PRODUCTION STUDY. Rogier Tonies
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1 Rogier Tonies
2 Introduction In November 2006, Caterpillar conducted a production study comparing a conventional road construction project guided by grade stakes, string lines and grade checkers with the use of AccuGrade, Caterpillar machine control & guidance. The road design simulated a highway intersection, roundabout or other complex road design. During the construction process measurements were taken to define overall productivity, machine utilization, fuel consumption, number of people on site and finished design quality.
3 The Job: Construction of two Roads One team of professional operators Two identical road design Identical Alignment and Profiles including Curves, Elevation Changes and Super Elevations Identical Cut and Fill Areas, Same Material Same equipment D6N Track-type Tractor 330D Excavator 140H Motor Grader Comparing Conventional vs. AccuGrade Way
4 The Team Gary (Foreman) Siggy (Dozer and Motor Grader Operator) Andy (Excavator Operator) Ron / Kelly (Articulated Dump Truck Operators) Kjeld (Compactor Operator) Eric (Site Surveyor) Rogier (Grade Checker) Amr / Marilyn (Time Keepers)
5 The Road Construction Job Site MDLC North Road: AccuGrade South Road: Conventional
6 The Road Design Top View Profile View North Road 80 m Cross Section View South Road A B C 8 m
7 The Conventional Equipment D6N Other Equipment: Compactor CS563 ATD 730 ATD 735 ATD 740 Ejector 330D 140H
8 The Equipment with AccuGrade D6N AccuGrade GPS Other Equipment: Compactor CS563 ATD 730 ATD 735 ATD 740 Ejector 330D AccuGrade GPS 140H AccuGrade ATS
9 The Measurements Taken Surveying & Staking vs Data Prep & ATS Setup Time / Number of Persons Machine Operation Operating Times Number of Passes / Buckets Fuel Consumption Finished Design Tolerances Subgrade Base
10 The Construction Process in Steps Step 1. Site Layout: Data Preparation / Staking Step 2. Bulk Earthworks Step 3. Subgrade Fine Grading Grade Checking Step 4. Base Course Construction Step 5. Base Course Fine Grading Grade Checking
11 Step 1. Site Layout - Conventional Staking 1. Staking Slope Rails & Digging Slope Pilots 2. Staking Road Profile Cross Section View 8 m 2,5
12 Step 1. Site Layout - AccuGrade Data Preparation Data Conversion using AccuGrade Office GPS Base Station was already on site Same Base Station used for GPS rover and AccuGrade Installation of ATS Total Station to grade road base Total Station
13 Step 1. Site Layout
14 Step 2. Bulk Earthmoving Construction of the subgrade of the road: 330D starts in the Cut area to dig the side slopes ATD s transport and dump material in the Fill area D6N pushed the material into the rough road shape Top View Profile Cut: 357 m 3 Fill: 347 m 3 80 m
15 Step 2. Bulk Earthmoving
16 Step 3. Subgrade Fine Grading The Subgrade supports the road base Fine grading of the Subgrade included: 1. The side slopes 2. The shoulders 3. The road box (profile with crown) m Cross Section View
17 Step 3. Subgrade Fine Grading
18 Grade Checking of Subgrade Three points every 5m were surveyed on the road A tolerance of ± 3cm was applied Conventional AccuGrade High: 35% High: 5% Low: 30% Low: 10% On Grade: 35% On Grade: 85%
19 Step 4. Base Course Construction 15 cm of highly compacted crushed aggregate Often referred to Referred to as the road base ATD dumps the aggregate and the D6N spreads Cross Section View 8 m 2,5 15cm
20 Step 4. Base Course Construction
21 Step 5. Base Course Fine Grading After the Soil Compactor CS563 compacted the aggregate, the 140H motor grader cut the base to the finished grade.
22 Step 5. Base Course Fine Grading
23
24 Summary of Results A tolerance of ± 2cm was applied Improved quality resulting in 11 % material savings Slopes and shoulders matched the design much better Conventional AccuGrade On Grade: 45% On Grade: 98%
25 Summary of Results 100% Increase in Productivity 3,0 days versus 1,5 days % fuel saving Conventional Increased Machine Utilization Less waiting time Longer passes Savings in Operating Cost 43% less Fuel consumption Less wear on U/C and GET D D6N 140H AccuGrade D D6N 140H
26 Summary of Results Surveying Cost reduction in setting out grade stakes and checking the grade. Job Site Safety No grade checkers or labour crew on site with the AccuGrade. Operator Satisfaction Even excellent operators become more productive and less stressed
27 On behalf of the whole team: Thank You!!
28
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SECTION 33 41 13 SPEC WRITER NOTES: Use this section only for NCA projects. Delete text between // // not applicable to project. Edit remaining text to suit project. PART 1 - GENERAL 1.1 SUMMARY A. Section
BASED ON DFD MASTER SPECIFICATION DATED 2/24/2014
1 0 1 0 1 0 1 SECTION 1. TRENCHING BASED ON DFD MASTER SPECIFICATION DATED // P A R T 1 - G E N E R A L SCOPE The work under this section shall consist of providing all work, materials, labor, equipment,