MC3D V1.1 - Match-Cast MC3D V1.1 - Match-Cast 3D Geometry Control 3D Geometry Control SoftwareSoftwareFor Precast Concrete Segmental BridgesFor Precast Concrete Segmental Bridges

By Interactive Design SystemsBy Interactive Design Systems

MC3D OverviewMC3D Overview• Segmental Construction• Short Cell Casting• Match-Casting Technology• Geometry Control

Segmental ConstructionSegmental Construction• Bridge built-up with

multiple elements• Precast Segments• Geometry locked-in at

precast yard• Geometry Control is

critical

Short-Cell CastingShort-Cell Casting• Segments Cast One at a Time• Ensure that the segments fit together• Fixed Bulkhead• Match-Cast Segment

Match-Casting Match-Casting TechnologyTechnology• casting segment between a

fixed form and its neighboring segment

• Move to Match-Cast Position

• Cast Next Segment• Move to Storage

Geometry ControlGeometry Control• monitor the casting operations • establish “as-cast” curves step-by-step • verify that the actual superstructure geometry is in

close agreement with the geometry described in the design documents

Typical MC3D ProjectTypical MC3D Project• Precast Segmental• Balanced Cantilever

Erection• Span-by-Span Erection

Balanced CantileverBalanced Cantilever

Span-by-SpanSpan-by-Span

Understanding Understanding Geometry ControlGeometry Control• Positioning Match-Cast is critical• Match-cast position is function of previous segment

As-Cast compared to Theoretical• MC3D Computes Match-Cast “Set-up” based on As-

Cast Coordinates• Set-Up is a set of 4 bolt elevations and 2 horizontal

offsets for the Match-Cast Segment

Roadway GeometryRoadway Geometry• Horizontal Curve• Profile Grade Line• Super-elevation and Transitions• Camber Values

3D Spine Curve3D Spine Curve

Bridge SegmentationBridge Segmentation• Casting Set

Control PointsControl Points• Base Points • General Coordinates• Bolts for Elevations• Hairpins for Alignment• 2 Bolts on East Line• 2 Bolts on West Line• 2 Hairpins – North/South

Control PointsControl Points

General CoordinatesGeneral Coordinates

X (East)

Y (North)

Z (Positive Upward)

u

v

w

Positive Rotation Rz

W = U ^ V Vector Product

Casting Bed - Fixed Casting Bed - Fixed Bulkhead AssumptionsBulkhead Assumptions• Orthogonal Local System• Local x is centerline

positive toward South• Local y connects East and

West Base Points – Positive toward East

• Local z is vector product of unit vectors z = x y

• LOCAL z MUST BE POSITIVE UPWARD

Understanding Setup Understanding Setup and Surveyand Survey

Casting-Set DefinitionCasting-Set Definition• a portion of the project for which the concrete

segments are precast as a unit • all segments will be match-cast against previously

cast segments • “Starter Segment” usually cast between the “Fixed”

bulkhead and a “Floating” bulkhead. • Base Dimensions A, B and C

Casting-Set Base Casting-Set Base DimensionsDimensions

C Dimension

Base DimensionsBase Dimensions• A: Offset from Joint to Bolts (Rivets)

– An (North) and As (South) may be redefined for each Segment

• B: Offset from Centerline to Bolts (Rivets)– B is constant (East and West Line) for a Casting-Set

• C: Offset from Joint to Hairpins (Alignment Stirrup)– Cn (North) and Cs (South) may be redefined for each

Segment

Reference PlanesReference Planes• control based on a

theoretical “Reference” plane

• survey bolts (rivets), which cannot be placed perfectly in the reference plane, are measurements of the location of the plane rather than its actual definition

Starter SegmentStarter Segment• First Segment of a Casting Set to be cast• Must be cast between Fixed Bulkhead and a

“Floating Bulkhead” (or another already cast segment)

• MC3D assumes that second joint (Fixed Bulkhead for Starter Segment) is always positioned on theoretical.

