Innovative Construction at Guarulhos Airport: Aeromovel Technology and Digital Manufacturing with BIM

August 21, 2023

Innovative Construction at Guarulhos Airport: Aeromovel Technology and Digital Manufacturing with BIM

Currently, ongoing works are taking place at Guarulhos Airport, where Aeromovel technology will be used to connect the three airport terminals to the CPTM Train. This project is being carried out by the AeroGRU Consortium, led by AEROM and composed of the companies FBS Construtora, HTB Engenharia e Construção, and TS Infraestrutura.


The goal of this innovative project is to provide an efficient and rapid connection between the airport terminals, ensuring greater convenience and agility for passengers. The AeroGRU Consortium is at the forefront of this initiative, coordinating and executing the necessary works for the implementation of the Aeromovel system.

Aeromovel Technology: Precision in Construction

The Aeromovel operates through a pneumatic propulsion system, utilizing a segregated and exclusive track. Stationary, highly energy-efficient fans pressurize the air, which is directed into a duct in the center of the elevated track. This technology enables swift and comfortable movement of passengers between the airport terminals and the CPTM Train.

The construction of the central duct, located in the center of the beams, is crucial for the proper functioning of the Aeromovel system. Strict specifications must be followed, including an extremely precise construction tolerance of just 2mm on each side of the span. This requirement ensures the integrity and correct alignment of the duct, providing an adequate flow of air.

Digital Tools: BIM and Autodesk Civil 3D

To meet these demands for construction precision, digital manufacturing tools and concepts are being employed, notably the Building Information Modeling (BIM) methodology. The project is developed and manipulated using Autodesk Civil 3D software, allowing for a comprehensive and accurate visualization of all elements involved in the construction.

Based on the project modeled in Autodesk Civil 3D, coordinates (x, y, z) are extracted from 14 reference points in each metal form module, where the beams will be poured. These coordinates serve as a basis to ensure the precise positioning of the pieces within the established construction tolerances.

Comparison between the Modeled Project and the Actual Structure

The accurate positioning of the modules is achieved with the assistance of the Trimble SX10 Total Station and the Trimble 360 Miniprism. These high-precision measuring devices are used to ensure that each module is correctly positioned, following the coordinates extracted from the project.

After the concreting of the beams, the integrated laser scanner in the Trimble SX10 Total Station is used to capture actual images of the executed beams. This reality-capture process allows for a comparison between the constructed structure and the designed model, identifying any discrepancies and correction needs.

The data captured by the laser scanner is processed in Trimble Business Center software. From this data, a point cloud is generated that represents the surface of the beams, both on the external face and the inner span face. This point cloud is overlaid onto the designed model, enabling a precise analysis of the real structure in relation to the project.

Using Trimble Business Center, a scan inspection is performed to compare the discrepancy between the designed model and the actual structure. This process identifies any deviations that could compromise the integrity and functionality of the Aeromovel system. If significant discrepancies are found, corrections are made to ensure project compliance.

The Importance of BIM: Digital Manufacturing, Authoritative Modeling, and Quality Control

The use of the BIM methodology in this project is directly linked to digital manufacturing, reality capture, authoritative modeling, and quality control. Autodesk Civil 3D and Trimble Business Center are essential tools in this process, allowing for efficient integration between design, construction, and structure inspection.

With the aid of the mentioned technology and methodology, the construction of the Aeromovel system at Guarulhos Airport is being carried out with precision and efficiency. Digital manufacturing, combined with the use of BIM, ensures conformity with dimensions and construction tolerances, guaranteeing the proper functionality of the infrastructure.

A Step Forward in Urban Transportation

The construction of the Aeromovel system at Guarulhos Airport represents a significant advancement in urban transportation. This innovative technology will provide a swift and efficient connection between the airport terminals and the CPTM Train, improving the passenger experience and contributing to the modernization and sustainability of public transportation.