Stringless Paving, Where we are today

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1 Stringless Paving, Where we are today Anthony Cerisano Vice President Flores Automation & Machine Control / acerisano@floresautomation-mc.com February 11, 2016

What technology is currently in the market? 5.

2 Presentation Outline 1. Flores Automation & Machine Control Introduction 2. What is 3D stringless paving? 3. Benefits of going 3D 4. What technology is currently in the market? 5. What infrastructure does a contractor need in place to implement stringless technology? 6. What needs to happen once the 3D technology is purchased and in place? 7. Workflow of Stringless Paving

Company History CEO Frank Flores started Flores Automation in 2007 Specialized in industrial/mobile automation contracts to OEM s Built engineering and management staff of 14 employees Started

3 Company History CEO Frank Flores started Flores Automation in 2007 Specialized in industrial/mobile automation contracts to OEM s Built engineering and management staff of 14 employees Started Guntert & Zimmerman relationship in 2010 Currently programming S400, S600, S850SL, S1500, PS1200, & MP550 OEM engineering and programming that compliment FAMC controls Currently performing paving machine retrofits for FAMC Started Flores Automation & Machine Control in 2012 Current Leica paving dealer covering all of North America Full services of training, support and service on your jobsites! Machine control modeling services

S84 W18693 Enterprise Drive Muskego, WI 53150 We are North America s resource to assist contractors in their

4 S84 W18693 Enterprise Drive Muskego, WI We are North America s resource to assist contractors in their transition to stringless paving. We provide services that are accountable, accurate, and accommodating of your contracts demands

5 Presentation Outline What is 3D stringless paving? Overview. Difference between 2D and 3D How many contractors in North America using stringless paving? When/where was the first time 3D paving was used?

6 What is 3D stringless paving? The technology of monitoring your paving machine s position with surveying instruments, and comparing to a digital model to control the movements of steering and elevation No Wires Onsite!

7 What is stringless paving? When a paving contractor goes stringless it means: 1. They no longer have to setup wirelines to guide the machines 2. They must have Survey Control Point Information 3. They must have a specifically prepared MODEL

8 What is 3D stringless paving? Difference between 2D and 3D controls for slipform paving 2D control is controlling the steering and elevation of the paving machine with the use of 5 volt based wand sensors For Steering: 0 v 2.5 v = Steer Left 2.5 v 5 v = Steer right For Elevation: 0 v 2.5 v = Move Down 2.5 v 5 v = Move Up These sensors require a physical reference on the site to follow along. (Wire Line set to grade) The wire line is set for steering and elevation reference by a surveyor

9 What is 3D stringless paving? Difference between 2D and 3D controls for slipform paving 3D control is controlling the steering and elevation of the paving machine with the use of CAN Network data. This data is derived from surveying instruments monitoring the machine, and comparing to a digital model for deviations. Like the range of the wand sensors the onboard computer software creates an arbitrary range of numbers for the movements of the machine For Steering: 265 to 465 = Steer Left 465 to 665 = Steer Right For Elevation: 265 to 465 = Move Down 465 to 665 = Move Up Total Station, GPS, or Laser Augmentation instruments monitor an X,Y, and Z of the paver

10 Workflow of Stringless Paving vs Wire Working with Stringline Inspect design calculate setting-out lists for each lane Setup a total station, survey each hub or pin position with total station (or GPS if accuracy isn t important!) Hammer (or drill) in each pin, minimum 1 line for each lane of concrete/asphalt Reference Point Check pin alignment & adjust if required Survey and set stringline height on each pin (min. 2 men) Install & tension clamps and stringlines Walk left 5ft! Walk right 1ft! Up a bit! Down a bit! STOP! Reference Point Eyeball & adjust stringlines before paving Move machine into position, set sensors to stringline Check machine position relative to stringlines Start Production, monitor machine position Ensure (or hope!) nothing disturbs or damages stringlines during paving/milling

11 Leica Geosystems History

12 Leica Geosystems History Kern & Co. was founded in 1819 in Aarau, Switzerland by Jacob Kern. Company started with the manufacturing of drawing tools. Later, he became well known for his geodetic and astronomical instruments. In 1857, his sons, Adolf and Emil join the firm. Adolf manager of Measuring Tools and Emil manager of Surveying Instruments

