Digital Twin Construction in Practice: A Case Study of Closed-Loop Production Control Integrating BIM, GIS, and IoT Sensors

Digital twin construction (DTC) integrates digital representation of product design and process planning, automated monitoring on site, intelligent data interpretation, and predictive analytics to provide managers with situational awareness and guide subsequent cycles of production planning and control. This study presents a case study of a DTC system integrating building information modeling (BIM), the Internet of Things (IoT), and GIS for real-time monitoring and process optimization in an industrial silo construction project in Canada. The system consists of four key components: IoT sensors that collect real-time construction data, automated data transmission and storage, BIM-based design and planning models, and interactive dashboards for project monitoring and decision-making. The system enabled just-in-time pull delivery of steel elements, precise placement of components within the slip-formwork, and continuous progress tracking. As a result, construction time was reduced by 28% and material wastage decreased by 15% due to data-driven decision-making and real-time monitoring. The primary contribution of this study is demonstrating a structured approach to integrating DTC technologies into construction workflows, providing a practical framework for bridging digital models with real-time execution. This research highlights how the integration of BIM, IoT, and GIS enhances construction accuracy, efficiency, and automation, addressing challenges related to interoperability, real-time monitoring, and predictive analytics. Despite challenges such as the initial setup costs and specialized staff training requirements, the long-term benefits, including improved resource allocation, cost savings, and enhanced project management capabilities, justify the investment. The findings suggest that adapting advanced DTC systems can significantly enhance construction productivity, accuracy, and sustainability, leading to better-managed and more efficient projects. Future research should explore scalability across different construction sectors and locations to further validate the economic and operational impact of this approach.