How Engineering Firms Can Accelerate Digital Transformation

When ACCIONA saved AUD 105 million in rework on Melbourne's M80 Ring Road through digital twin technology, they didn't just cut costs, they also proved that engineering firms’ next competitive battleground isn't technical expertise alone. It's data mastery.

Today's engineering executives face a difficult reality. In 2022 alone, 85,000 engineers retired or left core disciplines in the U.S. while only 76,000 new graduates entered the field — a net workforce gap of 8,400 professionals, according to ACEC Research Institute’s 2025 The Workforce of the Future report. At the same time, 68% of firms report they must automate 10% to 29% of current work tasks just to maintain output levels, all while meeting sustainability standards and coordinating dozens of stakeholders across complex, multiyear projects, according to the Firm of the Future: AI Adoption report also from the ACEC Research institute. Traditional CAD-based workflows can't meet this expectation. Data silos, disconnected teams, and static designs cost firms money in rework and competitive opportunities.

The engineering firms winning today's most competitive pursuits share a common thread where they've evolved from creating static digital drawings to deploying living digital twins that unify design, construction, and operational intelligence. These dynamic models aren't just changing how infrastructure gets built — they're rewriting the rules of engineering firms’ profitability, workforce productivity, and client value delivery.

Why Traditional Approaches are Failing

Engineering executives today face a perfect storm of challenges that traditional workflows simply cannot address.

Data Silos Are Crippling Collaboration

On major infrastructure projects spanning civil, structural, and environmental disciplines, teams often work in isolation, each working with their own datasets and tools. A structural engineer makes a design change, but the drainage team may not see it until days later. An environmental consultant needs GIS data that lives in a separate database. Often, miscommunication is common, rework is costly, and critical insights slip through the cracks.

When project data exists in fragmented systems like CAD files, disconnected spreadsheets, or isolated databases, it becomes challenging to maintain a SSOT (single source of truth). Project teams are then faced with delays, errors, and, potentially, thousands to millions of dollars in rework.

Stakeholder Coordination Can be Overwhelming

Modern infrastructure projects require coordination among dozens of stakeholders including designers, contractors, owners, regulators, and the public. Email chains become unmanageable while file versions multiply. Approval cycles may drag on for weeks because stakeholders cannot visualize proposed changes or assess their impacts without scheduling site visits, and then they cannot be addressed until the next design review meeting.

The Workforce Crisis Is Intensifying

The engineering industry faces a growing workforce gap. As stated above, in 2022 alone, approximately 85,000 engineers retired or left core disciplines such as civil, electrical engineering, and other engineering disciplines — outpacing the influx of new graduates. With fewer young professionals entering the field and experienced talent walking out the door, firms must find ways to amplify the productivity of every team member they have.

AI and automation are emerging as critical tools to address this gap, but they need a foundation of connected, accessible data to deliver value. Siloed information systems actively prevent firms from leveraging these technologies effectively.

How Digital Twins Help Solve Today's Critical Challenges

Digital twins unify design, construction, and operational data into a single, living model where all project information lives in a shared, open environment. A civil engineer can integrate GIS data to assess impacts and visualize how a design change may potentially affect existing utility infrastructure without waiting for a file request. The digital twin becomes the SSOT, transforming fragmented workflows into synchronized, collaborative efforts where every decision is informed and every stakeholder is aligned.

Amplifying Workforce Capacity through AI Integration

Here's where digital twins and AI (artificial intelligence) converge to address the workforce crisis. Recent research from ACEC Research Institute's “Firm of the Future: AI Adoption in AEC” report reveals that 85% of engineering firms believe AI is important to their success, and 87% of professionals feel AI will enhance their job performance. But AI requires rich, connected data to deliver value — exactly what digital twins provide. A digital twin with connected data can power AI capabilities to help close the gap with automated tasks to allow engineers to focus time on creating and delivering better projects and keeping their customers satisfied. Consider Bentley’s OpenTower iQ, which uses AI, machine learning, and photogrammetry to generate accurate 3D models of cell tower infrastructure, creating a SSOT that helps engineers plan efficiently across the entire tower lifecycle. Another example of how AI can augment work is Georgia Power's strategy of adopting AI for storm response and restoration. Georgia Power aims to leverage connected data to provide customer with faster, more accurate power restoration estimates while also improving workflow efficiency.

Real Results from Industry Leaders

ACCIONA cuts AUD 105 million in rework with a digital twin strategy.

For the AUD 3.8 billion M80 Ring Road project in Melbourne, Australia, ACCIONA leveraged Bentley's suite of solutions to transform infrastructure 4D planning for one of Australia's most complex urban highway upgrades. The project removes 19,000 vehicles from daily travel on local roads while adding 10 kilometers of walking and cycling paths and landscape bridges, plus coordination among multiple stakeholders, all of which require precision in construction sequencing.

By deploying a comprehensive digital twin that integrated design models, construction schedules, and real-time coordination data, ACCIONA created a SSOT for the entire project team. In addition, for 4D construction planning capabilities, ACCIONA enabled the team to digitally rehearse complex construction sequences, identify potential conflicts before mobilization, and optimize logistics across the massive corridor upgrade. This digital-first approach accelerated traffic management approvals, reduced planning time by 75%, and should save over AUD 105 million through risk mitigation and reduced rework.

