stringless paving: preparing & handling models

Levi MichaelNebraska Concrete Paving Association

January 19, 2016

Stringless Paving: Preparing and Handling Models.

Presentation Overview

Stringless Paving Overview -Flores Automation & Machine Control Introduction -Nebraska’s Contractors Paving Stringless

-Stringless Components

-Advantages of Stringless Paving -How to Minimize Risks -Achieving Bonus Ride Numbers

FAMC Company History…

F R A N K F LO R ES ( C EO) S TA RT E D F LO R ES AU TO M AT I O N I N 2 0 0 7

Specializing in industrial/mobile automation contracts. In 2010, started relationship with Guntert & Zimmerman to do

controls on S600, S850SL, PS1200, and most recently S400 and MP550 belt placer.

Built engineering and management staff of 14 employees. Currently performing paving machine retrofits for FAMC

S TA RT E D F LO R ES AU TO M AT I O N & M A C H I N E C O N T R O L I N 2 0 1 2

Started providing 3D Machine Control Services Project consultation, onsite trainings, remote support, data

preparation Obtained Leica Geosystems relationship in 2013 Current Authorized Leica distributor for paving applications in the US Almost 30 years of combined AMG knowledge among the FAMC

group

.

Contractors Paving Stringlessin Nebraska

Gerring Columbus, NE

Paulsen Western Nebraska

Luxa Blair, NE

Hawkins Omaha, NE

IHC Sydney, NE

Stringless System Components

What are the major components?● Stringless Machine hardware - Computer on machine - Dual Axis Slope Sensor(s) (controls Cross/Long slope) -Interface cable to communicate with machine controller - Mast-mounted 360º prism(s)

● Stringless Data Software - Control file loaded into “guns” - CAD file on machine

3D for Concrete Pavers System Components

Machine Computer& Radios

Prism Prism

Slope Sensors

System ComponentsMachine Computer

◦ Contains work screen interface to make adjustments

◦ Stores all stringless dimensions

◦ Additional abilities of tuning machine for stringless signal

◦ Machine should have NavPac (battery supply) incase power is turned off to machine

System Components Slope Sensors, and Machine Radio Solutions

Dual Axis Slope Sensor

Radios for total station/machine pc communications

System Components3D Sensors – Total Stations

1” total station preferred For all surveying & machine control tasks 12Hz measurement rate Tracking accuracy ±3mm at 100m (300ft) Typical working Range ± 100m (300ft)

(= 200m/600ft total) Synchronized EDM/Hz/V data Fully robotic operation Automatic prism tracking

Stringless Data Components explained.

The Stringless Data Components are files that orientate the total stations and machine to the jobsite

Control File for Total stations-for orientating total station to jobsite

A .txt or .csv file containing Point ID, Northing,

Easting, Elevation for each control hub Critical that all control points used are a closed

loop to avoid elevation steps in control (smooths out the error between control hubs to put them on same relative plane)

Stringless Data Software explained

CAD Model for Machine PC-orientating machine/stringlines to “top of concrete”A CAD file containing elevated polylines (polylines representing EP/grade break is

always good practice)Loading XML with true curve data always best option for smoothness (need

alignment and profile for edge of pavement and grade breaks)

Checking model in ProVal for smoothness,always highly recommended

Data Prep needs to be organized and all data needs to be verified before production A Dropbox folder is a great way to transfer

data, never email unzipped data

3 Major Stringless ManufacturesLeica

-Dual total station solution

-1up GPS with total station for grade (Current Curb & Gutter application)

Trimble

-Dual total station solution

TopCon

-GPS with laser for elevation

And their solutions

Advantages of paving stringless

-Not just replacing wire guidance

-Lay out your own hand pours, Drainage Inlets, Gores and more

-Literally any future construction can be laid out before hand, an invaluable tool

Advantages of paving stringless

Double check agency and grading crew. -Can check your cut/fills wherever final grade has been established.

-With an elevated CAD file, check anything on the job!

Advantages of Stringless Paving-Check your profile smoothness before you ever pave!

-Closely monitor yields with Cut/Fill maps

-Be in total control of your site data!

No wire to trip over and cause bumps.

No longer worry about smoothing a wire due to a survey bust or “loose” survey

Open up access around pave (construction standard 5’ to EP from wire)

Remove the safety hazard from your jobsite

Remove the waiting period for an overworked survey crew

Advantages of Stringless Paving-Check final subgrade without the need of wire set.

-Stored grade checks can easily be turned into a Cut/Fill map

Manage your yield!

Don’t get caught off-guard!

Stringless Paving – How to minimize your risks

What are the real disadvantages of paving stringless?

-If “Critical” Stringless equipment becomes faulty, pave is shut down on the spot

We recommend keeping inventory on critical components (critical inventory

is mostly cables)

Stringless Paving – How to minimize your risks

-If poor Data Prep is presented, poor product will most likely be the result

We recommend using a service such as, Dropbox, to organize files into three categories.

1. Engineer- all data given by engineering firm

2. Outputs- all road jobs created from rough files

3. Work- all of your rough files (profiles, alignments, etc.)

Paving crew

• Most crucial aspect of paving well

• Communication is key

• Communication quickest way to break learning curve

Achieving Bonus Ride Numbers with Stringless Paving

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


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.


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


Proper training – Standard Operating Procedures

• 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

• Create Standard Operating Procedures for your company’s specific operation


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



Stringless Paving will change your Work-Flow!

1. Prepare 3D Model

2. Request\Set Survey Control

3. Machine Setup

4. Sub-Grade\Model verification

5. Plan Total Station locations and hopping patterns

6. Paving adjustments needed while paving

Main Ride Issues Consistency is key!

Track grade aligned to profile of PCCP crucial

Multiple stops in a 528’ segment most likely bump out of incentive

Machine pan setup perfect

Machine controller is set up correctly

TUNING!!! An ill-tuned machine WILL mitigate all the hard work prepped to pave correctly


Presentation Overview

Stringless Production Overview

-Production-Achieving Ride Bonus Stringless◦ A. Crew◦ B. Main ride issues

-Contractor Discussion: How close to over-reactive does the machine need to be for best results?

Thank you! Please come visit with us!

Hydraulic Locks & Timeouts

How do we, as contractors, minimize our risk?-Maintaining an organized “Critical Inventory” list is mandatory!!! No exceptions or you will get burned and end up throwing away 10+ trucksdue to missing something as simple as a $15 fuse.-Running your profile through ProVal is mandatory to check for errors. All models, control files, versions of firmware, and anything else that pertains to your data prep and stringless technology should always be accessible at any time through Dropbox or the likes.

stringless paving: preparing & handling models

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