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1. MC3D V1.1 - Match-Cast 3D
Geometry Control Software
For Precast Concrete Segmental Bridges
By Interactive Design Systems
2. MC3D Overview
• Segmental Construction
• Short Cell Casting
• Match-Casting Technology
• Geometry Control
3. Segmental Construction
• Bridge built-up with
multiple elements
• Precast Segments
• Geometry locked-in at
precast yard
• Geometry Control is critical
4. Short-Cell Casting
• Segments Cast One at a Time
• Ensure that the segments fit together
• Fixed Bulkhead
• Match-Cast Segment
5. Match-Casting Technology
• casting segment between a
fixed form and its
neighboring segment
• Move to Match-Cast
Position
• Cast Next Segment
• Move to Storage
6. Geometry Control
• monitor the casting operations
• establish “as-cast” curves step-by-step
• verify that the actual superstructure geometry is in
close agreement with the geometry described in the
design documents
10. Understanding Geometry
Control
• Positioning Match-Cast is critical
• Match-cast position is function of previous segment
As-Cast compared to Theoretical
• MC3D Computes Match-Cast “Set-up” based on As-
Cast Coordinates
• Set-Up is a set of 4 bolt elevations and 2 horizontal
offsets for the Match-Cast Segment
14. Control Points
• Base Points
• General Coordinates
• Bolts for Elevations
• Hairpins for Alignment
• 2 Bolts on East Line
• 2 Bolts on West Line
• 2 Hairpins – North/South
17. Casting Bed - Fixed Bulkhead
Assumptions
• Orthogonal Local System
• Local x is centerline
positive toward South
• Local y connects East and
West Base Points –
Positive toward East
• Local z is vector product of
unit vectors z = x y
• LOCAL z MUST BE
POSITIVE UPWARD
19. Casting-Set Definition
• a portion of the project for which the concrete
segments are precast as a unit
• all segments will be match-cast against previously
cast segments
• “Starter Segment” usually cast between the “Fixed”
bulkhead and a “Floating” bulkhead.
• Base Dimensions A, B and C
21. Base Dimensions
• A: Offset from Joint to Bolts (Rivets)
– An (North) and As (South) may be redefined for each
Segment
• B: Offset from Centerline to Bolts (Rivets)
– B is constant (East and West Line) for a Casting-Set
• C: Offset from Joint to Hairpins (Alignment Stirrup)
– Cn (North) and Cs (South) may be redefined for each
Segment
22. Reference Planes
• control based on a
theoretical “Reference”
plane
• survey bolts (rivets), which
cannot be placed perfectly
in the reference plane, are
measurements of the
location of the plane rather
than its actual definition
23. Starter Segment
• First Segment of a Casting Set to be cast
• Must be cast between Fixed Bulkhead and a
“Floating Bulkhead” (or another already cast
segment)
• MC3D assumes that second joint (Fixed Bulkhead
for Starter Segment) is always positioned on
theoretical.
24. Typical Segment
• Wet-Cast segment is cast between Fixed Bulkhead
and Match-Cast Segment
• Match-Cast Set-up is based on computed As-Cast
Coordinates at previous step
• Set-up accounts for twist that may occur when
moving segments from wet-cast to match-cast
position
25. Starter Segment Set-Up
• Floating Bulkhead Set-Up
– East Punch Mark Elevation
– West Punch Mark Elevation
– Center Punch Mark Offset
• Fixed Bulkhead Set-Up
– East Punch Mark Elevation
– West Punch Mark Elevation
– Center Punch Mark Offset
• Lengths of East and West Line
– This is the length to be given to the starter segment
26. Typical Match-Cast Set-Up
• 4 bolts elevations
– North East Bolt Elevation
– North West Bolt Elevation
– South East Bolt Elevation
– South East Bolt Elevation
• 2 Hairpin Offsets
– North Hairpin Horizontal Offset
– South Hairpin Horizontal Offset
• Length on Center
– This is the length to be given to the wet-cast segment
27. Typical Survey
• After typical segment is cast (wet-cast)
• The 4 bolt elevations, hairpin offsets and length on
centerline of both wet-cast and match-cast are surveyed
• This produces the relative position of wet-cast and match-
cast.
• From these measurements, MC3D computes the general as-
cast coordinates of the typical segment (wet-cast).
• As-Cast coordinates indicate how the structure is actually
cast as compared to the theoretical general coordinates.
