MTC&E 2023 ISIC Track - Session 04 - Milling and Paving

1. IS-IC.ORG
ISIC TRACK
Digital Workflow from Design to Construction
Milling and Paving
Equipment and the use of 3D
Models
Kevin Garcia, Trimble
Laikram Narsingh (Nars), Wirtgen
Jim Preston, TOPCON

2. What we’ll cover today
There are three main components to be aware for AMG
1.Model Creation
• It’s not just a digital version of the plans!
2.Machine Setup
• Ensuring you understand tractor operations/physics
for consistent performance
3.In Field Technology and Execution
• Steps for success

3. Modelling and Pre-Construction

6. • More realistic representation of existing road surface conditions
• Leverage software to determine if specifications are able to be achieved
• Maximize financial bonus opportunity for smoothness / rideability with most efficient design

14. Design surface

15. Understanding Machine Setup and Operation

16. 1. Physical Reference
Automatic Paving & Milling – Sensors following 2 Types of Reference
Joint, Base, Curb
or String Line
Averaging Ski
Following Mat
or Base
Z RH
Y
Z LH
X
2. 3 D Coordinates as Reference
3D Model
Traverse
Slope
Sensor
reading
Slope Beam

17. What is Needed for 3D Paving or Milling
1. 3D Models – Surveying Companies, Topcon Trimble & Leica, Etc.
2. 3D Positioning Instruments – Topcon, Trimble and Leica etc.
3. Machine Controls & Equipment with Proper Setup
Topcon, Trimble or Leica, Etc. Positioning Instruments
GPS / UTS
3D Models
3D Paving & Milling
Machine & controls with Proper Setup

18. Setup for 3D Milling
Setup / Benchmarking Is Straightforward
 Drum Width is Fixed
 Drum Moves in Direct Relation to the Mill Legs
 Speed limited by Hydraulics & 3D Data Processing

19. Setup for 3D Paving
Could Control 1, 2 or 3D
 Pavement Depth – LH & RH (Z)
 Pavement Width (X)
 Direction of Pavement (Y)
For Proper Setup:
Must Understand Principles of the
Free Floating Screed & Screed Design
D3 Steering
Control (Y)
D Mat Depth
L (Z)
D Mat
Depth
R (Z)

20. Principles of the Free Floating Screed
The screed Floats on the Asphalt like a Water Skier
 Pavement Depth Held by 5 Forces ….. Not Mechanical like the Mill
 Pull Force Exerted at Towpoint
 Towpoint also Increase / Decrease Pavement Depth
Depth Crank –
Increase / Decrease
Screed Angle
Tow Point
Pull Force

21. Depth Controlled By Increasing / Decreasing Screed Angle of Attack
1. Manually with Depth Crank or Tow Point
 Depth Crank Can Set Screed Flat with Towpoint at Different Position
2. Automatic Control of Towpoint
 Dept Crank should be locked
 Depth Crank must be Set to 0 when setting up for 3D Paving
Towpoint
Cylinder
Depth Crank
Principles of the Free Floating Screed

22. 2 Types of Extendable Screeds – Front & Rear Mount
 Each with 3 Sections
1. Main Screed
2. LH Extension with Slope & Height Adjustment
3. RH Extension with Slope & Height Adjustment
Rear Mounted Extensions Screeds
Main Screed
RH Extension
LH Extension
Unequal Width Front Mount Screed
Main Screed
LH Extension RH Extension
Screed Design

23. Main
Front Mount Extension Height Adjustment (MH)
 Sets Trailing Edges of Extension to Main
 Extension is usually ¼” Below the Main
Mat Depth
Plane B – Trailing Edge
Ext
MH Main
Screed Design

24. Main
LH & RH
Extension
Trailing Edges
Mat
Depth
MH
Main Screed
RH Extension
LH Extension
Rear Mount Extension Height Adjustment (MH)
 Sets Trailing Edges of Extension to Main
 Extension is usually ¼” Above the Main
 Could also be Sloped
Screed Design

25. Screed Design
Rear Mount Extension Screed – Match Height & Slope & Crown

26. Rear Mount Extension Screed – Match Height & Slope
Extension Match
height Moves Up /
Down & Slope
Screed Design

27. Setup Procedure When using Trimble on Vögele / VR 600
Rear Mount Extension Screed – Match Height & Slope

28. Depth must be verified in a Few Locations
 Under the Main Screed
 Under Both Extensions Screeds
 Must Consider Rolldown for Final Elevation
Verifying Pavement Depth When using 3D Controls

29. It takes approx. 5 x Length of tow arm to reach new Depth after Corrections
 Must allow the screed to react before Checking Grade after Corrections
2 nd 1st
3 rd
4 th
5 th
65 %
85 %
100 %
Verifying Pavement Depth When using 3D Controls

30. Slope Sensors used in 3D Paving
Mast Lean Slope Sensor
Traverse Slope
Sensor – Mount
on the Slope
Beam
Vögele Extension
Slope Sensor

31. Verifying Malfunctions
Malfunctions could be Driven by the Following:
 Paving / Milling Equipment ……… or 3D Instruments ……….or Model
 Could easily Switch to Physical Reference to Verify Equipment

32. Setup must be done based on 1, 2 or 3D Controls
Setup Procedure for Leica System

33. Setup Procedure for Trimble System

35. Infield Technology and Steps for Success

39. RDMC
LPS/UTS
MMGPS
3D Applications

40. Adequate overlap Control
Out of the way of traffic
Establishing Control Points

41. Steps for Success

42. •Proper control (i.e. TS or level) and has verified using mmGPS.
•Location of control points…
 Distance to machine to laser (500 feet MAX)
 Pattern of truck traffic & machine travel
 Adequate Reference/Bench hubs 100’ from Control
Horizontal Working Range for Paving
±500ft ±500ft ±500ft
Tx #1 Tx #2 Tx #3 Tx #4
±2000ft
±250ft ±250ft

43. Job Setup
 Verify you have a tight localization that is not set using GPS.
 Set multiple “control points” to be used for the transmitters.
• These transmitter control points should not be set using GPS.
 Set a second control point or grade verification hub approximately 100’/30m from
each transmitter location to be used to verify transmitter height.
• These control points should not be set using GPS.
 Set multiple control points or grade verification hubs around the site to be used to
verify grade during the project.
• These control points should not be set using GPS.
 Minimize operational distance from the transmitter.
• 750’ for grading applications
• 500’ for asphalt paving applications
• 300’ for concrete paving applications
• In windy conditions, reduce operating distances.

44. Job Setup
 Consider truck & equipment traffic when placing transmitter locations.
 If using fixed height tripods, put sand bags on them to reduce vibrations.
Set to minimum heights whenever possible.
 Calibrate the transmitter before starting a new project.
 Verify transmitter setup every day.
• “Check-in” on multiple control points or accurate verification hubs.
• If transmitter calibration is suspect, first rotate on all four axis to
verify, then calibrate if needed.
 When on airport projects or locations susceptible to radio interference,
test the radios on the project before starting the project.

45. Asphalt Paving
 Assign a person to continuously verify grade behind the paver.
 Assign a person to be responsible to continuously monitoring the control box
and truck traffic, and immediately switch to manual control when the
transmitter is blocked.
 Make sure the crew understands how to make proper transmitter switching
transitions.
 For best results when joint matching, use a Sonic Tracker.
 Have extra batteries for sensors, data collectors, transmitters.
Possibly run transmitter off marine battery.
 Have backup equipment.
 Make sure all machine measurements and calibrations are correct.

46. Questions?