13 Leica Geosystems History In 1899 a trainee at Landestopographie named Heinrich Wild takes a company provided theodolite to the mountains of Switzerland to perform surveying tasks. Due to his bad experiences with the high mountain triangulation with conventional theodolite design, he starts redesigning in From 1905 to 1907, Heinrich was a member of the Swiss Military Commission charged with finding/developing new range finders. In 1908 Heinrich moves to Jena, Germany and is employed as the manager of the Geo department of Carl Zeiss.

14 Leica Geosystems History In 1919, after WWI, Heinrich moves back to Switzerland and continues to work for Zeiss as a consultant. In 1921 Heinrich Wild started his own company in Heerbrugg, Switzerland, Wild Heerbrugg. In 1923 Heinrich produces the Wild ThI. With the production of the Wild THl, Heinrich Wild started what we know as modern surveying Heinrich signs a contract with Kern to start manufacturing a line of theodolites, eventually buying Kern & Co.

Leica Geosystems History Over the last 200 years,

and would keep that name until production stopped

15 Leica Geosystems History Over the last 200 years, Leica Geosytems has grown to become the world s first in surveying innovation. The Wild Thl instrument was soon renamed "Wild T2" and would keep that name until production stopped in Total Stations have taken on a variety of looks over the years.

16 Leica Geosystems History Paving started with Leica on a project in 1996 with a stop and go machine.the first machine automation test with robots was on a Wirtgen Test site in Windhagen, Germany 1997.

Leica Geosystems History In 1997 the German Railway Agency proposed a project to 10 contractors to show new methods of building high-speed rail.

5 contractors backed out due to not wanting to maintain 240 miles of wireline through farmland. In 1998 A section from Berlin to Hannover was paved.

17 Leica Geosystems History In 1997 the German Railway Agency proposed a project to 10 contractors to show new methods of building high-speed rail. The Railway Agency required the contractor to maintain the wireline through the length of the project. 5 contractors backed out due to not wanting to maintain 240 miles of wireline through farmland. In 1998 A section from Berlin to Hannover was paved. QC was completed soon after paving operations and the first stringless project was conducted from Köln-Frankfurt on a ICE high speed-rail 120 Miles long. Complex high-speed rail geometry, up to 11% crossslope

18 Who is paving stringless in North America? ACME Spokane, Wa Acura Inc. Bensenville, IL Anthony Allega Valley View, OH Archer Western - Fort Lauderdale, FL CC Myers Rancho Cordova, CA Cemex - Mexico Cold Spring Construction Akron, NY Concrete Placing Company Boise, ID Emery Sapp Springfield, IL ET Simonds Carbondale, IL Flat Iron - Canada Flynn Company Dubuque, IA Fred Weber - Maryland Heights, MO Golden Triangle Imperial, PA Granite Construction Co - Texas Hawkins Construction Omaha, NE Head Inc. - Louisiana K-Five Chicago, IL Kiewit Dallas, TX Lindahl Brothers Chicago, IL McCarthy Improvement Dubuque, IA MCM Dallas, TX Milestone Indianapolis, IN Toebe Construction Wixom, MI WK Construction Waterloo, IA Zachry North Carolina and Texas

19 Presentation Outline Benefits of going 3D Cost savings Logistical advantages Safety

20 Benefits of going stringless Cost Savings Removes wire lines and conventional survey pins from the jobsite Eliminates the drilling, pounding, & surveying in pins to base the wire elevation Eliminates material costs and transport for posts, wire arms, and wire Eliminates bumps to the wire during operation The survey instruments included give the ability to measure before and after your paving for exact quality control The stringline is virtually created, and put right on the machine computer No waiting for surveying before production Significantly reduces over-milling, over-pouring Increases productivity, quality and performance bonuses

21 Benefits of going stringless Logistical Advantages Roadway is now open Trucks no longer need to back up so far No Gates in wireline needed Better versatility moving through site Wireline Clearance Track grade is now the width of the actual machine

