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Stringless Concrete Paving -Scuillo 08/05/2015

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STRINGLESS CONCRETE

PAVING

ACPA BUS TOUR

AUGUST 5, 2015

Stringless Concrete Paving

Presentation Overview

1) Manufactures

2) Components needed for Stringless Paving

3) Conventional Methods VS Stringless Methods

4) How it works?

5) Questions


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MANUFACTURES OF STRINGLESS PAVING COMPONENTS

There are multiple manufactures that developed Stringless Technology.

Leica – Was the first to develop stringlessconcrete paving. – Late 1990’s

Wirtgen-2010

Trimble- 2013

Topcon- 2014

Mainline Slipform Paving


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TYPES OF STRINGLESS

APPLICATIONS

Mainline Slip-forming

Curb & Gutter, Barrier

Milling

MAINLINE PAVING


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CURB & GUTTER & OFFSET PAVING

MILLING APPLICATIONS


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WHAT IS LEICA PAVESMART 3D?

External Control system developed by Leica Geosystems specifically for stringless concrete paving.

Works with a variety of Concrete Paver Manufactures

Gomaco

Guntert and Zimmerman

Power Curbers

Wirtgen

Vogele

Controls the steering and elevation of the concrete paver by the use of 3D models and robotic total stations.

SYSTEM BENEFITS...

Removes stringlines and conventional survey pins from the jobsite

Eliminates the drilling, pounding, & surveying in pins to base the string elevation

Eliminates material costs and transport for posts, wands, and string

Eliminates “bumps” to the string during operation

Increases jobsite safety & “Opens” up truck routes within work area

The survey instruments included give the ability to measure before and after your paving for exact quality control


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The stringline is virtually created, and put right on the machine computer

Create 3D Models in all Major CAD Software packages

No waiting for surveying before production

Significantly reduces over-milling, over-pouring. (during overlay projects)

Increases productivity, quality and performance bonuses

Controls Machine height, slope, steering automatically

Allows for digitally fine tuning your machine to move as you want

Allows for you to override automatics and change alignment or profile on the fly

Improves material yields

Posted system accuracies of .01’

SYSTEM BENEFITS CONT.

Typical Mainline Paver System

(5) 1” Robotic Total Stations

3-4 are typically dedicated to tracking the machine. Need at least 2 to operate the machine.

1 is typically utilized as a checking tool behind the machine

(4) Backsight Setups that sit over control points that set up total stations

(1) Grade Checking Rod with Hand-held controller that checks grade, and measures points. It also reports station, offset, and cut/fill information

(1) Machine Computer/Software

Rugged on-board computer with PaveSmart3D Software

(1) Machine Installation Kit-incl. cables/paver prisms/slope sensors


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SYSTEM MAIN COMPONENTS

ROBOTIC TOTAL STATIONS – LEICA VIVA TS15

(TRACKING THE MACHINE OR GRADE CHECKING)

1” total station

Used For all Surveying & Machine Control applications

12Hz measurement rate

Tracking accuracy 1/8” at 300 ft (±3mm at 100m

Typical working Range 300ft (± 100m )(600ft/200m total)

Synchronized EDM/Hz/V data

Fully robotic operation

Automatic prism tracking

Runs VIVA Software interface same as Data Collector

SYSTEM MAIN COMPONENTS CONT.

Leica CS15 Data Collector

Runs VIVA Software for Data Collection, Surveying, or Grade Checking

Runs on Windows Mobile Operating System

SD, CF, and USB Ports available

Full VGA display

i.MX ARM core processor

“Antenna” Radio communication with the LRBT Radio Handle, which makes this control any TS15 Total Station