Typical SegmentTypical Segment• Wet-Cast segment is cast between Fixed Bulkhead

and Match-Cast Segment• Match-Cast Set-up is based on computed As-Cast

Coordinates at previous step• Set-up accounts for twist that may occur when

moving segments from wet-cast to match-cast position

Starter Segment Set-UpStarter Segment Set-Up• Floating Bulkhead Set-Up

– East Punch Mark Elevation– West Punch Mark Elevation– Center Punch Mark Offset

• Fixed Bulkhead Set-Up– East Punch Mark Elevation– West Punch Mark Elevation– Center Punch Mark Offset

• Lengths of East and West Line– This is the length to be given to the starter segment

Typical Match-Cast Set-Typical Match-Cast Set-UpUp• 4 bolts elevations

– North East Bolt Elevation– North West Bolt Elevation– South East Bolt Elevation– South East Bolt Elevation

• 2 Hairpin Offsets– North Hairpin Horizontal Offset– South Hairpin Horizontal Offset

• Length on Center– This is the length to be given to the wet-cast segment

Typical SurveyTypical Survey• After typical segment is cast (wet-cast)• The 4 bolt elevations, hairpin offsets and length on

centerline of both wet-cast and match-cast are surveyed• This produces the relative position of wet-cast and match-

cast. • From these measurements, MC3D computes the general as-

cast coordinates of the typical segment (wet-cast). • As-Cast coordinates indicate how the structure is actually

cast as compared to the theoretical general coordinates.

Match-Cast Set-Up - Match-Cast Set-Up - ConceptConcept• Expression of General Coordinates from Local

Coordinates– {P} ={ O} + [ R ] {p}– Where O is Origin of Local System– [ R ] is Rotation Matrix

• In Matrix Form:

Match-Cast Set-Up - Match-Cast Set-Up - ConceptConcept• Local Coordinates in Match-Cast System:

• Local Coordinates in Wet-Cast System (Cell)

• In As-Cast System of the Match-Cast:

The above matrix equation represent the “Set-Up” of the Match-Cast Segment, i.e. the Transformation to be applied to the Match-Cast Local System to achieve exact theoretical coordinates at the fixed bulkhead.

As-Cast CoordinatesAs-Cast Coordinates• Express General Coordinates of Wet-Cast Points

based on Local System built with Match-Cast Survey (As-Cast)

x

z

As-Cast vs. Theoretical As-Cast vs. Theoretical Joint Coordinates Joint Coordinates • MC3D displays the As-Cast Coordinates at the last

joint, compared with the theoretical required general coordinates

• Also Displayed are the As-Cast coordinates of the bolts (may be used for Erection Control)

Twist ControlTwist Control• A change of slope on East or West Bolt Line

occurring from Wet-Cast to Match-Cast• Match-Cast Twist must be Controlled and Corrected• If not corrected, it will induce a constant warp• Twist errors are magnified at the end of casting-set

(cantilever tip or last span segment)• MC3D automatically corrects Match-Cast Bolt

Elevations for Twist

Getting Started with Getting Started with MC3DMC3D• Project Setup

Segment Definitions

Casting-Set Constant Dimensions A, B &C

Input of General Input of General CoordinatesCoordinates• Manually in Tab View Grid• Importing for Text Files• Copy/Paste from MS Excel (must be properly layed-

out)

General Coordinates General Coordinates TabTab

Click Read File For Text Input

Click Preview For Orientation Check

Click Apply to “initialize” joints

and segment definitions

Import from Text FileImport from Text File• Text File extension can be

anything, but usually “xyz”• Input of Joint Base Point

Coordinates• East, West and Center• Joints Numbered In order

of casting sequence

Copy/Paste from MS Copy/Paste from MS ExcelExcel

Excel Coordinates must be formatted

exactly like the MC3D coordinates grid

Camber ValuesCamber Values• Camber Values can be

input separately• Values are vertical

adjustments to coordinates• Based on long term

deflections• MC3D adds camber to

general coordinates prior to Set-Up

Vertical Deflection at Joint

Working with MC3DWorking with MC3D• Creating Casting-Set Input of General Coordinates• Complete Project Definition• Create Camber Input• Starter Segment Setup and Survey• Typical Segment Set-Up and Survey• Review (and Export) As-Cast Coordinates