22 Benefits of going stringless Safety Site Hazards Walking hazard eliminated for workers near stringline Vehicle hazard eliminated for driving near stringline

23 Presentation Outline What technology is currently in the market? Overview of the different manufacturers for the paving industry Overview of the instrument technology types offered and their applications Overview of the support system for each

24 Overview of the different manufacturers for the paving industry

25 What technology is currently in the market? Overview of the instrument technology types offered and their applications Total Station accuracy +/-.01 *line of sight Millimeter GPS accuracy +/-.01 *with good satellite signal GPS RTK accuracy +/-.1 *with good satellite signal Slipform pavers Trimmers Milling Machines Curb & Gutter Asphalt paving Trimmers Milling Machines Curb & Gutter Asphalt paving Placer/Spreaders Follow-up Machines Curb & Gutter Steering Asphalt Paving Steering Grading Market

26 What technology is currently in the market? Overview of the support system for each Direct Paving Dealers Same support personnel for all paving applications in North America Manufacturer support for FAMC Local Machine Control Dealer Network (Sitech) Manufacturer support for the Sitech dealer Local Machine Control Dealer Network Manufacturer support for the dealer

27 Presentation Outline What infrastructure does a contractor need in place to implement 3D technology? Open-minded crew, adapt to change Survey/Grade Checker resources Ground-man, adjustments to machine Data prep resource

28 What infrastructure does a contractor need in place to implement 3D technology? Open-minded crew, adapt to change Market as a whole is still new and changing often Software/Hardware updates are provided frequently Many procedures in the field are new until learning curve is complete

29 What infrastructure does a contractor need in place to implement 3D technology? Survey/Grade Checker resources Many layout abilities are possible with the instruments Any surveying experience is a benefit Accurate checks and adjustments need to be communicated to ground man Bridging the gap between data prep and field work benefits the crew as a whole, it is good for the Surveyor/Grade Checker to have this experience to help the communication between office and field.

30 What infrastructure does a contractor need in place to implement 3D technology? Ground-man, adjustments to machine One man will usually monitor the corrections needed to keep quality of the paving This will usually be someone with paving experience of what to look for Good communication on what he is adjusting within the pave crew is ideal

31 What infrastructure does a contractor need in place to implement 3D technology? Data prep resource The model now becomes as important to the spread as the wire would be The quality of these models is dependent on success of paving accurately Without this in-house ability, it is highly recommended to use a professional service to provide accountability Good support within the software products you use is crucial.

32 Presentation Outline What needs to happen once the 3D technology is purchased and in place? Defining roles Proper training Reasonable expectations of crew workload

33 What needs to happen once the 3D technology is purchased and in place? Defining roles Total Station - setups and care of equipment Groundman - for adjustments to machine Data Prep - resource in house or contracted QC and Staking - Grade Checking, Layout, and Topo

34 What needs to happen once the 3D technology is purchased and in place? Proper training Thorough understanding of operation and troubleshooting instruments Proper understanding of maintenance of instruments (calibrations) Initial training away from production Follow through training while in production Understanding of how to measure and report production

35 What infrastructure does a contractor need in place to implement 3D technology? Reasonable expectations of crew workload Understand what your investment leaves you capable to handle One mainline system will not always be feasible to move between sites Production rates of stringless need to be established by how well the crew has accomplished the learning curve of the new workflow Management of the survey, modeling, and capable crew members must be taken into account

36 Presentation Outline Workflow of Stringless Paving Verify Survey Control - or - Request it properly for what you need Prepare 3D Model Machine Calibration and Tunings Plan Total Station Arrangements and hopping patterns

37 Survey Control CP105 Need to have a control point file to setup the total stations. Fore each of the Control points we need the following: 1. Point Number 2. Northing CP Easting 4. Elevation CP104 Site Control Points Machine Control is only as good as the control! CP101 CP102 With this information, we can setup total stations anywhere we want based on the survey information provided. 37 CP100

38 Setting up the Total Stations... Free Station Resections Backsight Setup on a Control Point XYZ=? XYZ ±?mm

39 Workflow of Stringless Paving 3D Modeling Overview

40 Types of Models 3D Line-work Models Cad based format of elevated lines All lines are selectable for reference to that line s position and elevation All alignments are tangent based, true curves not supported for alignments Based on Northing, Easting, Elevation

