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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Leica PaveSmart 3D v3.0 – Jan 2013 - 17
Machine
Computer and Radios
Prism Prism
Slope
Sensors
Layout of Stringless ComponentsSystem Main Components
Leica PaveSmart 3D v3.0 – Jan 2013 - 18
System Main ComponentsOn-Machine Components
2.) On-Machine
Computer w/
PaveSmart3D
1.) Rugged
360deg Prisms
3.) Dual Axis
Slope Sensors
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Leica PaveSmart 3D v3.0 – Jan 2013 - 19
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...
Leica PaveSmart 3D v3.0 – Jan 2013 - 20
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Leica PaveSmart 3D v3.0 – Jan 2013 - 21
Leica PaveSmart 3D v3.0 – Jan 2013 - 22
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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Leica PaveSmart 3D v3.0 – Jan 2013 - 23
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
Leica PaveSmart 3D v3.0 – Jan 2013 - 24
Paver
Calibration
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Leica PaveSmart 3D v3.0 – Jan 2013 - 25
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!
Leica PaveSmart 3D v3.0 – Jan 2013 - 26
How to Build the Model...All major CAD platforms produce files for Leica PaveSmart 3D
CAD System
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Leica PaveSmart 3D v3.0 – Jan 2013 - 27
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
Leica PaveSmart 3D v3.0 – Jan 2013 - 28
Setting up the Total Stations...
Free Station ResectionsCL
XYZ=?
XYZ
± 0.01’
Backsight Setup on
a Control Point
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Leica PaveSmart 3D v3.0 – Jan 2013 - 29
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.
Leica PaveSmart 3D v3.0 – Jan 2013 - 30
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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Leica PaveSmart 3D v3.0 – Jan 2013 - 31
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??…