Joint and Segment Joint and Segment InitializationInitialization

Click Apply For Initialization

Coordinate Check and Coordinate Check and PreviewPreview

Check of “B” Constant

Check of Bulkhead Angle Check of Cross-

Slope

Check of Local System

Orientation

Set-Up & Survey Set-Up & Survey OperationOperation• Starter Segment

• Run MC3D for Starter Segment Setup• Cast Starter Segment (Wet-Cast) and Survey• Input Starter Segment Survey • Set-Up as Match-Cast

• Typical Segment• Run MC3D for Match-Cast Segment Setup• Cast Typical Segment (Wet-Cast) and Survey• Input Wet-Cast and Match-Cast Survey• Consult As-Cast Results

Starter Segment SurveyStarter Segment SurveyFloating Bulkhead

Set-UpBolt Longitudinal

Offsets

Survey

“Perfect Cast” to be used for testing only

Click Apply to record the

Survey

Typical Segment SurveyTypical Segment Survey

Survey

Match-Cast Set-

Up

Bulkhead Movement

TwistValue

Click Apply to record the

Survey

Twist ControlTwist Control• Twist can occur when moving segment in Match-

Cast Position• Twist induces a Warping error which would be

magnified at end of Casting-Set• MC3D Compares East and West Line Longitudinal

Slope and Displays a difference in Elevation• MC3D corrects Match-Cast Elevations so the

original Slopes (measured in Wet-Cast Position) are maintained

As-Cast CoordinatesAs-Cast Coordinates

As Cast-Coordinates

As-Cast Coordinates - As-Cast Coordinates - ReportsReports

Click for MS Excel Export

As-Cast Coordinates – As-Cast Coordinates – Export to MS ExcelExport to MS Excel

Print and Print PreviewPrint and Print Preview

Click Preview Button

Working with FilesWorking with Files• MC3D creates one file per casting set• The files have extension .mc3• They can be saved and re-opened as needed.• When working with multiple casting cells, we suggest to use

one folder per casting cell.• Several surveyors can use the same copy of MC3D on one

computer, assuming the files are stored as suggested.• Backing-up mc3 files is also strongly suggested and can be

done per directory

Project Directory Project Directory StructureStructure• One Directory per Casting-Machine• One File per Casting-Set in this Directory

Example of Survey FormExample of Survey Form

What’s New for MC3D What’s New for MC3D V1.1V1.1• Crowned Top Slab• General and Local System Orientation Check

Crowned Top SlabCrowned Top Slab• MC3D computes Theoretical Center Point

Coordinates

West Base Point

East Base Point

Center Point

Computed Center Point

General and Local General and Local Systems Orientation Systems Orientation CheckCheck• MC3D V1.1 checks that the local z axis of the Cell

local system is positive upward• This check ensures that:

– The General System is orthogonal and properly orientated

– The North-South orientation of the Casting-Set is correct– Elevations are positive upward

Current and Future Current and Future DevelopmentsDevelopments• Structure Geometry – General Coordinates

GEOM3D• GEOM3D Export of Base Point General Coordinates• GEOM3D/MC3D Client Server Configuration

Structure Geometry – Structure Geometry – General Coordinates General Coordinates GEOM3DGEOM3D

GEOM3D Export of Base GEOM3D Export of Base Point General Point General CoordinatesCoordinates

GEOM3D/MC3D Client GEOM3D/MC3D Client Server ConfigurationServer Configuration

Geom3D Database

Server

Geom3D Client

MC3D Client

MC3D Web Client

Design Office

Site Office

MC3D Web Client