Episode Content

Gary Cowan, Head of Digital Construction at Kane Group and a member of the Autodesk Expert Elite program, joins the Digital Construction Podcast to discuss the evolution of precision in the AEC industry. Drawing on twenty years of experience, Gary explains how his team utilizes Design for Manufacturing and Assembly (DfMA), high Level of Development (LOD) models, and Extended Reality (XR) to build projects "like a machine" in the digital world before they are recreated on-site. The episode explores the shift from 2D AutoCAD to highly detailed 3D models that serve as a single "source of truth" for everyone from accountants to site installers.


Building Like a Machine: The Power of DfMA

A core pillar of Gary's strategy is shifting construction from the unpredictable site to a controlled factory environment. This DfMA mindset allows for the pre-fabrication of complex elements, like bathroom pods or massive MEP steel frames, which are then brought to the site as "big Lego pieces". This approach turns the construction site into an assembly yard, enabling the team to meet aggressive timelines with millimetre accuracy.


Precision through Insanely High LOD

Gary is an advocate for maintaining insanely high LOD (400-450) models. Because Kane Group fabricates directly from the model, every tag and measurement must be exact. This level of detail has the added benefit of enabling live digital take-offs, where the digital bill of materials keeps a live tally of every component as the model is updated.


Reality Capture as a Digital Twin

To bridge the gap between the office and the site, Gary utilizes Reality Capture and point cloud technology. By taking a digital snapshot of existing conditions or new installations, his team creates a representation of reality that is "finer than a human hair". This allows the Revit team to compare the actual site geometry against the model in a matter of hours, ensuring that pre-manufactured components will fit perfectly upon arrival.


Immersive Coordination with XR

Gary has evolved from a gaming aficionado into a leader in Extended Reality (XR) for construction. Using tools like Autodesk Workshop XR, he conducts design reviews where team members walk through a completed "digital article" to understand the scope before work begins. This bidirectional system allows him to flag an issue in VR that a site member can then inspect in real-time using an AR-enabled tablet, creating a seamless loop between the digital and physical worlds.


The AI Dilemma: Tool vs. Illusion

Regarding the future, Gary views AI as a double-edged sword. He warns against "bluffers" who use AI to generate misinformation or "ghost answers" that are not based on actual industry standards. While he believes AI will be a phenomenal tool for those with the technical knowledge to verify its output, he maintains there are no shortcuts to success and that AI must enhance, rather than replace, real-world experience.


Advice for the Next Generation

Gary’s primary advice for emerging leaders is to never fear failure, but to treat it as a necessary lesson. He encourages young engineers to avoid bluffing their way through their careers and instead have the confidence to ask questions in a room full of experts. Success, in his view, comes from walking the path, touching the "coalface" of construction, and remaining authentic to one's knowledge.


Key Takeaways

  • Precision first: Always double-check decisions to ensure certainty before committing resources.
  • DfMA Mindset: Treat the construction site as an assembly yard for factory-tested components.
  • Model as Truth: Use high LOD (400-450) models to drive fabrication and live data take-offs.
  • Technology Integration: Leverage XR and Reality Capture to create a bidirectional feedback loop between design and site.
  • Authentic Leadership: Use AI as a tool for improvement, not as a replacement for technical foundational knowledge.