Digital Twin Implementation for Data-Driven Planning and Assembly of 525 kV Transmission Towers in Brazil

Modelling (BIM) to create a comprehensive digital replica of the line, transforming how data is used throughout transmission line construction. Historically, construction planning relied on simplified methods and experience-based decisions, with limited digital support for site operations. Engineering teams often lacked access to structured and integrated data, leading to inefficiencies, rework, and increased safety risks. Pre-assembly planning, particularly the organization of thousands of steel components into packages for staged assembly, proved especially challenging when based solely on 2D drawings and spreadsheets. The adoption of a

Digital Twin enabled structured data capture, intelligent component grouping, and 3D visualization of tower structures. The Digital Twin platform allowed site engineers to interact with detailed 3D models, track pre-assembly status, and automatically generate bills of materials (BOMs) for material verification, sorting, and logistics control. Additional tools supported weight calculations, center-of-gravity determination, and the generation of rigging plans, contributing to safer and more efficient tower erection, including operations involving cranes and helicopters.

The Digital Twin also supported real-time data registration across four key stages: preassembly, review, assembly, and final inspection. This workflow enabled early identification of inconsistencies, reduced manual interventions, and promoted structured decision-making. In towers exceeding 10,000 components and packaging matrices longer than 60 pages, the digital environment ensured traceability and significantly mitigated the risk of assembly errors.

The initiative aligns with ISO 19650 and Lean Construction principles, integrating

Common Data Environment (CDE) practices, structured governance, and site feedback loops.

By embedding intelligence into the asset from the design stage, the project demonstrates a shift from static documentation to dynamic, data-driven construction workflows. The main outcomes include increased productivity, improved safety, and reduced rework. Preliminary site results indicate a potential schedule gain of up to four months, highlighting the strategic value of digitalization. Given the frequency of incidents in transmission line construction worldwide, this study argues that Digital Twins should become a standard tool for tower planning, particularly in complex environments with tight rights-of-way and environmental constraints.