Sam Burns, Director of Virtual Design and Construction, Balfour Beatty

At Balfour Beatty, we’ve built our legacy on collaboration, and continuous improvement. As the commercial construction landscape evolves, so too do the tools and processes we rely on to deliver in the field. One area that has seen dramatic transformation in recent years is field layout a critical step in translating design drawings into the physical structures that we are entrusted to build.

Today, we’re seeing a shift from manual measurements and string lines to automated layout solutions that harness the power of robotics, laser scanning and BIM-integrated workflows. These technologies are not only enhancing accuracy they’re helping us build smarter, safer and more efficiently.

FROM TAPE MEASURES TO TOTAL STATIONS

For centuries, field layout has been a mostly manual process. Crews have relied on chalk lines, measuring tapes and printed drawings to translate dimensions to the field. While effective, this approach is labor-intensive and prone to compounding errors.

The introduction of robotic total stations marked a major turning point. When paired with BIM and layout software, RTS empower a single operator to perform the same layout work that previously took a two-person crew. Layout points could be uploaded directly from a coordinated model and precisely staked in the field with millimeter-level accuracy.

At Balfour Beatty, these systems have become a standard part of our field toolkit enabling tighter tolerances, improved quality assurance/quality control and faster field verification.

BRIDGING BIM AND THE FIELD

The integration between BIM coordination and layout workflows has unlocked new levels of efficiency. Rather than waiting for 2D drawings, layout teams can now extract points directly from federated models, minimizing translation errors and reducing downtime. We’ve seen measurable benefits on complex MEP-intensive projects, where accurate hanger and embed layout early in the schedule translates to fewer clashes, smoother inspections and reduced rework.

AUTOMATION AND ROBOTICS ON THE RISE

The future of layout is not just about digitizing old processes it’s about automation and scalability. New tools like the Dusty Robotics FieldPrinter and HP SitePrint are making it possible to perform layout of interior walls, doors and overhead MEP with unmatched efficiency. Multitrade layout can now be performed in one step, resulting in all trades now building from the same single source of truth. “Modern layout tools like robotic printers and laser scanning have transformed fieldwork, delivering real gains in speed and accuracy. But rework remains a significant risk. It is critical that proper quality control of layout files happens early in the process to minimize errors before they reach the field,” explained Justin Cadwallader, Balfour Beatty senior VDC manager.

ACCURACY, ACCOUNTABILITY AND REDUCED REWORK

At its core, the evolution of field layout is about reducing risk. Every misaligned sleeve or misplaced embed carries downstream impacts costly rework, loss of productivity and strained relationships with trade partners.

Todd Stewart, Balfour Beatty operations director, put it best, saying, “How we perform field layout has evolved significantly in recent years. With smarter tools and stronger pre-planning efforts, we’re improving efficiency and reducing rework delivering greater value to our clients and trade partners.”

By connecting our layout workflows directly to coordinated BIM models and leveraging advanced tools like robotic total stations, laser scanners and layout robots, we’re achieving:

• Tighter installation tolerances
• Fewer change orders due to misalignment
• Enhanced documentation of as-built conditions

These capabilities not only improve project outcomes but also strengthen trust with owners, designers and trade partners who depend on Balfour Beatty and our trade partners to deliver with precision.

QUALITY CONTROL AND CHECKING FIELD ROUGH-IN

Despite advances in layout technology, rework still occurs and the earlier it’s identified, the less disruptive it is. To support early detection, we leverage digital tools that visually compare installed conditions against the coordinated model.

Solutions like Procore BIM AR, Gamma AR and others allow teams to perform rapid visual checks in the field. When discrepancies are identified, they trigger a deeper review process that may include manual measurements, laser scanning and collaboration with project stakeholders to pinpoint the root cause. This isn’t just about fixing the issue it’s about learning from it. By analyzing where communication or coordination broke down, we can refine our workflows and reduce the likelihood of recurrence. These feedback loops are essential to improving layout accuracy and minimizing downstream impacts.

THE ROAD AHEAD

At Balfour Beatty, we’re continuing to explore technologies that enhance layout validation through AR overlays, AI-driven quality checks and autonomous robotic workflows. But even as the tools evolve, our focus remains the same: reducing rework on our projects and empowering our people to build with confidence, efficiency and excellence.

Because when layout is done right, the rest of the project follows suit.