1 3D Automated Machine Guidance [AMG] In Construction References a - - PDF document

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1 3D Automated Machine Guidance [AMG] In Construction References a - - PDF document

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Machine Control Technology in Paving and Milling Session W36 Kevin Garcia and Brian Girouard Trimble Inc. Notable/Award Winning Projects Telluride CO Airport Project with Kiewit New St-George UT Airport Project with Western Rock

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Machine Control Technology in Paving and Milling Session W36 Kevin Garcia and Brian Girouard Trimble Inc.

  • Telluride CO Airport Project with Kiewit
  • New St-George UT Airport Project with Western Rock [Staker Parson/Oldcastle Group]

– https://www.youtube.com/watch?v=35uxS4BE4ag

  • Provo River Constructors [PRC] I-15 Project in Provo UT
  • Port Mann-Hwy 1 Project in Vancouver BC with Kiewit
  • Circuit Of The Americas [COTA] F1 Track in Austin TX with Austin Bridge & Road

– https://www.youtube.com/watch?v=ygC-vbVv7oc

  • Western Wake Expressway Raleigh NC with Lane
  • Colorado Springs CO Peterson AFB Runway Project with Kiewit
  • Honolulu HI Reef Runway Project with JAS W Glover

– https://www.youtube.com/watch?v=DKKjUXrIQLU

  • Bowling Green KY National Corvette Museum Motorsports Park [Corvette Test Track] with Scotty's Contracting

– https://www.youtube.com/watch?v=napiTkJT2os

  • Quebec Ministry of Transportation
  • Bogota El Dorado International Airport
  • US Bank Vikings Stadium in Minneapolis MN with Park Construction

– https://www.youtube.com/watch?v=UUbKFCW2-NY

  • Numerous FHWA/State DOT Intelligent Compaction Projects

Notable/Award Winning Projects 3D AMG in Construction

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3D Automated Machine Guidance [AMG] In Construction

  • References a method of placing and managing materials on

a project

  • Utilizes technology to guide a machine while referencing an

engineering design

  • Does not reference anything on the ground for grade

control

  • AMG is a term used with State DOT’s and the FHWA
  • By technology standards, 3D AMG is a “seasoned” method in

construction dating back to the 1990s!

– It is a survivor… Remember PCMCIA Cards and Y2K?!?

3D AMG In Construction

  • 3D AMG is a process [not just a product]
  • Includes:

– Survey Control Reference Points – 3D Design – 3D Technology – 3D Support Team – Training – Etc…

  • It is an investment
  • Requires a commitment to change
  • There is no magic button!

3D AMG In Construction

  • 3D AMG Technologies:

– Precise Real-Time [e.g.: RTK] Global Navigation Satellite System [GNSS]

  • 0.1’ [30mm] or better
  • Typically “Golf Ball” accuracy or better
  • Technology used on mass-ex, subgrades, etc…

– Universal Total Stations [UTS]

  • 0.01’ [3mm]
  • Technology use for fine 3D Grading, 3D Milling, 3D Curb & Gutter and

3D Paving

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3D AMG Examples

This one is from the 1990’s!

2D and 3D Milling-Paving Terminology 2D and 3D Milling-Paving Terminology

  • 2D Milling-Paving – guidance to grade [elevation-thickness]

and/or slope

– 2D is Ground-up – 2D Systems typically place a constant thickness over the base

  • 3D Milling-Paving – guidance to grade and slope at a known

position using a design/model

– 3D is Design-down and does not use the existing surface for any guidance

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Flat or Level (no slope) Reference Elevation

  • 1D

Machine Guidance Positioning

  • 2D

Elevation [e.g.: Sonic] Slope [e.g.: Slope Sensor]

Machine Guidance Positioning

  • 3D

CL EP Z N E

Machine Guidance Positioning

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Why use 3D Milling and 3D Paving in intelligent Construction [iC]?

To build better pavement structures!!!

Sample Engineering Specifications

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“Traditional” 2D Milling Method: Non-Graded Surfaces 3D Milling Method: Graded Surfaces

Traditional 2D Milling & 3D Paving

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3D Milling – Making Grade with iC Why 3D Mill?

  • Increased production, lower cost

– Only mill where needed

  • Increased smoothness

– Remove longitudinal waves

  • Decreased asphalt usage

– No need to fill in low spots [leveling course]

  • Change/Fix Cross-Slopes

– New State/Federal Specs

  • Mill complex designs

– Transitions, supers, drainage, etc.