Internal Digital Camera for site photos

Docking/Charging Station

Lemo Port on bottom for USB Connection to PC, or direct connect to GPS Receivers


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SYSTEM MAIN COMPONENTSLEICA MPC1310 MACHINE COMPUTER

Microsoft Windows®

Embedded

Operating Temp. Range -20°C to +60°C

MilSpec connectors

Remote Access via Internet

Power max 2A, 9-30VDC

CE & FCC approved

IP65 Housing

Daylight-readable display

Freewave Radios

SVGA Colour Touch screen

4 x RS232 Ports CANBus & PowerUSB Port

Rugged Housing

Leica PaveSmart 3D v3.0 – Jan 2013 - 16

Computer

& Radios

Slope Sensors

Layout of Stringless Components

Primary Total Station

Prisms

Secondary Total Station

System Main Components


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Machine

Computer and Radios

Prism Prism

Slope

Sensors

Layout of Stringless ComponentsSystem Main Components


System Main ComponentsOn-Machine Components

2.) On-Machine

Computer w/

PaveSmart3D

1.) Rugged

360deg Prisms

3.) Dual Axis

Slope Sensors


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Survey uses a total station to set pins with fill values to the top of concrete

every 25’ outside of the pave lane

Then drilling, and pounding in stakes, and installing tension clamps/wands

for line and measuring up to grade to set the string at each survey pin

Fine tune string by “eye” for smoothness

Set machine in place and adjust wand sensors into position to trace the

string line

Contractor is ready to pave to the string line with breaks every 25’!

Ensure (or hope!) nothing disturbs or damages string lines during paving

Workflow for “String-Line” Conventional Paving...



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Stringline VS CAD Based Road Models...Stringline = approximation

Levelling, “Eyeballing” &

Tensioning adds error

True Vertical Curves Improved Thickness/Smoothness, no “pin bumps”

Horizontal Curve

“Chording”

Wastes

Concrete


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Workflow for “String-Less” Paving...

BEFORE PROJECT BEGINS:

Contractor Builds a 3D model of the concrete edge lines (Virtual Stringline)

Surveyor Sets Control Points every 500’-750’ of each side of the road

Contractor Calibrates the Paver

ON PAVE DAY:

Contractor sets up (2) total stations backsights the instruments based on

the surveyors control points and tracks the (2) Masts on the machine (15

minutes)

Contractor is ready to Pave. Automatically!

** Contractor sets up (2) total stations every 500’ and “leap-frogs” to each

setup as the paver gets there throughout the pave day


Paver

Calibration


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How to Build the Model...All major CAD platforms produce files for Leica PaveSmart 3D

Most Modeling Software Packages can generate a .DXF file of

the long-slope lines of the road.

You load this dxf file into the data collector and it converts it to a

.DBX format which can be staked for Station, Offset, and Cut Fill

to top of concrete, great info!


How to Build the Model...All major CAD platforms produce files for Leica PaveSmart 3D

CAD System


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Site Control Points…

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

3. Easting

4. Elevation

CP 2

CP1

CP 3

CP 4

CP 6

CP 5

With this information, we

can setup total stations

anywhere we want based

on the survey information

provided.

MACHINE CONTROL is only as good

as the PROJECT SURVEY CONTROL


Setting up the Total Stations...

Free Station ResectionsCL

XYZ=?

XYZ

± 0.01’

Backsight Setup on

a Control Point


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Survey Control & “System Accuracy”

Machine Control is only as accurate as the

Survey Control!

High-order, well-braced network essential.

±0.01ft in Z & ±0.03 ft XY is our published accuracy

for slipforming

±0.02 ft in Z & ±0.03 ft in XY is our published

accuracy for milling

Dependent on Accurate Survey Control

Insist control is available for 3- or 4-point

Resections anywhere on the project

When setting up instrument, always use at least two

control points from the previous setup.

Always need line of sight to the paver prisms. Be

aware of truck routes and other obstructions that

may block sight from total station.


The Working Screen...

Dashboard(Status &

Warnings,

Troubleshooting)ProductionMonitoring

Operator

Menu

PositionControl

Outputs ProjectPlan View

(click for

string

selection)

Clean, simple, machine-like user interface

All essential production information available at-a-glance

Varies according to application requirements (asphalt/milling/concrete)


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Once the contractor is paving stringless...

1. There are not reference points (survey pins) all over the site indicating

where the line and grade of the concrete should be

2. Tape measure will only tell how thick the slab is

How do you check what’s going on?

Is the slab where it should be Horizontally?

Is the slab at the right elevation?

The answer is to use the same technology...

Total Station Road Stakeout


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Questions??…

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