44 Types of Models 3D Surface Models Full site coverage using Triangulation between known elevations Usually not seen by the operator, but calculates corrections anywhere on the site in the background of your software Used in combination with a 3D Line-work File for visibility Based on Northing, Easting, Elevation

48 Types of Models 3D Alignment Models -or- 3D Road Models Built from Alignment Data, Profile Data, and Template Data Support True Horizontal and Vertical Curves! Can be exploded to be line-work/surface formats previously mentioned or bundled in XML for true road curves Based on Station, Offset, and Elevation

49 Alignment Understands where horizontal curves begin and end Understands true curve information Understands the stationing

50 Profile Understands where vertical curves begin and end Understands true curve information Understands stationing

51 Templates Build other elevated lines based upon the profile line Base these other lines on slope and distance Outputs of these elements results in having a 3D Linework or Surface File

52 Types of Models 3D Alignment Models -or- 3D Road Models = 3D Line-Work File = 3D Surface File = Job_01_Road.XML

53 What is a Model? Surface Model Formats: Job_01_Surface.DBX Line-work Model Formats: Job_01_Linework.DBX Alignment Based Formats: Job_01_Road.DBX

54 What is a Model? Surface Model Formats: Job_01_Surface.TTM Line-work Model Formats: Job_01_Linework.DXF Alignment Based Formats: Job_01_Road.RXL

55 What is a Model? Surface Model Formats: Job_01_Surface.TN3 Line-work Model Formats: Job_01_Linework.LN3 Alignment Based Formats: Job_01_Road.RD3

56 Differences between grading and paving models Grading Models Paving Models Grading uses GPS guided machines that are accurate to one tenth of a foot (+/-.1 ) Paving uses robotic total station guided machines that are accurate to one hundredth of a foot (+/-.01 ) 3D line-work and surface files are used in the grading market Alignment based models are used in the paving market

57 How are Models Built? Skill Sets for a Good Model Builder 1. Thorough understanding of plan data and specifications 2. Experience in looking at and understanding engineer CAD data 3. Experience in the profiling process 4. Overall technically savvy with market standards 5. Field experience is invaluable

Design Engineers software has different tools for creating 3D Data 2.

58 How are Models Built? Available software packages used in the market for ENGINEERS 1. Design Engineers software has different tools for creating 3D Data 2. These packages are for design engineers at Engineering houses or DOT s, and are the formats we can receive to start our modeling process

59 How are Models Built? Available software packages used in the market for Trimble Modeling Trimble Terramodel Trimble Business Center

60 How are Models Built? Available software packages used in the market for Leica Modeling Leica icon Office

61 How are Models Built? Available software packages used in the market for Topcon Modeling Topcon 3D Office

62 How are Models Built? Available software packages used in the market 3 rd Party for all Hardware These packages export generic formats that the manufacturer software can recognize Linework =.DXF Surface=.XML Alignment Models=.XML

63 What is a Model Methods of Road Modeling Step 1: Request all digital data the engineer will provide: Alignments, Profiles, Templates PDF of most recent version of approved plans Step 2: Review what has been provided and decide if anything is useable in your software Step 3: Start KEY-ing in the road elements Start with alignments Next input the profile information based on station, and curve info Build the template information, and the sequence of transitioning Step 4: Details of output formats

64 What makes a good Model? Control of how many cross sections create the polylines paved on True Vertical Curves Improved Thickness/Smoothness, no pin bumps Horizontal Curve Chording Levelling, Eyeballing & Tensioning adds error Wastes Concrete

65 What makes a good Model? Error Checking Procedures for surface and line-work files. 3D Polyline Editors

66 What makes a good Model? Error Checking Procedures for surface and line-work files. 3D View Reference (looks good)

67 What makes a good Model? Error Checking Procedures for surface and line-work files. 3D View Reference (looks like a problem)

68 What makes a good Model? Error Checking Procedures. 3D Road Report

69 What makes a good Model? Is the model Smooth?, new procedures Convert an edge of paving to a TXT file of points, then import to PROVAL Simulate ride scores on your smoothness specification Check for frequencies of breaks in your profile Once you know the ride score of your data, you can adjust what to expect from your AMES or SSI scores

70 What makes a good Model? Is the model Smooth?, new procedures

71 What makes a good Model? Is the model Smooth?, new procedures

72 What makes a good Model? Is the model Smooth?, new procedures

73 What makes a good Model? Volume Reports! Cut-Fill Plots Comparing 2 Designs Example: Existing VS Subgrade Example: Subgrade VS Top of Concrete Control your Yields.

