Stringless Paving, Where we are today

Anthony CerisanoVice President

Flores Automation & Machine Control949.923.8966 / acerisano@floresautomation-mc.com

February 11, 2016

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’sBuilt engineering and management staff of 14 employees

Started Guntert & Zimmerman relationship in 2010Currently programming S400, S600, S850SL, S1500, PS1200, & MP550OEM engineering and programming that compliment FAMC controls

Currently performing paving machine retrofits for FAMC

Started Flores Automation & Machine Control in 2012Current Leica paving dealer covering all of North AmericaFull services of training, support and service on your jobsites!Machine control modeling services

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…

S84 W18693 Enterprise DriveMuskego, WI 53150

Presentation Outline…What is 3D stringless paving?

Overview.Difference between 2D and 3DHow many contractors in North America using stringless paving?When/where was the first time 3D paving was used?

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!

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”

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

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

Workflow of Stringless Paving vs WireWorking 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

Check pin alignment & adjust if required

Survey and set stringline height on each pin (min. 2 men)

Install & tension clamps and stringlines

“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…

ReferencePoint

Walk left 5ft!Walk right 1ft!

Up a bit!Down a bit!

STOP!

ReferencePoint

Leica Geosystems History…

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

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 1905.

• 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.

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.

• 1935 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, 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 1996.

• Total Stations have taken on a variety of looks over the years.

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.• 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 wirelinethrough 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% cross-slope

Who is paving stringless in North America?

ACME – Spokane, WaAcura Inc. – Bensenville, ILAnthony Allega – Valley View, OHArcher Western - Fort Lauderdale, FL CC Myers – Rancho Cordova, CACemex - MexicoCold Spring Construction – Akron, NYConcrete Placing Company – Boise, IDEmery Sapp – Springfield, ILET Simonds – Carbondale, ILFlat Iron - CanadaFlynn Company – Dubuque, IAFred Weber - Maryland Heights, MOGolden Triangle – Imperial, PA

Granite Construction Co - Texas Hawkins Construction – Omaha, NEHead Inc. - LouisianaK-Five – Chicago, ILKiewit – Dallas, TXLindahl Brothers – Chicago, ILMcCarthy Improvement – Dubuque, IAMCM – Dallas, TXMilestone – Indianapolis, INToebe Construction – Wixom, MIWK Construction – Waterloo, IAZachry – North Carolina and Texas

Presentation Outline…Benefits of going 3D

Cost savingsLogistical advantagesSafety

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

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

Benefits of going stringless…Safety

Site Hazards

Walking hazard eliminated for workers near stringline

Vehicle hazard eliminated for driving near stringline

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 applicationsOverview of the support system for each

Overview of the different manufacturers for the paving industry

What technology is currently in the market?Overview of the instrument technology types offered and their applications

Total Station accuracy +/-.01’

*line of sight

Slipform paversTrimmers

Milling MachinesCurb & GutterAsphalt paving

Millimeter GPS accuracy +/-.01’

*with good satellite signal

TrimmersMilling Machines

Curb & GutterAsphalt paving

GPS RTK accuracy +/-.1’

*with good satellite signal

Placer/SpreadersFollow-up Machines

Curb & Gutter SteeringAsphalt Paving Steering

Grading Market

What technology is currently in the market?Overview of the support system for each

Direct Paving DealersSame support personnel for all paving applications in North

AmericaManufacturer 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

Presentation Outline…What infrastructure does a contractor need in place to implement 3D technology?

Open-minded crew, adapt to changeSurvey/Grade Checker resourcesGround-man, adjustments to machineData prep resource

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

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.

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

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.

Presentation Outline…What needs to happen once the 3D technology is purchased and in place?

Defining rolesProper trainingReasonable expectations of crew workload

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

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

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

Presentation Outline…Workflow of Stringless Paving

Verify Survey Control - or - Request it properly for what you needPrepare 3D ModelMachine Calibration and Tunings Plan Total Station Arrangements and hopping patterns

Survey Control

37

Site Control Points…Machine Control is only as good as the control!

Need to have a control point file to setup the total stations.Fore each of the Control points we need the following:1. Point Number2. Northing3. Easting4. Elevation

CP101

CP100

CP102

CP103

CP104

CP105

With this information, we can setup total stations anywhere we want based on the survey information provided.

Setting up the Total Stations...Free Station Resections

XYZ=?XYZ ± ?mm

Backsight Setup on a Control Point

Workflow of Stringless Paving3D Modeling Overview

Types of Models3D 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

Types of Models3D 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

Types of Models3D 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

Alignment Understands where horizontal

curves begin and end

Understands true curve

information

Understands the stationing

Profile Understands where vertical

curves begin and end

Understands true curve

information

Understands stationing

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 Line-

work or Surface File

Types of Models3D Alignment Models -or- 3D Road Models

= 3D Line-Work File= 3D Surface File= Job_01_Road.XML

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

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

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

Differences between grading and paving models

Grading Models

Grading uses GPS guided machines that are accurate to one tenth of a foot (+/- .1’)

3D line-work and surface files are used in the grading market

Paving Models

Paving uses robotic total station guided machines that are accurate to one hundredth of a foot (+/- .01’)

Alignment based models are used in the paving market

How are Models Built ?

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

Skill Sets for a Good Model Builder

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

How are Models Built ?Available software packages used in the market for Trimble Modeling…

Trimble Business CenterTrimble Terramodel

How are Models Built ?Available software packages used in the market for Leica Modeling…

Leica iCON Office

How are Models Built ?Available software packages used in the market for Topcon Modeling…

Topcon 3D Office

How are Models Built ?Available software packages used in the market 3rd Party for all Hardware

These packages export generic formats that the manufacturer software can recognize

Linework = .DXF Surface= .XML Alignment Models= .XML

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

Control of how many cross sections create the polylines paved on

Levelling, “Eyeballing” & Tensioning adds error

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

Horizontal Curve“Chording”

WastesConcrete

What makes a good Model ?

What makes a good Model ?Error Checking Procedures for surface and line-work files….

3D Polyline Editors

What makes a good Model ?Error Checking Procedures for surface and line-work files….

3D View Reference (looks good)

What makes a good Model ?Error Checking Procedures for surface and line-work files….

3D View Reference (looks like a problem)

What makes a good Model ?Error Checking Procedures….

3D Road Report

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

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

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

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

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

What makes a good Model ?Error Checking Procedures, for confidence and reference in the field….

3D Road Reports Per Alignment

Presentation Outline…Workflow of Stringless Paving

Machine Calibration and Tunings

Workflow of Stringless Paving Machine Calibration... WHEN and WHY ??

• WHEN?• At First Installation• At EVERY subsequent change of the machine.

• After raising/lowering removing/mounting prism masts• After pan width changes

• WHY?• 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

Workflow of Stringless Paving

Settings on the Machine ControllerUsually 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”

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

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 100.00 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.

Workflow of Stringless Paving

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.

Dry runsWorkflow 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

Workflow of Stringless Paving

Thank you for your attention…Time Permitting Question & Answers

Web References…Positioning Manufactures:www.leica-geosystems.comwww.trimble.comwww.topconpositioning.com

Machine Control Market Website:www.machinecontrolonline.com

Software Manufacturers:www.autodesk.comwww.carlsonsw.comwww.agtek.comwww.12d.comwww.bentley.comwww.hexagon.com/en/sbg.htmwww.vianovasystems.com/Products/NovapointDCMwww.liscad.com