1. 3D DESIGN FOR MACHINE CONTROL GRADING A Case Study of ODOT's I-5: Willamette River Bridge Project Eugene/Springfield, Oregon

2. Tom Metcalf, PE – OBEC Consulting Engineers in Eugene, Oregon – 13 years of roadway engineering experience – Lead Roadway Engineer on the I-5: Willamette River Bridge Project – Phone: 541-683-6090 – Email: Tmetcalf@obec.com PRESENTATION BY:

3. CASE STUDY BACKGROUND ODOT I-5: Willamette River Bridge Project – $150M bridge replacement project in Eugene, Oregon Twin 1900- foot-long I-5 Bridges 2500 feet of I-5 Roadway Work 2300 feet of I-5 Roadway and Ramp Reconstruction

4. How did machine control grading get incorporated into the I-5: Willamette River Bridge project? – Project is an alternative delivery project where the prime contractor(Hamilton) participates in the design – K&E Excavating requested machine control grading to be utilized because of cost savings CASE STUDY BACKGROUND

5. ODOT utilizes a 3D design software program called InRoads to model proposed surfaces – Past version of InRoads were not as powerful What is 3D Design?

6. Note the "tethered modem"!

7. Initiating Redesign!

8. ODOT utilizes a 3D design software program called InRoads to model proposed surfaces – Past version of InRoads were not as powerful What is 3D Design?

9. Old industry standard – Minimized design effort (save design time and design expenditures) by providing just enough design data for field staff to "fill in the gaps" New industry standard due to machine control grading – Increased design effort to eliminate all gaps in 3D design to minimize "field modifications" during construction How Machine Control Grading Changes 3D Design

10. Used to do "close enough" 3D modeling – Why? Remember – Past industry practice was to minimize design effort (save design time and design $$$) by providing just enough design data for field staff to "fill in the gaps" – Examples? How Machine Control Grading Changes 3D Design

11. BEWARE: TECHNICAL CONTENT AHEAD!!!!!! How Machine Control Grading Changes 3D Design

12. Old = Large gaps between template drops New = Smaller gaps How Machine Control Grading Changes 3D Design

13. Modeling around bridges, abutments and wingwalls How Machine Control Grading Changes 3D Design

14. Guardrail benches, sideslope transitions and structure section transitions How Machine Control Grading Changes 3D Design

15. Some modeling was accidentally overlooked, such as drainage features How Machine Control Grading Changes 3D Design

16. Need experienced field staff to interpret design for "field fitting" gaps in the design Quantity overages since modeling is not accurately reflecting final field conditions Change orders for "filling in" the gaps in the design Effects of Past 3D Design on Construction Projects MORE RISK TO CONTRACTORS = MORE RISK BUILT INTO PROJECT BIDS = MORE EXPENSIVE PROJECTS FOR ODOT

17. Greatly reduces field interpretation of design More accurate quantities LESS RISK TO CONTRACTORS = LESS RISK BUILT INTO PROJECT BIDS = LESS EXPENSIVE PROJECTS FOR ODOT This is a proven concept. For a number of years, contractors have been requiring and paying for this level of modeling effort from designers on design- build projects. Results of New 3D Modeling Practices on Construction Projects Design $$$ < Construction $$$

18. Must decide at the beginning of a project to do more detailed modeling – Difficult and time-consuming to upgrade a design not tailored for machine control grading Introduces need for QA review of modeling – This results in substantially more design time and design dollars Impacts of New 3D Design on Engineering Efforts

19. How does the 3D design get to the construction equipment? Contractors don't use InRoads….they all have different proprietary software Have to convert design models to Proprietary software models for machines to "read" Designer must QC proprietary software models before work begins Increases design time and design expenditures Impacts of New 3D Design on Engineering Efforts

20. Can utilize this concept for other design disciplines, such as traffic control plans – Converting 2D traffic control plans to 3D staging design Impacts of New 3D Design on Engineering Efforts

22. ODOT's current design software is InRoads XM, and it is more than capable of generating the 3D designs required for machine control grading. This is not a futuristic concept. It has been utilized on a number of past and current projects. 3D designs require more design time and design budget. Embrace change = Better product = Reduced construction cost to ODOT CONCLUSION

23. Tom Metcalf, PE – OBEC Consulting Engineers – Phone: 541-683-6090 – Email: Tmetcalf@obec.com QUESTIONS