28. Match-Cast Set-Up - Concept
• Expression of General Coordinates from Local
Coordinates
– {P} ={ O} + [ R ] {p}
– Where O is Origin of Local System
– [ R ] is Rotation Matrix
• In Matrix Form:
29. Match-Cast Set-Up - Concept
• Local Coordinates in Match-Cast System:
• Local Coordinates in Wet-Cast System (Cell)
• In As-Cast System of the Match-Cast:
The above matrix equation represent the “Set-Up” of the Match-Cast
Segment, i.e. the Transformation to be applied to the Match-Cast Local
System to achieve exact theoretical coordinates at the fixed bulkhead.
30. As-Cast Coordinates
• Express General Coordinates of Wet-Cast Points
based on Local System built with Match-Cast
Survey (As-Cast)
x
z
31. As-Cast vs. Theoretical Joint
Coordinates
• MC3D displays the As-Cast Coordinates at the last
joint, compared with the theoretical required
general coordinates
• Also Displayed are the As-Cast coordinates of the
bolts (may be used for Erection Control)
32. Twist Control
• A change of slope on East or West Bolt Line
occurring from Wet-Cast to Match-Cast
• Match-Cast Twist must be Controlled and Corrected
• If not corrected, it will induce a constant warp
• Twist errors are magnified at the end of casting-set
(cantilever tip or last span segment)
• MC3D automatically corrects Match-Cast Bolt
Elevations for Twist
33. Getting Started with MC3D
• Project Setup
Segment
Definitions
Casting-Set Constant
Dimensions A, B &C
34. Input of General Coordinates
• Manually in Tab View Grid
• Importing for Text Files
• Copy/Paste from MS Excel (must be properly layed-
out)
35. General Coordinates Tab
Click Read File
For Text Input
Click Preview For
Orientation Check
Click Apply to
“initialize” joints
and segment
definitions
36. Import from Text File
• Text File extension can be
anything, but usually “xyz”
• Input of Joint Base Point
Coordinates
• East, West and Center
• Joints Numbered In order
of casting sequence
37. Copy/Paste from MS Excel
Excel Coordinates
must be formatted
exactly like the MC3D
coordinates grid
38. Camber Values
• Camber Values can be
input separately
• Values are vertical
adjustments to coordinates
• Based on long term
deflections
• MC3D adds camber to
general coordinates prior
to Set-Up
Vertical Deflection
at Joint
39. Working with MC3D
• Creating Casting-Set Input of General Coordinates
• Complete Project Definition
• Create Camber Input
• Starter Segment Setup and Survey
• Typical Segment Set-Up and Survey
• Review (and Export) As-Cast Coordinates
42. Set-Up & Survey Operation
• Starter Segment
• Run MC3D for Starter Segment Setup
• Cast Starter Segment (Wet-Cast) and Survey
• Input Starter Segment Survey
• Set-Up as Match-Cast
• Typical Segment
• Run MC3D for Match-Cast Segment Setup
• Cast Typical Segment (Wet-Cast) and Survey
• Input Wet-Cast and Match-Cast Survey
• Consult As-Cast Results
43. Starter Segment Survey
Floating Bulkhead
Set-Up
Bolt Longitudinal
Offsets
Survey
“Perfect Cast” to
be used for
testing only
Click Apply to
record the
Survey
45. Twist Control
• Twist can occur when moving segment in Match-
Cast Position
• Twist induces a Warping error which would be
magnified at end of Casting-Set
• MC3D Compares East and West Line Longitudinal
Slope and Displays a difference in Elevation
• MC3D corrects Match-Cast Elevations so the
original Slopes (measured in Wet-Cast Position) are
maintained
50. Working with Files
• MC3D creates one file per casting set
• The files have extension .mc3
• They can be saved and re-opened as needed.
• When working with multiple casting cells, we suggest to use
one folder per casting cell.
• Several surveyors can use the same copy of MC3D on one
computer, assuming the files are stored as suggested.
• Backing-up mc3 files is also strongly suggested and can be
done per directory
53. What’s New for MC3D V1.1
• Crowned Top Slab
• General and Local System Orientation Check
54. Crowned Top Slab
• MC3D computes Theoretical Center Point
Coordinates
West Base
Point
East Base
Point
Center Point
Computed
Center
Point
55. General and Local Systems
Orientation Check
• MC3D V1.1 checks that the local z axis of the Cell
local system is positive upward
• This check ensures that:
– The General System is orthogonal and properly
orientated
– The North-South orientation of the Casting-Set is correct
– Elevations are positive upward
56. Current and Future
Developments
• Structure Geometry – General Coordinates
GEOM3D
• GEOM3D Export of Base Point General Coordinates
• GEOM3D/MC3D Client Server Configuration
