Stringless 3D Control

Systems for GOMACO

Pavers & Trimmers

Karl Soar BEng

g MSc,,
Product Manager, Paving Systems
Leica Geosystems AG
Heerbrugg, Switzerland

Why are paving contractors Going

Going Stringless
Stringless?
?
Because stringlines
are expensive, time-consuming and error-prone to install - typically
US$1.50 per pin, or > US$500 per mile (European figures, excludes
surveyor costs)
are easily damaged during paving
are easily misaligned (errors increase costs)
are a significant site safety hazard
interfere with site logistics, increase, concrete delivery time,
haulage costs, and reduce productivity.
greatly increase pre-production planning & surveyors workload

Faster more accurate Trimming

Faster,
Trimming
Optimum concrete slab thickness saves money

Smoother paving
paving
Reduces vehicle wear and passenger fatigue

Smoother paving
paving
Earns Performance (Ride Quality) Bonuses

No Stringline Installation
Installation
Saves money on staff and safety/access equipment

24 hrs per day

day, 7 days per week production
production
Earns Early Completion bonuses

Restricted access (zero-clearance) paving

paving
Tackle complex projects with less planning & costs

Improved site logistics

logistics
Keeps the traffic moving

Why are paving contractors Going

Going Stringless
Stringless?
?
Advantages with Leica Stringless System
Good site engineers/surveyors are hard to find, and expensive
Stringlines dont always model the concrete design accurately
Go in, pave & get out ability minimizes machine standing time ideal for
time-critical paving operations (e.g. live airports, roads)
Estimated 50% survey cost reduction - one surveyor or engineer
manages the Leica system (during production only)
Estimated 20% productivity increase (up to 50% in complex areas)
Direct construction from CAD design no intermediate rework
One 3D model for trimming and paving = material cost savings

10

Where are paving contractors Going

Going Stringless
Stringless?
?
Typical Projects
Commercial Airports: Runways, Taxiways, Aprons
Military Airfields: Runways, Taxiways, Aprons
Motorways & Highways
Rigid-trackbed Railways
Rail and Road Tunnels

If you want to pave it, Leica can control it

11

Some Completed & Current Projects

Airports

Military: RAF Fairford (UK); USAF Kirtland (NM, USA); USAF Lakenheath (UK); Belle Chasse Naval Reserve
New Orleans, LO (USA); Homer Regional Airport, LO (USA);
Civil: Zurich Intl. Airport (Switzerland); London Heathrow Terminal 5, Edinburgh Intl., Farnborough, Luton Intl.
(UK); Hartsfield Jackson Atlanta Intl., Baton Rouge, LO (Louisiana, USA); Airbus Industrie A380 Testbed,
Toulouse (France); St Louis; Indianapolis

Highways

E40 Ghent-Brussels, Belgium (4 x 10km); Interstate 30 - Dallas-Fort Worth, USA (4 x 20km);

Pacific Coast Highway (Sydney-Brisbane) Australia (4 x 11km); Thorney Bypass, Peterborough UK (2 x 15km)

Tunnels

Sophia Rail Tunnels, Rotterdam, 11km (Netherlands);

Channel Tunnel Rail Link, 35km, London (UK)
Madrid Metro, Spain (commencing Feb 06)

High-Speed Rail (Rigid Trackbed)

Koln-Frankfurt ICE, Germany, 2 x 120km;

N b
Nrnberg-Munich
M i h ICE
ICE, Germany,
G
2 x 100km
100k

12

Changing your Working Method

13

Workflow for Paving with Stringline

Stringline

Inspect the Design make/calculate setting-out lists for each lane

Setup theodolite, survey each pin position with total station (min. 2 men)

Hammer in (or drill-in!) each pin, 2 lines for each lane of concrete

Check pin alignment & adjust if required

Use a surveyors level to survey

Reference
Point

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

Install & tension stringlines

Inspect & adjust stringlines before paving

Move paver into position, adjust sensors to stringlines, re-check

Start Paving

Ensure (or hope!) nothing disturbs or damages the stringline during paving!
14

Go Left 5m!
Go Right 1m!
Up a bit!
Down a bit!
STOP!

Workflow for Paving with Leica

Leica
Before project starts

Convert design into a surface model, load onto Leica machine computer

Throw away the pins!

