Automated Machine Guidance / Stringless Paving

Tim Tometich

Manatt’s, Inc

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Topics of Discussion

➢Types of Machine Control

➢File Types used in Machine Control /

Electronic Needs

➢Accuracies of Machine Control Equipment

➢Electronic Needs

➢Challenges using AMG

➢Survey Needs

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GPS Machine Control Grading –

Adoption

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Crush and Pave

GPS Grade

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Trimmer Guided by Total Station

Pavesmart Software

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Profile Milling Operations

Paver Guided by Total Station

Pavesmart / iCon Software

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How does Stringless Paving work?

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Pavesmart

Leica iCon Pave

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Paving with Multiple Computers

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Electronic File Needs

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Electronic File Needs➢ For Machine Control Grading (Dozers, Motorgraders,

Excavators)

➢ Surface (Triangular Irregular Network(TIN))

➢ Linework File (Horizontal Only)

➢ File Types – XML’s or .DXF’s

➢ For Machine Control Paving, Milling, Trimming

➢ 3D Alignment Models or 3D Polylines - XML’s or

DXF’s

➢ Alignment – XML’s

➢ Transition Locations (Supers)

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Electronic File Needs

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3D Models - TIN (Triangular Irregular Network)

Primarily used for GPS Grading

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3D Models

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3D Models - Stringlines (3D Polylines or Breaklines)

Primarily used for Stringless Operations

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3D Models - Stringlines (3D Polylines or Breaklines)

Primarily used for Stringless Operations

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3D Models - IRI Profile Testing

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3D Models - IRI Profile TestingStart Station End Station IRI (in/mi) Classification

10630+00.00 10635+28.00 5.25 Smoothest

10635+28.00 10640+56.00 5.41 Smoothest

10640+56.00 10645+84.00 5.62 Smoothest

10645+84.00 10651+12.00 1.90 Smoothest

10651+12.00 10656+40.00 1.50 Smoothest

10656+40.00 10661+68.00 7.77 Smoothest

10661+68.00 10666+96.00 7.53 Smoothest

10666+96.00 10672+24.00 7.87 Smoothest

10672+24.00 10677+52.00 6.58 Smoothest

10677+52.00 10682+80.00 4.57 Smoothest

10682+80.00 10688+08.00 4.74 Smoothest

10688+08.00 10693+36.00 5.15 Smoothest

10693+36.00 10698+64.00 5.98 Smoothest

10698+64.00 10703+92.00 9.19 Smoothest

10703+92.00 10709+20.00 6.73 Smoothest

10709+20.00 10714+48.00 0.37 Smoothest

10714+48.00 10719+76.00 0.37 Smoothest

10719+76.00 10725+04.00 1.78 Smoothest

10725+04.00 10730+32.00 4.46 Smoothest

10730+32.00 10735+60.00 4.20 Smoothest

10735+60.00 10740+88.00 4.15 Smoothest

10740+88.00 10746+16.00 4.20 Smoothest

10746+16.00 10751+44.00 4.60 Smoothest

10751+44.00 10756+72.00 1.85 Smoothest

10756+72.00 10762+00.00 0.35 Smoothest

10762+00.00 10767+28.00 0.89 Smoothest

10767+28.00 10772+56.00 6.81 Smoothest

10772+56.00 10777+84.00 6.98 Smoothest

10777+84.00 10783+12.00 7.29 Smoothest

10783+12.00 10788+40.00 4.35 Smoothest

10788+40.00 10793+68.00 1.12 Smoothest

10793+68.00 10798+96.00 1.10 Smoothest

10798+96.00 10804+24.00 10.63 Smoothest

10804+24.00 10809+52.00 7.56 Smoothest

10809+52.00 10810+43.96 18.49 Smooth

Tue Oct 17 19:29:27 2017

International Roughness Index Report

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Electronic File Challenges➢ Files do not reflect actual field conditions

➢ “Field Verify” – Should be a thing of past

➢ File sizes can be a challenge

➢ Road Projects- Typically thin out the vertices

➢ Lines overlapping each other

➢ For stringless operations, polylines crossing

eachother

➢ Run-in and Run outs

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Electronic File Challenges➢ Electronic information doesn’t include special

case areas – special shaping

➢ Recently had a project tying into a Rairlroad

o File didn’t represent the cross slopes

➢ Storm Sewer protruding through bottom of

concrete

o Made a quick profile change, exported the

new 3D file, placed rock, trimmed and

continued paving

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Electronic File Challenges➢ Intersecting roads or ramps not tied in

correctly.

