Integrating Design Tools with ERP: A Step-by-Step Guide

Connecting your BIM design tools directly to your ERP system is the single highest-impact integration a precast manufacturer can implement. When Revit or Tekla models feed piece data, reinforcement schedules, and material lists directly into CastLogic ERP, you eliminate the manual data entry that consumes engineering hours, introduces transcription errors, and delays project timelines. This guide walks you through the complete process of integrating DesignLogic plugins with your design environment and CastLogic ERP, from initial installation through your first successful sync and beyond into ongoing production workflows.

Before You Begin: Prerequisites

Before starting the integration, ensure you have the following in place. Missing any of these prerequisites will cause delays during setup, so it is worth verifying each one before proceeding.

• Supported Design Software: Autodesk Revit 2023 or later, or Tekla Structures 2023 or later, installed and licensed on your workstation. DesignLogic also supports Allplan, AutoCAD, Bentley ProStructures, and SketchUp, but this guide focuses on the Revit and Tekla workflows.
• CastLogic ERP Access: An active CastLogic ERP account with API access enabled. Your ERP administrator can provide the API endpoint URL and authentication credentials.
• DesignLogic License: A valid DesignLogic plugin license key. Contact your IntraSync account manager or email info@intrasyncindustrial.com if you need one.
• Network Access: Outbound HTTPS access on port 443 from your workstation to the CastLogic API server. If your organization uses a proxy or firewall, coordinate with your IT team to whitelist the CastLogic endpoint.
• A Test Project: A BIM model with at least 10 to 20 precast elements that you can use for initial testing. Avoid using a live production project for your first sync.

Step 1: Plugin Installation

For Revit installations, the plugin registers as an external application and adds a DesignLogic ribbon tab to the Revit interface. For Tekla, the plugin installs as an extension accessible from the Applications & Components catalog. After installation completes, launch your design application and verify that the DesignLogic tab or panel appears. If it does not, check the application's plugin/add-in manager to ensure DesignLogic is listed and enabled.

Revit Plugin Location:
  %APPDATA%\Autodesk\Revit\Addins\[version]\DesignLogic.addin
  C:\Program Files\IntraSync\DesignLogic\Revit\

Tekla Plugin Location:
  %APPDATA%\Tekla\Structures\[version]\Extensions\DesignLogic\
  C:\Program Files\IntraSync\DesignLogic\Tekla\

Configuration File:
  %APPDATA%\IntraSync\DesignLogic\config.json

Log Files:
  %APPDATA%\IntraSync\DesignLogic\logs\

Step 2: Configuration and ERP Connection

Click the Test Connection button to verify that the plugin can reach the CastLogic server and authenticate successfully. A green checkmark confirms the connection is working. If the test fails, verify your credentials, check network connectivity, and ensure your CastLogic account has the API Access permission enabled. Common connection issues include expired passwords, disabled accounts, and corporate proxy servers that block outbound HTTPS traffic.

Next, configure the sync preferences. The Settings panel allows you to control which data fields are synchronized, the sync direction (design to ERP, ERP to design, or bidirectional), conflict resolution rules when the same field has been modified in both systems, and automatic sync intervals or manual sync triggers. For your first integration, we recommend starting with design-to-ERP unidirectional sync with manual triggers. This gives you full control over when data flows to the ERP and allows you to verify each sync before it takes effect. Once you are confident in the data quality, you can enable bidirectional sync and automatic intervals.

{
  "erp_connection": {
    "endpoint": "https://yourcompany.castlogic.com/api/v2",
    "company_code": "PRECAST01",
    "auth_method": "oauth2",
    "timeout_seconds": 30
  },
  "sync_settings": {
    "direction": "design_to_erp",
    "trigger": "manual",
    "auto_interval_minutes": 0,
    "conflict_resolution": "design_wins",
    "include_reinforcement": true,
    "include_embeds": true,
    "include_finishes": true,
    "include_weights": true
  },
  "field_mapping": {
    "piece_mark": "model.Mark",
    "width": "model.Width",
    "height": "model.Height",
    "length": "model.Length",
    "concrete_mix": "model.Material.Name",
    "weight": "model.Weight.Calculated",
    "volume": "model.Volume.Net"
  }
}

Step 3: Model Preparation

Start by verifying piece mark assignments. Every precast element in the model must have a unique piece mark that follows your company's naming convention. DesignLogic uses the piece mark as the primary identifier for linking model elements to ERP records. Duplicate or missing marks will cause sync errors. In Revit, piece marks are typically stored in the Mark parameter of precast family instances. In Tekla, they are stored in the Part mark or Assembly mark fields depending on your workflow.