ACCIONA led this transformative infrastructure project which demonstrates how digital twins enable engineering firms to deliver large-scale infrastructure projects with greater confidence and control. This project earned recognition as a finalist in Bentley's 2025 Going Digital Awards, showcasing best-in-class 4D construction planning.

ACCIONA successfully used Bentley's suite of solutions to reimagine Melbourne's M80 Ring Road, coordinating multiple stakeholders throughout the project. Image source ACCIONA.

ADAX Consultants Cuts an Urban Project’s Time by 59% and Costs by 90%

The Social and Environmental Program for Manaus and the Interior project in Manuas, Brazil, aims to relocate more than 2,400 families in high-risk areas, provide new safe housing, basic infrastructure, and additional public spaces. Overall, the project seeks to benefit 60,000 people in an effort to reduce flooding, disease, and inequality.

ADAX Consultants leveraged ProjectWise for managing a connected data environment across the different project stakeholders and OpenFlows and OpenRoads to create BIM models of the sanitation networks for residential areas. The team also used SYNCHRO to plan material logistics for the construction site and helped improve environmental impact indicators. Lastly, they used OpenBuildings Designer to create models for housing and related facilities. This helped them produce several layout options and enhance flexibility in the feasibility study phase, enabling changes and improvements to the original urban project plan. ADAX was able to benefit from the interoperability of Bentley’s software and streamline collaboration across multiple teams. As a result, ADAX reduced their project time by 59% and project costs by 90%, proving that integrated digital workflows are essential for collaboration, coordination, and workflow efficiencies.

ADAX Consultants used Bentley software to save approximate 59% of project time and 90% of project costs to re-envision an area that affects more than 60,000 people in Manaus, Brazil. Image source: ADAX CONSULTORIA EM TECNOLOGIA DA INFORMAÇÃO LTDA on behalf of Unidade Gestora de Projetos Especiais (UGPE).

Pennoni Saves 50% in Modeling Design Time

The I-95 Central Access Philadelphia (CAP) project in Philadelphia, Pennsylvania, was led by Pennoni. The I-95 Landing CAP project aims to reconnect the city to its Delaware River waterfront, which includes constructing an 11.5-acre park and designing a complex bridge structure over the I-95 that requires coordinating with 21 subconsultants.

Pennoni adopted a comprehensive model-based approach using a collection of Bentley applications. To manage all the design data in one connected data environment, the team used ProjectWise to manage files and collaborate among 21 different subconsultants. For the innovative bridge design, the team used OpenBridge Modeler and OpenRoads Designer to model the highway and large box culvert among other applications used for geotechnical analysis and structural analysis.

The result was a more efficient design process that accommodated stakeholder feedback without delays, maintained design accuracy throughout multiple iterations, and delivered on-time results for one of Philadelphia's most transformational infrastructure projects. The team saw a 50% reduction in modeling hours for civil and highway design and an overall estimated 45,000 work hours across the project. This integrated digital approach demonstrates how model-based design enables engineering firms to design and analyze complex projects with tight deadlines while delivering projects on time. This project also earned recognition at Bentley’s 2025 Going Digital Awards in the bridges and tunnels category.

Pennoni used Bentley’s ProjectWise to maintain a model of the I-95 Landing CAP project in Philadelphia throughout its design process, noting a 50% reduction in modelling hours. Image source Pennoni.

Getting Started with Digital Transformation

Engineering firms don't need to transform overnight. Even with limited data, organizations can begin building the foundation for more impactful capabilities over time.

Start with one high-impact project: Identify where data silos or stakeholder coordination have the most pain points. Deploy a digital twin focused on solving that specific challenge, learn from the results, and scale.

Choose open, interoperable platforms: Digital twins don't require abandoning your current tools. Look for open applications that work with your existing CAD software, project management systems, and data sources to increase collaboration across your ecosystem.

Invest in people, not just technology: Develop governance frameworks, upskill your team to work with digital twins and AI-augmented workflows, and identify internal champions who can guide adoption across the organization.

The Competitive Imperative

The engineering sector stands at a turning point. Firms face unprecedented challenges — workforce shortages, demanding clients, complex multi-stakeholder projects, and mounting pressure to deliver sustainable infrastructure faster and more cost-effectively than ever before.

Digital twins aren't a luxury or a distant future concept. They're a strategic imperative for firms that want to remain competitive in 2025 and beyond. The technology exists today. The business case is proven. And the firms moving now are already pushing ahead.

Those still relying on disconnected CAD files and siloed data systems aren't just falling behind—they're actively limiting their ability to compete for tomorrow's projects, attract and retain talent, and deliver the level of service that clients increasingly expect.

Take the Next Step

Engineering firms looking to stay competitive and deliver long-term value can start realizing the benefits of digital twins today. Whether you're designing resilient bridges, managing complex infrastructure projects, or planning sustainable cities, digital twin technology can connect every phase of your project lifecycle — from design and construction to operations and maintenance.

Viewpoint articles are tech-focused and thought-leadership editorial written by experts from the CAD industry. This article was written Maria Lamas-Gomez, Senior Industry Marketing Manager for Engineering Firms at Bentley Systems.

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