➢ T-intersection – Crown is not transitioned

correctly into the intersecting road

➢ Designs that do not align with paving

operations. Designers don’t always understand

a paver’s capabilities or incapability's

➢ Grading operations – ditch profiles not

matching pipe inlets elevations, etc…

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Stringless Paving Challenges➢ Iowa DOT projects

▪ Not all detour pavements or cross-overs are

electronically designed – Contractor Design

➢ Iowa DOT and County Overlays- Contractor

Design

▪ Time-consuming if topo is performed after

nominal milling

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Survey Needs

➢ For GPS Grading

• Control Points that surround the working

area (Minimum of 4 points)

• For Linear (road) Projects – points should be

placed as wide as possible

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Survey Needs

➢ For Stringless Machine Control (Total Station)

• Control points spaced every 500 ft on each

side of road staggered.

• Tie-in locations shot and verified

• Horizontal and Verticals as tight as possible

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Survey Needs

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Survey Issues

➢ GPS Control not matching Paving Control

➢ Paving Control set in the fall to be used in the

spring - Freeze Thaw Cycle

➢ Paving Control too loose – set with longer

distances

➢ Topo cross-sections spaced too far apart

➢ Topo shot with incorrect control

➢ 3D Models don’t match field conditions

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PCC Overlays – To mill or not to mill

➢ Every project is unique.

➢ Projects requiring pavement scarification

❖What is profile milling?

✓ Is it just cutting a nominal depth with a

cross slope? Maybe? Up for

Interpretation??

✓ Does it need to follow the same profile of

the PCC Pavement top minus the

thickness of concrete?

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Profile Milling Operations

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PCC Overlays – To mill or not to mill?

➢ From a contractors perspective –

➢ We believe the cost savings in concrete

yield outweighs the cost of 3D Profile Milling

▪ We have seen savings from of 120-125%

yields down to 105-110% yields

▪ Produces a more consistent slab and can

better utilize the materials

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PCC Overlays – To mill or not to mill?-

Continued

➢ From a contractors perspective –

➢ Less disruption in traffic – wait time on

survey and design model is less

➢ Re-invest in the slab thickness

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Preliminary Survey Collection

Leica TS16

Insert Scanning

Picture here

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Preliminary Survey Collection

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Electronic Files used in Bidding➢ Primarily used to help speed up the Estimating

Process

➢ Calculation of earthwork, earthwork balancing

and haul distances

➢ Verifying quantities and helping to plan the

project.

➢ Calculation of Paving Runs (Mainline Paving

vs. Handwork)

➢ Calculation of Materials

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Conclusion - Machine Control

Benefits from a Contractor’s Perspective

▪ Increased Productivity – 10 % Avg - as much as 100%

▪ Increased Accuracy – 0.01-0.02 ft with right tools

▪ Increased ability to make changes quickly

▪ Safer Projects / Shorter Schedules

▪ Operators and Supervisors can be more empowered

▪ More Cost Effective Projects

▪ More Satisfied Owners

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▪ Gives the Contractor Real Time Information in the Field

▪ Allows the Contractor and Inspector to verify work

efficiently

▪ If the 3D Model is not provided, Contractors have proved

they will pay for it to prepared

▪ Survey Costs are greatly reduced – 50% in some instances

▪ Shifts some survey work from the field back to the office for

Design. 90% in field reduced to 40%

Conclusion

Benefits Continued – Contractor’s Perspective

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QUESTIONS / COMMENTS ??