From 3D-road scanning to 3D-milling

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Viljo Palo
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1 From 3D-road scanning to 3D-milling Highway 51 pavement rehabilitation pilot -introduction Mika Jaakkola, Destia Manu Marttinen, NCC INFRA FINBIM PILOTTIPÄIVÄ nro 5

2 Highway 51 motorway project Introduction Road 51 is the main road from Helsinki to west Client is Finnish Road Administration Design-build-maintenance contract 10 km of motorway, 10 bridges, 3 interchanges 15 year maintenance, total M 8 SAADUT PALAUTTEET Sivu 2

Design-build-maintenance contract 10 km of motorway, 10 bridges, 3

3 Highway 51 pavement rehabilitation pilot main contractors point-of-view Old two-lane road will be part of a four lane highway Aim to reconstruct wearing course by milling and paving Construction project along a very busy road Goal to improve surveyor work safety Destia investigated the usability of laser scanned model in 3D rehabilitation design R&D funding from national Infra FinBIM development consortium Measurements, modelling and repair planning and cutting executed May-Aug 2012 Co- operation group: Geotrim Ltd, Terrasolid Ltd and NCC Ltd SAADUT PALAUTTEET Sivu 3

usability of laser scanned model in 3D rehabilitation design R&D funding from national Infra FinBIM development consortium Measurements,

4 Road rehab process and technology Mobile Mapping Trimble MX8 GPR & Core samples Point cloud processing, Terrasolid Terrain model (TIN) creation, Tekla Civil Alignment design and optimization, Tekla Civil Alignment export in VGP and line format BC-HCE, Export in binary to GCS900 SAADUT PALAUTTEET Sivu 4

Civil Alignment design and optimization, Tekla Civil Alignment export in VGP

5 Why Mobile laserscanner technology was used? High accuracy requirements 10 mm in height Surveyor work safety Short timeframe for the milling project Survey with traditional surveying techniques too much work and inadequate grid density SAADUT PALAUTTEET Sivu 5

Short timeframe for the milling project Survey with traditional

6 Mobile Mapping vehicle Trimble MX8 Simultaneous collection of laser point cloud and digital images 2 x laser scanners 4 x 5 digital cameras Integrated GNSS + IMU SAADUT PALAUTTEET Sivu 6

7 Surveying signal marks and GPR for pavement thickness measurements Control point measurements with total station, GNSS and precise leveling Survey data used for point cloud georeferation and modelling Three continuous GPR profiles measured along the road Bore hole samples as reference points for interpretations Middle of the road pavement thickness avg cm Side of the road pavement thickness avg cm In some deflection areas pavement thickness cm Pavement thickness data used for design process SAADUT PALAUTTEET Sivu 7

samples as reference points for interpretations Middle of the road pavement thickness avg.

8 Point Cloud Processing Processing with Terrasolid SW TerraScan & TerraMatch Pre-Processing GNSS Quality Trajectory quality Signal points SAADUT PALAUTTEET Sivu 8

9 Point Cloud Processing TerraMatch Trajectory matching SAADUT PALAUTTEET Sivu 9

10 Point Cloud Processing Final matching of the point cloud by means of signal points Internal accuracy: Average dz m Std deviation z m Cloud delivered to Destia design crew, max. point distance 0.50m Max. deviation from median surface 1 cm Digitized center line Absolute accuracy (Z) ~15 mm Major factors in absolute accuracy: Signal points (quality & timing) GNSS solution, conditions SAADUT PALAUTTEET Sivu 10

11 Model based reconstruction design Grade line alignment designed in the middle of the two lanes Horizontal geometry and staking follow new highway s road line One-sided cross slope designed for alignment by highway s original construction plan Vertical alignment geometry by previously made construction plan Pavement surface model created as in original construction plan Milling level surface 8 cm below upper surface Merging interchange ramp structures considered and their models designed SAADUT PALAUTTEET Sivu 11

alignment geometry by previously made construction plan Pavement surface model created as in original construction plan Milling

12 Optimization and detailing Mass quantities calculation by using designed layers Structure conducted to center line Cross sections and longitudinal sections used to visualize difference between pavement and cutting surfaces Milling and filling areas also visualized by coloured surface difference maps All vertical main points adjusted sophisticated Road elements changed slightly Site managers comments on models before last version Major change was to convert two-sided cross-sections into one-sided Machine control model from Tekla Civil as 3D-lines SAADUT PALAUTTEET Sivu 12

difference maps All vertical main points adjusted sophisticated Road elements changed slightly Site managers comments on models before last

13 Machine control model Tekla Civil Design model imported into Trimble Busines Center SW Surface model created in BC HCE Export of machine control model into Trimble GCS900 Surface Alignment Breaklines as design map Cut / Fill areas as design map SAADUT PALAUTTEET Sivu 13

control model into Trimble GCS900 Surface Alignment Breaklines as

14 Conclusions Old road surface model produced quickly, model accuracy even better than 15 mm Design of pavement repair based on accurate surface model well planned job, half done Road repair actions and quantities can be planned and optimized in advance > shorter lead time Road geometry can be repaired based on model optimization saves materials (milling/hauling) 3D Machine control systems in milling machine and paver improve accuracy and efficiency - work quality improved SAADUT PALAUTTEET Sivu 14

shorter lead time Road geometry can be repaired based on model optimization saves materials (milling/hauling) 3D Machine

15 Heini Raasakka RAKENNETTU YMPÄRISTÖ Tarvitaanko tätä palkkia? Built Environment Process Reengineering (PRE) InfraFINBIM PILOTTIPÄIVÄ nro 5, NCC Roads Oy, Manu Marttinen MAINTENANCE-BIM Kt 51 ja Vt 6 osapilotit Built Environment Process Innovations Reengineering Page 15

16 Massatasaus ja tasausjyrsintä, koneohjaus SAADUT PALAUTTEET Sivu 16 Page 16

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24 lipan jyräys.mp4 SAADUT PALAUTTEET Sivu 24

25 Huomioita ylläpidon koneohjaukseen Malli hyvä ulottaa reilusti työalueen ulkopuolelle Yhteys katkeaa, jos prisma jää ulkopuolelle Case: tasausmassan veto peruspalkilla, zoomit kiinni Jyrsinnän suunnan suunnittelu etenkin taitekohdissa Korkeusasema prisman kohdalta Kaltevuus rummun keskeltä Muu oma kalusto täky-prisma -yhteyden haittana Liittymien levitys ja jyräys Kuljetuskalusto rakennuskohteissa SAADUT PALAUTTEET Sivu 25 Page 25

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Built Environment Process Reengineering (PRE)

RAKENNETTU YMPÄRISTÖ Tarvitaanko tätä palkkia? Built Environment Process Reengineering (PRE) InfraFINBIM PILOTTIPÄIVÄ nro 5, 3.10.2012 Nissolan ratasuunnitelma SITO / Juha Liukas Built Environment Process