  • No Stringline or wire required

– Reduce costs – Better truck/traffic management – Safer

Why 3D Mill? – Con’t

  • Variable depth and slope milling:

– Remove more or less material as per project specifications – Provides uniform surface for pavement

Guide Policy for Geometric Design of Freeways and Expressways - NAASRA 1976
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Other Advantages of 3D Milling

  • Increased Smoothness

The issue of differential compaction when paving: 3D milling takes away the issue:

Other Advantages of 3D Milling – Con’t

  • Decreased asphalt usage
  • 3D Milling minimizes asphalt usage

Asphalt filling of low spots [Levelling Course]

Results of better Pavement Structures using 3D

  • Smoother

– Easier to control vehicles at higher speeds – Less impact, especially with heavier loads

  • Safer

– Better drainage, reduce ponding/hydroplaning – Better traffic control

  • Quebec Ministry of Transportation increased off-ramp +10km/h [+6mph]
  • Longer lasting

– Lower maintenance costs – Better snow removal hence

  • reducing additional wear
  • premature failures from undulating surfaces
  • Taxpayers enjoy driving on smooth roads 
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Control System Overview

Contact Sensors 2D OEM Control System Machine Hydraulics [Leg Control] Sonic Sensors Wire Rope Sensors

  • 2D Position only
  • Ground up

Up/Down Left/Right Corrections 3D System

  • 3D Position Sensor
  • Relative to design
  • Top Down

3D Mills – In the Field 3D Paving – Making Grade with iC

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Why 3D Pave?

  • Achieve the highest accuracy and smoothness levels

– Better material management – Better material yields

  • Eliminate the stringlines:

– Reduce staking labor, downtime and errors – Reduce costly rework – Finish the project faster

  • Pave variable depth and slope including complex designs
  • Use an “Uncompacted Design” to help differential compaction issues

– For most applications, includes “levelling course” in the same pass

3D Paving Applications

  • Any project where a contractor uses Stringline, wire or “grade

marks” for elevation grade

  • Variable depth and slope paving applications

– Roadways, Airports and commercial surfaces – Base material [P209, gravel, etc…] – Asphalt – Roller Compacted Concrete [RCC] – Concrete Treated Base [CTB]

3D Paving – Managing Differential Compaction

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  • 3D Designs describe the final finished surface
  • 3D AMG systems use vertical offsets to build up to this surface
  • Final asphalt lift is designed to finish at this design surface
  • If existing paving surface is not to grade or not level, low areas

will compact more

– Paved surface will have longitudinal waves affecting smoothness

  • Traditional practices are to place multiple lifts hoping the

waves are reduces and or eliminated by final lift

– ~60% to +80% of waves reduced per lift

Managing Differential Compaction

  • 3D paving can help manage differential compaction

– Using a paving machine guidance Uncompacted Design

  • Paving machine guidance Uncompacted Design uses 3 key components:

– Existing Surface – Design Surface [e.g.: first lift of compacted asphalt] – Compaction Factor

  • E.g.: 2” compacted, placed at 2.5”
  • Compaction Factor = 2/2.5 = 0.80
  • 3D Paving goal is to place “levelling course” at the same time as design

grade

– Compacted material is placed at grade

Managing Differential Compaction

Paving & Rolling on a smooth or 3D AMG graded surface

Managing Differential Compaction

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This surface represents long longitudinal roadwaves This is N.T.S and is extremely exaggerated

  • If you lay a thicker lift you get more compaction

Managing Differential Compaction

  • Place the asphalt to the “Uncompacted” Design

– A little thicker over the low areas

  • Rolling will leave a smooth level surface
  • Consider using a 3D mill prior to paving!!!

This surface represents long longitudinal roadwaves This is N.T.S and is extremely exaggerated

Managing Differential Compaction

Control System Overview

Contact Sensors 2D OEM Control System Machine Hydraulics [Screed Control] Sonic Sensors Averaging Beams

  • 2D Position only
  • Ground up

Up/Down Left/Right Corrections 3D Machine Control

  • 3D Position Sensor
  • Relative to design
  • Top Down
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Available Options w/AMG

  • Automatic Paver Steering*

– Keeps the paver online and removes a task for the paver operator to be concerned with

  • Auto screed width*

– Keeps paving simpler especially when adding in automatic steering

  • * – Not available from all technology providers and not

available on all Makes or Models of paver

3D Milling & 3D Paving – Pavement Preservation 3D Milling – Pavement Preservation

ORIGINAL ROAD SURFACE @ +1.5” Crown @ -2% Crossfall

** Minimum Depth 3D Milling while maintaining existing asphalt structure!

QUEEN KAAHUMANU HWY NB LANE – KONA HAWAI’I JANUARY 2018 N.T.S.