74 What makes a good Model? Error Checking Procedures, for confidence and reference in the field. 3D Road Reports Per Alignment

75 Presentation Outline Workflow of Stringless Paving Machine Calibration and Tunings

76 Workflow of Stringless Paving Machine Calibration... WHEN and WHY?? WHEN? WHY? At First Installation At EVERY subsequent change of the machine. After raising/lowering removing/mounting prism masts After pan width changes Prism Locations freshly measured relative to the paving kit. Slope Sensors are freshly calibrated after measuring Precise Paving, Good Practice Optimal Machine Performance RISKS IF IGNORED? Mis-matched slope sensors can cause machine twisting causing poor concrete surface finish Mis-alignment of track angles can cause a Skew in your steering alignment

77 Workflow of Stringless Paving Settings on the Machine Controller Usually performed with assistance of operator or machine setup crew Track Alignment / Swing Leg Alignment Highly recommended you take the time to run stringline through the front and rear track, adjust what is straight and null this value in the machines operator interface. If your machine runs a swing leg arrangement, you must square this and null as well. This will make the 3D steering as accurate as possible. Steering and Elevation Gain Settings Advise the operator to adjust his elevational gain settings to a #1 value Advise the operator to adjust his steering gains to a #1. Stringline tuning is usually much higher Could cause irregular unexpected movements of the machine Steering and Elevation Control set to 3D

Workflow of Stringless Paving Machine Calibration (without DBI) Step 1... Mark your points Raise the Machine for ability to mark 4 points on the pan Measure forward.

78 Workflow of Stringless Paving Machine Calibration (without DBI) Step 1... Mark your points Raise the Machine for ability to mark 4 points on the pan Measure forward.1 from the back of the pan and 2 in from the side on each side of the pan Measure forward 3.5 from the back of the pan and 2 in from the side on each side of the pan

79 Workflow of Stringless Paving Machine Calibration (with DBI) First Mark 4 points on the main paving pan. Typically 2 in from side edge, and.1 forward from back edge on each side for tempa1 and temp A2. Typically 2 in from side edge and 3.5 forward from back edge for A3 and A4 Stringline through your tempa1 and A3 back to find the location of where your A1 point will be on the OCB. Once you have string run, Level the OCB with the pan, then check all elevations with Total Station * the OCB will shift back and forth, so once the calibration is checked and shot the point will no longer be valid for calibration. * the OCB needs to be on the EXACT plane that the front pan is on. If the front pan is level and elevation the OCB should read 100 as well. Adjustments to the elevation of the OCB are almost always necessary. Intersect the point you marked with string, and.1 forward from the back edge, and mark your A1 and A2 point on the OCB.

80 Workflow of Stringless Paving Dry runs After model for paving production is loaded, dry run the machine to tune steering, elevation and ensuring model is correct. This ensures an added level of insurance as to a step being skipped or not done correctly.

Workflow of Stringless Paving Total station

81 Workflow of Stringless Paving Total station hopping pattern Dry runs are a good time to envision total station layouts Depending on truck routes, line-of-site objects (trees, signs, etc.) Different jobs have limited options and distances between total stations

82 Thank you for your attention Time Permitting Question & Answers

83 Web References Positioning Manufactures: Machine Control Market Website: Software Manufacturers:

Presentation Overview

Stringless Concrete Paving STRINGLESS CONCRETE PAVING ACPA BUS TOUR AUGUST 5, 2015 Presentation Overview 1) Manufactures 2) Components needed for Stringless Paving 3) Conventional Methods VS Stringless