Creating a connected digital ecosystem and digital twins enables the timely delivery of projects and leads to substantial cost savings and reduced environmental impact.
As part of Indonesia’s Nusantara capital city megaproject, a new 62-kilometer toll road network is being built to establish a smart and sustainable forest city.
PT Waskita Karya is the main contractor partnering with PT Nindya Karya and PT Modern Widya Technical for the 675-kilometer section 5A, Simpang Tempadung- Balang Island Bridge connection.
They determined that creating digital twins would avoid construction delays to help deliver the project on
They relied on Bentley applications to establish a real-time, cloud-based design review and digital construction management.
Improving Connectivity to Purpose-built Capital City
Establishing the new national capital, Nusantara (IKN), is set to be inaugurated in August 2024, replacing Jakarta. Spanning approximately 2,560 square kilometers, the planned city is situated on the eastern coast of Borneo in East Kalimantan province, surrounded by hills, forests, and a natural bay. With a focus on national identity that promotes economic transformation and tourism, the metropolis is leveraging artificial intelligence (AI) and advanced technologies to support sustainable transportation, renewable energy, and green development.
The construction of connecting roads, government offices, utilities, and essential infrastructure is underway to achieve intelligent, sustainable industrial development while preserving surrounding forests and enabling zero carbon emissions to establish a world-class smart forest city.
As part of this smart city megaproject, 75.62 kilometers of toll road infrastructure is being developed to enhance connectivity and reduce travel times between Balikpapan and the capital’s Central Government Core Area (CGCA) from 2.5 hours to 30 minutes. PT Waskita Karya is the primary contractor responsible for the 6.675-kilometer Simpang Tempadung-Jembatan Pulau Balang section 5A of the roadway network, linking the new IKN VVIP Airport to the CGCA via the existing Pulau Balang Bridge.
“As the main contractor, having effective data communication among stakeholders is crucial to ensure the project stays on schedule,” stated Indah Nurcahyani, BIM engineer at Waskita Karya.
Site Constraints, Design Compatibility, and Change Management
The new capital in the middle of the Indonesian archipelago faces challenges due to the hilly rainforest topography with soft soil and clay. “One of the conditions to be considered in determining the design is the extreme terrain, which requires cutting several hills, and the geological conditions, dominated by soft soil and clay layers,” said Nurcahyani.
The design must account for cutting through hills and the geological conditions. Additionally, the toll road needs to align with the existing Pulau Balang Bridge, which has already been constructed. Waskita Karya discovered discrepancies in the initial design plan and had to quickly make adjustments to accommodate the existing bridge.
“There is a horizontal alignment difference of about 1.5 meters; for vertical alignment, there is an average elevation difference of 4 meters,” said Nurcahyani.
To address these challenges, they aimed to establish a coordinated design review process that allowed for potential changes while ensuring structural integrity. They sought a multidiscipline collaboration platform to facilitate virtual visualization and communication for making timely decisions regarding design changes.
“The primary and essential focus is reviewing and changing designs quickly, precisely, and accurately,” said Nurcahyani.
Establishing Collaborative Workflows and Digital Twins
Waskita Karya implemented a shared data platform using ProjectWise® to provide all stakeholders with access to up-to-date project information. Through the use of iTwin®, they established a real-time, cloud-based environment for design review. Using drones, they conducted a site survey to capture high-resolution images of the existing topography and bridge conditions, which were then processed into a reality mesh using iTwin Capture Modeler (formerly ContextCapture). This resulted in a high-fidelity 3D model of the bridge that was uploaded to the cloud. By integrating Bentley’s open 3D modeling applications, they created a 3D design model and digital twin of the bridge and toll road.
Working collaboratively in a digital environment, the team reviewed and provided feedback on the models and conducted clash detection to anticipate potential construction issues. As discussions progressed and design decisions were made, the models were seamlessly updated and synchronized via Bentley’s iTwin Platform, eliminating the need for time-consuming file import and export processes. Field crews also had access to the digital twins through tablets to directly record their inspections on the models.
Nurcahyani stated, “Working with the 3D digital twins allowed the field team to remotely inspect the basic design plan, record their findings directly on it, and accurately identify areas in need of repair.”
The cloud-based digital twin solution streamlined collaboration among Waskita Karya’s designers and construction personnel, facilitating informed decision-making to ensure bridge and roadway alignment and maintain project progress.
Connected Digital Ecosystem Industrializes Delivery
The use of Bentley’s integrated modelling applications created a connected digital ecosystem that enabled the generation of digital twins and facilitated real-time coordinated design reviews. This resulted in a 40% reduction in design time and a 50% decrease in field inspection time. Nurcahyani stated, “The digital twins serve as a valuable communication tool, providing real-time collaboration and problem-solving without disrupting current processes.”
Through the optimization of road alignment in a 3D virtual design environment, Waskita Karya saved IDR 12.5 billion in potential rework costs within the first kilometer of the design plan. By utilizing Bentley software as an environmental and digital design and construction management platform, Waskita Karya was able to link multiple data sets, resolve visibility issues, and provide accurate material information to construction teams. This approach saved critical time and costs while achieving higher-quality deliverables compared to previous design workflows.
The implementation of the digital twin solution improved communication among engineers, field personnel, and stakeholders by eliminating 20,000 truck movements during initial construction, resulting in a reduction of diesel fuel consumption by 32,800 liters and saving IDR 590 million. Establishing a connected digital ecosystem and a single source of truth enhanced design quality, mitigated risks, and provided a solid digital framework for construction. Nurcahyani commented, “The project is now under construction, and we anticipate a more accurate design to minimize the need for on-site rework and associated costs.”
Image caption/courtesy: The digital twin solution improved communication, eliminating 20,000 truck movements during initial construction, and lowering diesel fuel consumption by 32,800 litres to save IDR 590 million. Image courtesy of PT Waskita Karya (Persero) Tbk.
Author: Meg Davis is the industry marketing director for Bentley’s road and bridge solutions from planning through operations. She has worked in the transportation industry for over 25 years and has held marketing leadership positions at several companies that provide transportation software solutions. She holds an undergraduate degree from UC Berkeley and an MBA from the University of San Francisco. She can be reached at meg.davis@bentley.com.
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