Next, verify material assignments. Every precast element should have a concrete material assigned that specifies the mix design, unit weight, and strength class. Elements without materials will sync with blank or default values in the ERP, requiring manual correction later. Check that material names in the model match the mix design identifiers used in your CastLogic ERP. For example, if your ERP uses "5000-NW" for 5000 psi normal weight concrete, the model material should be named identically or mapped through the DesignLogic field mapping configuration.

Run the DesignLogic Model Validation tool, accessible from the DesignLogic ribbon tab. This tool scans the entire model and generates a report of issues that will affect data extraction. Common issues flagged by the validator include elements with missing piece marks, elements with no material assignment, duplicate piece marks across different element types, elements with zero or negative dimensions, reinforcement not hosted to a precast element, and embeds floating outside their host element boundaries.

Step 4: Data Mapping

The essential field mappings that must be configured for a basic sync include piece mark, which serves as the primary record identifier in the ERP, piece dimensions including width, height, length, and thickness, concrete material or mix design identifier, piece weight calculated from geometry and unit weight, concrete volume in cubic yards, element category or type classification, and project or job number assignment.

Beyond the basic fields, you should map reinforcement data including rebar bar sizes, quantities, lengths, and bend types, strand patterns for prestressed members, and mesh specifications. Embed and hardware data should also be mapped, covering embed plate sizes and locations, headed stud configurations, threaded insert types and locations, lifting hardware types and capacities, and bearing pad specifications. Surface finish data rounds out the mapping, including finish types for each face, reveal patterns, form liner specifications, and exposed aggregate or sandblast areas.

DesignLogic includes a set of default field mappings that work for most Revit and Tekla model configurations. Review these defaults and adjust any that do not match your specific model parameter names or ERP field structure. The mapping configuration is saved per project type, so you only need to configure it once for each standard project template you use.

Step 5: First Sync

To execute a selective sync in Revit, select the elements in the model view, then click the Sync Selected button in the DesignLogic ribbon. In Tekla, use the DesignLogic panel to filter by assembly marks and sync the selected subset. The plugin will extract all mapped data from the selected elements, package it into the CastLogic API format, and transmit it to the ERP server.

The sync process displays a progress window showing each element as it is processed. After completion, a summary report lists every element synced, the data transferred for each one, and any warnings or errors encountered. Review this report carefully for your first sync. Common first-sync issues include field mapping mismatches where a model parameter contains data in an unexpected format, unit conversion discrepancies between model units and ERP units, missing required fields in the ERP that were not mapped from the model, and character encoding issues in piece marks or descriptions that contain special characters.

DesignLogic Sync Report
=======================
Project: Sacramento Office Tower
Date: 2026-01-05 14:32:18
Direction: Design -> ERP
Scope: Selected elements (8 of 247)

SYNCED SUCCESSFULLY (7):
  WP-101  Wall Panel    12'-0" x 30'-0" x 8"    5,400 lbs  OK
  WP-102  Wall Panel    12'-0" x 28'-6" x 8"    5,130 lbs  OK
  DT-201  Double Tee    10'-0" x 60'-0" x 32"   18,720 lbs OK
  DT-202  Double Tee    10'-0" x 60'-0" x 32"   18,720 lbs OK
  COL-01  Column        24" x 24" x 14'-0"      4,200 lbs  OK
  BM-301  Beam          18" x 36" x 28'-0"      8,820 lbs  OK
  SP-401  Spandrel      3'-6" x 30'-0" x 8"     6,300 lbs  OK

WARNINGS (1):
  SB-501  Stair/Beam    Missing finish spec on Face 3
          -> Synced with default finish "Smooth Gray"

ERRORS (0):
  None

Data transferred per element:
  Dimensions, weight, volume, material, piece mark,
  reinforcement (14 bar entries), embeds (3 entries),
  finish specs (6 face entries), lifting hardware (2)

Step 6: Validation Checks

1. Piece dimensions: Verify that width, height, length, and thickness in the ERP match the model geometry exactly. Pay attention to units: ensure that all dimensions are in the expected unit system (typically imperial for US producers).
2. Weights and volumes: Compare the ERP weight and volume values against the model's calculated values. Small rounding differences (less than 0.5 percent) are acceptable and result from unit conversion precision.
3. Material assignments: Confirm that each piece in the ERP has the correct concrete mix design. Verify that the mix names match your production facility's standard mix identifiers.
4. Reinforcement data: Check that rebar quantities, sizes, and lengths transferred correctly. For prestressed members, verify strand patterns, strand diameters, and jacking forces.
5. Embeds and hardware: Verify that all embed plates, studs, inserts, and lifting hardware are present in the ERP records with correct specifications.
6. Piece marks: Confirm that piece marks in the ERP exactly match the model, including any prefix, suffix, or numbering conventions used by your team.