On paving days only

Setup 3 theodolites

g
Start Paving

Move theodolites nearer to paver

when maximum range is reached

15

Equipping the Machine

16

Leica 3D Stringless Control System

Compatible with all GOMACO machines
All machines with GOMACO
CAN network controller
(retro-fit kits available from GOMACO)
Height and Steer Control for Trimmers
and 1-Track Steer Curb & Gutter by
1 theodolite and 1 slope sensor
Control for mainline slipform
pavers by 2 theodolites and
2 dual-axis slope sensors

17

Leica 3D Stringless Control System

Whats Needed on the Machine?
Leica Computer
Computer, Software & Radios
Slope Sensors
Prisms & Masts

18

Stringless Control System for Pavers

System Components
360 Prism

Machine
Computer
360 Prism

Reference
Point

Radios
Slope
Sensor

Reference
Point
19

Theodolite #3
(As-builts &
Leapfrog)

Theodolite #1
(Guidance)
Theodolite #2
(Guidance)

Stringless Control System for Placer/Spreaders

System Components
Machine
Computer

Reference
Point
360 Prism

Radio

Slope
Sensor

Theodolite #2
Optional for
Leapfrog
20

Reference
Point

Theodolite #1
(Guidance)

Example: New Generation GHP-2800 Paver

Computer & Radios
360
Prism

360
Prism
Slope Sensor

21

Stringless Control System for Trimmers

System Components
Reference
Point

Reference
Point

360 Prism
Machine
M
hi
Computer
Radios

Slope
Sensor

Theodolite #2
(As-builts &
Leapfrog)
Theodolite #1
#
(Guidance)

22

Example: 9500 Series Trimmer

360
Prism
Slope Sensor

23

Computer & Radios

Replacing the Stringline

by Modelling the Project

24

Replacing the Stringline - 3D Design Modelling

The D45 Model
17

15

13

11

1
25

Working
g
Offset
(Position)

18

16

14

12

10

C
Cross-Section
S ti
8

Coordinate
(Easting X,
Northing Y,
Height Z)

How do we make a 3D Design?

The D45 Model
D45 file
fil contains
t i virtual
i t l stringlines
t i li
(i
(in th
the project
j t coordinate
di t system).
t )
Simple ASCII text file; data can be extracted from almost any CAD system,
or created/edited
t d/ dit d iin a spreadsheet
d h t
Complete Freedom! The model can represent existing stringline data,
slab edges (virtual
( virtual slabs
slabs)), or any arbitrary offset (position and/or height)
Machine can pave anywhere, any time, as long as the D45 is prepared

26

D45 Modelling
What does a D45 model look like?
P i t ID
Point

Position
P iti (X)

P
Position
iti (Y)

H
Height
i ht (Z)
Reference Point

Steering Offset
Steering Reference Line

27

D45 Modelling
What does the machine operator see?

Reference
Point
Steering
Reference
Line
Steering
Offset

28

Why use a rectangular grid?

Like a stringline, it gives smooth results

3
4
Smooth cross slope
transition

1
29

but
but it models the surface more accurately
(and with no surveying or setting-out!)

You can model the project as detailed (or undetailed!) as you need

Vertical, Horizontal Curves, transitions, superelevations:

More detail in D45 model = better curve paved
Cross-section interval could be
anything between 0.05m-1.0m
Straight sections:
less detail needed

Straight sections: less detail needed

Cross-section
Cross
section Interval could be
anything between 1.0m-5.0m
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Practical Issues

31

Practical Issues
Checking concrete (or subgrade) level and position

The third theodolite together with

ith
a prism measures the surface
as-built behind the machine

Errors (and adjustments)

shown on theodolite

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Report stored on Leica computer

Practical Issues
Adjusting the Machine
Iff the level needs adjusting
just like stringline control
we can adjust
dj t allll lleg h
heights,
i ht
and draft independently,
pp g p
paving
g
without stopping

33

Practical Issues
Adjusting the Machine
Iff position needs adjusting
just like stringline control
we can adjust
dj t position
iti att
front and rear independently,
pp g p
paving
g
without stopping

34

Practical Issues
Moving the Theodolites (Leapfrogging)

Ma im m Range Theodolite
Maximum
Theodolite-to-Paver
to Pa er is <=
< 200m (*depends on conditions)

We dont want to stop the paver for too long!

Before maximum range is reached, move 3rd Theodolite to new position &
setup (Position & Orientation Fix).

Press Swap Theodolite on computer

System switches control from #2 (or #1) to #3 Theodolite automatically

Move old Theodolite to new position, setup and repeat procedure

Ensure enough Reference Points visible for Setup (Position & Orientation Fix)

* - temperature, humidity, air quality

35

Leapfrogging
Leapfrogging Part 1
All Theodolites in Start Position

RefPoint

RefPoint

RefPoint

#1
#2
#3

RefPoint
36

Leapfrogging
Leapfrogging Part 2
Move Theodolite #3, Setup, Transfer Control (#2 #3)

RefPoint

RefPoint

RefPoint

#3

#1
#2

RefPoint
37

Leapfrogging
Leapfrogging Part 3
Move Theodolite #2, Setup, Transfer Control (#1 #2)
RefPoint

RefPoint

#2

RefPoint

RefPoint

#3

#1

RefPoint
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Leapfrogging
Leapfrogging Part 4
Move Theodolite #1, Setup, Transfer Control (#3 #1)
RefPoint

RefPoint
#2

#1

RefPoint

#3

RefPoint
39