Validating Interfaces Designed To Receive Manufactured Components

Construction projects often need to precisely match a built interface with components after being manufactured or assembled remotely. The most common and classic examples are complicated facades and large-scale Mechanical systems. Because one part is often built remotely, an error in the on-site as-built component will cause significant delays if discovered after manufacture, shipping, and attempted installation.

Project Description:

A new corporate headquarters was designed with an almost 100-yard-long twisting and undulating glass facade connecting to a cantilevered atrium roof.

SKUR Diffing was used in two ways. The first was to scan to validate the correct as-built positions of the cantilevered beams and the corresponding ground-level embedded fixtures.  The second series of scans and SKUR Diffs involved visiting the manufacturing plant to scan each undulating and twisting column during manufacture.

The onsite scans revealed two unique problems. First, several of the jutting beams were outside of lateral tolerances and would need to be repositioned. The second discovery was far more critical; the load of a roof garden opposite one area of the cantilevered facades was causing unacceptable, and variable, vertical fluctuations.

The remote scans revealed only minor deviances from the design specifications. However, due to the issues discovered on site, and the fact that the manufactured components had not yet been shipped, the client was able to reconfigure several components and delay shipping until on site issues were resolved.


The critical issue surrounding the roof garden load required significant re-engineering and retrofitting throughout the facade and roof garden sections of the development. Luckily the issues were discovered before many dependent construction phases were initiated or completed, and before many manufactured components had been shipped.

All aspects of the refit cost approximately $210,000.

In order to estimate ROI, the Project Management team calculated the cost of the refit by looking at subsequent milestones when the issues likely would have been detected. These milestones ranged from several weeks to several months down the project timeline. Stages evaluated for estimating cost included shipping and reshipping, remanufacturing, component removal, refitting, trade holds, and engineering and architectural fees.

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