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3D Milling – Pavement Preservation

ORIGINAL ROAD SURFACE @ +1.5” Crown @ -2% Crossfall

** Minimum Depth 3D Milling while maintaining existing asphalt structure!

QUEEN KAAHUMANU HWY NB LANE – KONA HAWAI’I JANUARY 2018 N.T.S.

3D Paving – Pavement Preservation

** 3D Paving to fill 3D milled areas and set road grade surface!

QUEEN KAAHUMANU HWY NB LANE – KONA HAWAI’I JANUARY 2018 N.T.S.

3D Paving – Pavement Preservation

QUEEN KAAHUMANU HWY NB LANE – KONA HAWAI’I JANUARY 2018 N.T.S.

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3D Paving – Pavement Preservation

QUEEN KAAHUMANU HWY NB LANE – KONA HAWAI’I JANUARY 2018 N.T.S.

3D Paving – Pavement Preservation

QUEEN KAAHUMANU HWY NB LANE – KONA HAWAI’I JANUARY 2018

3D Paving – Pavement Preservation

QUEEN KAAHUMANU HWY NB LANE – KONA HAWAI’I JANUARY 2018

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3D Paving – Pavement Preservation

QUEEN KAAHUMANU HWY NB LANE – KONA HAWAI’I JANUARY 2018 N.T.S.

Key Ingredients for a Successful 3D Automated Machine Guidance [AMG] Project

  • Consult with a qualified manufacturer and supplier prior to the project
  • Training and Support from a qualified distributor

– Plan and prepare for training prior to production on the project

  • Contractor is committed in using technology

– Should have a person on staff to be responsible – Product Solutions Investment and an Investment to change how you work

  • Contractor follows all machine manufacturer recommendations for operating the

machines equipped with Machine Guidance

– E.g.: Paving By The Numbers, etc… for pavers – There is no “magic” button when technology is install, you still need to know how to pave

Key Ingredients for a Successful 3D AMG Project

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  • Use the correct technology for the project application [s]

– Is there line of sight for the total stations? – Are there any obstructions? – High walls? Overpasses? Bridges? Trees? Buildings? Tunnels?

Key Ingredients for a Successful 3D AMG Project

  • Use the correct technology for the project

accuracy requirements

  • How does the 3D technology work with the

existing milling or paving 2D technology?

  • Machine is in optimum working condition

– Any wear or “slack” on the machine will affect results

  • Consider other machines for machine guidance

and not limit to just one. Look at the whole spread.

– One machine is productive, multiple machines are MORE productive!

Key Ingredients for a Successful 3D AMG Project

  • All Instruments need to be checked, cleaned, adjusted,

updated with a Certified Service Center

  • All Technology [e.g.: Instruments, Sensors, etc…] on the

project need to be field calibrated as per the manufacturer’s recommendations

  • Always check and double check equipment and technology
  • n the project
  • Check all range pole plumb bubbles and point for wear

– Every mm counts!!!

Key Ingredients for a Successful 3D AMG Project

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  • Project Survey Control Points must be accurate
  • Must be less than ½ the project specifications

– Example: Project Spec of 1/4” [0.006m], Survey Control less than 1/8” [0.003m], etc… – Contractors may chose to be more accurate than project spec to help manage material yields

  • Use a Digital Level system to reduce or eliminate human errors!
  • If you are 3D milling or 3D paving, mm accuracy is a must

– There is no reason for poor survey control accuracy

  • Should be no more than 500’ [150m] apart for Total Station Machine Guidance

– You need to know the technology ranges and/or limitations

  • Surround the project

– If working on a linear project [roadway, runway, etc…], survey control points should be staggered on each side of the corridor for the best geometry and accuracy. – If placing control points every 500’ on each side, actual survey control points will be every 250’ along the corridor

Key Ingredients for a Successful 3D AMG Project

  • Poor Survey Control

– Please Note: N.T.S.

Key Ingredients for a Successful 3D AMG Project

  • Good Survey Control Points

– Please Note: N.T.S.

