensive model-based QA/QC with a focus on validating logic and outputs rather than individual components.
• Custom-developed Tekla plugins for automated transfer and verification of detailed design metadata, ensuring accuracy and consistency for procurement and construction.

Project efficiency and predictability

• Automation and structured data flow enable accurate scheduling, progress monitoring and resource allocation.
• Parametric workflows significantly reduce manual effort, improve quality and deliver substantial cost and schedule benefits for clients.

Unique value proposition

• Proven ability to delivery high-precision, double-curvature steel bridge models to tolerances of less than one millimetre.
• Rapid, reliable response to evolving design requirements through end-to-end digital processes.
• Consistent delivery of richly detailed, data-driven models that streamline transitions from design to procurement and fabrication.

Contact us if you would like to learn more about our parametric design and advanced digital workflows for complex projects.