If you find discrepancies, trace them back to the source. Most first-sync issues are caused by field mapping misconfigurations that can be corrected in the DesignLogic settings. After correcting the mapping, delete the test records from the ERP and re-sync to verify the fix.

Step 7: Full Project Sync

After the full sync completes, review the summary report for any warnings or errors. Address any flagged issues before proceeding to use the ERP data for production planning. Run a summary comparison between the model statistics (total piece count, total concrete volume, total weight) and the ERP project totals. These should match within rounding tolerance. If you see a significant discrepancy, it usually means some elements were excluded from the sync due to missing piece marks or other validation failures.

Ongoing Workflow Best Practices

With the initial integration complete, adopt these best practices to maintain data accuracy and maximize the value of the design-to-ERP connection throughout the project lifecycle.

Sync After Every Major Model Update

Run a DesignLogic sync whenever the model undergoes significant changes such as design revisions, added or deleted elements, or updated reinforcement details. The plugin performs differential syncs, transferring only the data that changed since the last sync, so incremental syncs are fast even on large projects. Establish a cadence with your engineering team, such as syncing at the end of each workday or after each design milestone, to keep the ERP current.

Use Revision Tracking

DesignLogic maintains a revision log that records every sync operation, including what data changed and who initiated the sync. This log is invaluable for change order documentation, audit trails, and troubleshooting. Review the revision log periodically to understand the pattern of design changes and their impact on production data.

Establish Model Quality Gates

Create a model quality checklist that engineers must complete before syncing to the ERP. Include items such as all piece marks assigned and unique, all materials specified, all reinforcement hosted to elements, validation tool run with zero errors, and project manager approval for major revisions. This prevents incomplete or incorrect data from reaching the ERP and causing downstream issues in production planning, procurement, and scheduling.

Monitor Bidirectional Sync Carefully

When you enable bidirectional sync (where ERP changes can flow back to the design model), exercise caution. Production status updates, schedule dates, and costing data flowing from ERP to model are generally safe. But allowing ERP users to modify piece dimensions or reinforcement and push those changes back to the model requires careful governance. Define clear rules about which fields are editable from which system, and use the conflict resolution settings to establish which system's data takes precedence when both have been modified.

Troubleshooting Common Issues

Even with careful setup, you may encounter issues during the integration process. Here are the most common problems and their solutions.

• Connection timeout errors: If the sync times out, check your network connection and increase the timeout value in the DesignLogic configuration file. Large projects with hundreds of elements may require a timeout of 60 seconds or more. Also verify that no firewall or proxy is throttling the connection.
• Duplicate piece mark errors: The ERP will reject elements with piece marks that already exist in a different project. Ensure your piece mark naming convention includes a project prefix to guarantee uniqueness across your entire portfolio.
• Missing reinforcement data: If rebar or strand data is not appearing in the ERP after sync, verify that the reinforcement elements in the model are properly hosted to their parent precast elements. Unhosted reinforcement will not be associated with any piece during extraction.
• Weight discrepancies: If model weights do not match ERP weights, check the concrete unit weight parameter in the model material definition. A common issue is using the default Revit concrete density rather than the actual mix-specific unit weight. Normal weight concrete typically ranges from 145 to 155 pcf depending on the mix design.
• Sync performance degradation: If syncs become slow over time, check the log file size and consider archiving older logs. Also verify that the CastLogic API server is performing well by testing with a small sync operation. Network latency and ERP server load can both impact sync speed.

Conclusion

Integrating your design tools with your ERP through DesignLogic is not just a technology implementation; it is a workflow transformation. When piece data flows automatically from the 3D model to production planning, you eliminate the re-entry that consumes hours, introduces errors, and delays projects. The seven steps outlined in this guide provide a proven path from installation to production-ready integration. Take the time to prepare your model, validate your first sync, and establish ongoing best practices, and the return on investment will compound with every project.