1. Austin Bridge & Road Paving the 1st Formula One Purpose Track in the United States The 1st Formula One Track in the World to be 3D Paved
In this session, we will present how a contractor has managed to outperform the demanding specifications of the first purpose-built Formula 1 track in the USA using three 3D paving systems. The F1 track represented a highly complex design while prescribing tight elevation and smoothness specifications. This session is intended for the owners, projects managers, surveyors, site supervisors, foremen and operators of general and paving contractors
Matthew Hollensworth – Cody Lowery – Mike Ellingson

2. Integrity Performance Safety Responsibility Employee-Ownership
Austin
Integrity Performance Safety Responsibility Employee-Ownership
About Austin Industries
In this session, we will present how a contractor has managed to outperform the demanding specifications of the first purpose-built Formula 1 track in the USA using three 3D paving systems. The F1 track represented a highly complex design while prescribing tight elevation and smoothness specifications. This session is intended for the owners, projects managers, surveyors, site supervisors, foremen and operators of general and paving contractors
100 Years in the industry
25 years of employee-ownership

3. Heavy highway Aviation Heavy rail Light rail
Market Segments
Heavy highway Aviation Heavy rail Light rail
Site improvements
Sub-divisions
Tollways
Race tracks
Long list of customers

4. Formula 1 Racing
About Formula 1

5. 2004 World’s Highest Paid Athlete
F1 Car / Driver
Michael Schumacher
2004 World’s Highest Paid Athlete
Retires in 2012
May want to refer to the “car driving on the ceiling”
> 220 MPH
1” – 2” Ground Clearance

6. 2012 Race Circuit
Formula 1 Racing Schedule Season will Feature 20 events in 19 countries across five continents.

7. COTA Project Data Basic Track Project Data
Survey scope all of the complex

8. Quantities
80,000 tons of flex base placed with 3D paver & 50,000 tons of asphalt base paved with 3D Paver. Remaining course of asphalt placed with averaging beams.

9. The Layers of the Track
Note the 14 Different layers of the Track.

10. 3D Asphalt Paving

11. Our Strategy to 3D Paving
Research available 3D paving products
Decide the best fit for our company’s needs
Develop procedures and processes for our new paving system (including evaluating, training, and adding the right personnel)
Getting the buy in from Dr. Hart
Testing, trusting, and trying our new equipment
Exceling with our new product
What was our strategy at Austin to over come the task at hand?

12. Current Platform
Our Current Platform allows us to use our machine control the way we see fit. If we want it on a Dozer one day then a paver the next we have that ability using the Trimble GCS and PCS Platform.

13. Interchangeable Components
Robotic Total Station
CB460 3D Control Box
TSC3 Data Collector
The Right Grade Control Equipment
Being able to Interchange components was on of our reason for going with the Trimble Systems on this project. Also our current capital investment was another reason.

14. Trimble PCS 900 System UTS Right UTS LEFT Machine Radio
CB460 3D Display
CB440
CB440
Sonic Tracer or Ski
VM200 Valve Module
AS200 Slope Sensor
Sonic Tracer or Ski

15. Sub-Grade Topo Placeholder for list item
A topo of the site is performed and a cut sheet is generated

16. Processing Data & Un-Compacted Design

17. Multiple Setups / Accurate Control

18. Placing Base Material
Applications Beyond Asphalt

19. Placing Base Material
Very Successful Application

20. 3D Paving on Asphalt
1st Course

21. Checking – Checking – Checking
1st Course / Also Topo Shots

22. Paving Curves
Turn 1

23. Paving Under Bridges

24. Tangent – Curve – Widening

25. All Up Hill

26. 3D Milling

27. Bad Design Data

28. Good Design Data

29. Intelligent Repairs Working w/ Design Changes
Through the course of the project we received many design changes and some after we have already paved an area. This slide shows us using 3D Milling to shave a area down to better transition the curve.

30. All in one day – All at the same time
One of the first jobs to have 3D milling, robotic base and asphalt paving, Robotic topo collecting with roller along with robotic and GPS grading an not to mention the tremendous amount of survey that was happening in the back ground.

31. How Did We Do? Outstanding safety performance Met financial objectives
Opportunity
“Track is awesome”, Dr. Rainer Hart
“One of the top two tracks in the world”, Tilke Eng.
“Love it”, Mario Andretti
“Highest Rating”, Fédération Internationale de l'Automobile (FIA)
“Greatest racetrack on the planet”, The Tom Byrum

32. Learning Curves Control is Critical Modeling Methods
Training Techniques
3D Paving is NOT a grading tool (Sub-Grade is important)
3D Equipment is still limited to the capabilities of the paving machine (roller were added to tow arms to prevent binding)
Having an Extra Data collector made all the difference

33. Other Race Tracks (HWY 183 Ft. Worth, TX
Other Race Tracks (HWY 183 Ft. Worth, TX Average Race Speed 90mph in a F150)

34. Access Limitations

35. Managing Quantities

36. Mario Andretti 1st Ceremonial Lap
Mario Andretti makes ceremonial 1st. Lap as the official ambassador of Circuit of the Americas.

37. Q & A