Key Ingredients for a Successful 3D AMG Project

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  • Use Digital Level [Vertical]
  • Total Station [Horizontal]

Digital Level [V] Optical Level/Lenker Rod [V] GPS Rover [H]

Key Ingredients for a Successful 3D AMG Project

3D Data/Designs – Built for AMG

  • Must be Accurate
  • Built for Automated Machine Guidance [AMG] applications
  • If building a road/corridor, runway/taxiways, create the design

as per the specifications using:

– HAL, VAL, X-Section Templates, Stationing, Superelevations & Widening, etc…

  • Build the design as the project will be constructed

– Subgrade, Finish Grade, etc…

  • Optimized and densified for Machine Guidance
  • Must meet or exceed IRI/Smoothness Spec!

– Check design in BC-HCE prior to sending to machine

  • If the design is wrong the surface is wrong

– If you are milling or paving, this is your last chance to get it right!

Key Ingredients for a Successful 3D AMG Project

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Undensified Corridor Surface Curves and Vertical Curve surfaces are more segmented, not smooth Densified Corridor Surface Curves and Vertical Curve surfaces are more uniform and SMOOTH

  • Example of a not so good design

Key Ingredients for a Successful 3D AMG Project

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  • Results of a not so good design
  • If the data does not look good on

the computer, do not expect it to get fixed on the grade!

Key Ingredients for a Successful 3D AMG Project

  • When using 3D AMG, PLEASE make sure the existing

surface is to grade!

– Unless you want material overruns

  • There are projects where the finish surface is very different

to the existing

– New State/Federal Specifications, New design grades, etc…

  • If a Mill and Fill project, consider using a 3D mill
  • Always remember: 3D AMG will set the machine to the

design grade and not reference anything on the ground for grade control

Key Ingredients for a Successful 3D AMG Project

  • As-built or existing surface data accuracy should be equal or better

than the technology being used – If the AMG technology can achieve 3mm to 5mm [0.01’ to 0.02’], as- built data accurate at 10mm to +20mm [0.03’ to +0.07’] is not ideal – The data can be used for a 3D design and/or to verify was has been milled or placed

Key Ingredients for a Successful 3D AMG Project

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What could possibly go wrong?

  • Not understanding the 3D process and continue to apply

traditional methods

– Unable to measure, calculate the value and cost savings for 3D AMG

  • Unrealistic expectations

– The “magic” button – All 3D designs are created for 3D AMG – All Survey Control points on a project are sound and fit for 3D AMG – Not taking ownership

  • Setting unrealistic goals

– Implementing 3D AMG for the first time on the first day of production – No prior training

What could possibly go wrong?

  • Trying to combine “traditional” construction methods
  • Only using 3D AMG for “finish” grading or paving
  • Not applying 3D AMG to the complete construction

process

– Typical with Mill/Fill projects or “Pavement Preservation” projects – Who owns the milling equipment? – Paving Contractor? Sub Milling Company?

  • The following is an example of combining “traditional” 2D

milling with 3D paving:

What could possibly go wrong?

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  • Mill and fill project
  • Existing road surface milled at 2” thickness
  • Contractor checked milled grade using UTS Rover
  • Elevations did not match

– Typical milled areas were not deep enough

  • When the milling sub-contractor had to remove more

material, they over cut on average over +2” so they did not have to mill a third time!

  • Pavement spec thickness: 4” [0.33’]
  • In one mile, 25% overrun!!!

Example of paving on a non-3D surface 3D AMG Benefits 3D AMG Benefits – Owner [e.g.: DOT/FHWA]

  • Increase in safety on the job site
  • Contractor maximizes production during construction
  • Increase project delivery, reducing delays
  • Construction is more accurate and cost effective
  • Ability to catch possible errors and data inconsistencies in

design before construction

  • The ability to check Grade at any location on the project vs

at specified cross section locations

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3D AMG Benefits - Contractor

  • Increase in safety on the job site

– Tripping hazards, etc…

  • Increased Production, more Efficient, less Rework

– Fuel savings

  • Achieve the highest accuracy and smoothness levels

– Better material management – Better material yields

  • Eliminate the stringlines:

– Reduce staking labor, downtime and errors – Reduce costly rework – Better machine management on and off the grade

Other Technologies to Consider Technology Reaches Beyond AMG

  • Intelligent Compaction
  • Connected Site Technologies
  • Material Management Tools
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Questions? Thank You

Session Evaluations / PDHs

  • Professional Development

Hours logged in session feedback

  • Complete session feedback in

mobile app

  • Answer “Yes” to last questions

for PDHs See you again at:

  • World of Asphalt 2019

– February 12-14, 2019 – Indianapolis, IN

  • CONEXPO – CON/AGG 2020

– March 10-14, 2020 – Las Vegas, NV – 140+ education sessions