Digital construction has reached a point where manual modelling and reactive coordination are no longer sustainable. Projects are larger, design iterations are more frequent and coordination demands have become significantly more complex. One of the areas where this pressure is felt most clearly is in the modelling and management of areas such as blockwork walls, builders work openings and lintels. These components appear straightforward at first glance, but the volume of elements, the dependencies between trades and the consequences of inaccuracy make them a critical part of any BIM-enabled workflow, writes Ryan Donoghue, of AJ Digital, a leading provider of technical services to the construction industry.
However, before any automation can take place, the incoming design models must reach a minimum standard of consistency and technical correctness. In practice, architectural and structural models vary widely in detail and approach, particularly when multiple designers or phased releases are involved. To ensure the blockwork package is built on stable foundations, the first step involves verifying the models using Solibri. This is a model-checking and quality assurance software which allows designers, coordinators and contractors to validate, review and analyse 3D models.
These checks go beyond general model QA. They evaluate whether wall elements meet the criteria necessary for safe and compliant construction, by having the appropriate dimensions, clearances and separations.
This upfront verification matters. When the base model contains non-conformities, any automated workflow, no matter how advanced, risks replicating these non-conformities. By ensuring the model is technically sound before further processing, the workflow reduces rework later and supports more reliable coordination downstream.
Automating the replication of blockwork walls
Once the incoming models satisfy the Solibri checks, the next task is to convert the architect’s or engineer’s intent into a blockwork model that reflects buildable conditions. Doing this manually is labour-intensive and can lead to discrepancies.
This process interprets the geometry and metadata within the verified model and generates blockwork walls that respond precisely to the designer’s intent and the specialist subcontractor’s constraints. By automating this stage, walls are replicated much faster and any opportunity for human error is removed from the equation.
With the blockwork walls in place, the workflow moves to the more complex task of cutting openings and placing lintels. Builders work openings are often tied to multiple disciplines - architectural layouts, MEP penetrations, fire compartmentation, structural requirements - and these relationships must remain intact throughout the modelling process.
Through a series of automated routines, openings are cut into the blockwork walls based on the constraints dictated by the specialist subcontractor and the opening requirements set by other disciplines. The scripts assess the location and type of each opening, then apply rules to ensure it is placed correctly. These rules incorporate factors such as required clearances, minimum dimensions and required separation.
Lintels are then placed automatically using similar logic. Instead of manually selecting lintel types or calculating span requirements, the script evaluates design constraints and assigns the correct lintel for each situation. This rule-based method offers two advantages - it standardises lintel selection and ensures compliance with the project’s structural principles.
By automating both openings and lintels, the workflow provides consistent application of design rules, reduces human error and shortens the time required to update models during design changes.
Secondary verification to ensure model accuracy
Automation does not eliminate the need for verification. Once openings and lintels have been generated, the updated model is run through Solibri again. This second pass tests whether all generated elements continue to meet the required safety, spatial and design criteria.
This dual-check system - before and after automation - provides an important layer of accountability. It ensures that automated modelling does not unintentionally introduce issues and that all resulting geometry aligns with the project’s technical standards. It also supports a clear audit trail demonstrating how the model has evolved and how compliance has been maintained through each step.
Perhaps the most challenging aspect, however, of modelling blockwork walls and openings is not the initial creation, but managing what happens afterwards. Design models continue to evolve, where doors shift, services reroute and structural constraints change. When these updates occur, the blockwork model must respond to maintain accuracy.
To manage this, the workflow tracks each wall and opening individually. Every element generated through the automated process carries a unique identity, allowing it to be compared against revised models. When a new set of design information is issued, the system can identify which elements remain consistent, which have been modified and which require regeneration.
The benefit of this approach is clarity. Instead of revisiting the entire model with each design revision, the team can focus on specific walls or openings affected by the update. This reduces unnecessary rework and allows the impact of each design change to be understood immediately.
While the workflow described so far is technical in nature, its value is ultimately realised in the construction environment. Subcontractors rely on the accuracy of the digital model for sequencing, material ordering, installation planning and compliance. When the model is inconsistent or unclear, these tasks become difficult and costly.
By combining verification, automation and systematic change tracking, the process provides subcontractors with information that is both reliable and transparent. They gain confidence that openings and lintels have been placed according to consistent rules, that revisions have been accounted for and that nothing important has been overlooked during model updates.
This clarity helps reduce on-site queries, avoids buildability conflicts and supports smoother installation. It also creates a closer alignment between digital design and physical construction, an increasingly important objective across the industry.
A model-based approach for an evolving industry
We can see therefore that the automation of openings, lintels and change tracking represents more than a series of scripts or checks. It reflects a shift in how construction models are produced and managed. As projects grow in complexity, workflows must evolve to prioritise consistency, accountability and data integrity.
By embedding rule-based automation within a verified model environment, it becomes possible to manage large volumes of elements with greater accuracy and less manual effort. While no workflow eliminates the need for human expertise, this approach ensures that effort is focused where it is most valuable by evaluating design intent, understanding implications and making informed decisions.
