Miller Park Rail Scan

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Who we are

• Mark Deardorff PE, SIT Falk PLI Project
  Manager
• Purdue University 2001 BSCE BSLSE
• Started at Falk PLI in May 2001
• Brian Nelson SIT Falk PLI Project
  Engineer/Surveyor
• Purdue University 2004 BSLSE
• Started at Falk PLI in May 2004

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About Falk PLI

• Falk-PLI was founded in 1995 and is a privately
  held surveying and engineering firm located in
  Portage, Indiana. Our business philosophy is
  simply to help our clients realize gains in
  productivity and profitability through the use of
  the latest technology available.
• We have worked on projects across the United
  States, Canada, Serbia, and the Gulf of Mexico.
• Trades
• Technical Engineers Local Union 130, U.A.
• United Brotherhood of Carpenters/Millwrights
  1043, 1005, 1406

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Overview of Geomatics Opportunities at Falk PLI

• Traditional Surveying
• Leica Total Stations
• Trimble 5600 DR Robotic Total Stations
• Leica RTK GPS
• High Definition Laser Scanning
• HDS3000 pulse based Scanner
• HDS4500 phase based Scanner
• HDS6000 phase based Scanner
• High Precision Surveying
• Faro X Trackers
• Faro XI Trackers
• Faro XI V.2 Laser Tracker

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Traditional Surveying

• Typical Land Surveying Work
• ALTA/ACSM Surveys
• Boundary Surveys
• Construction Layout/Stakeout
• Environmentally Sensitive Site Planning
• Legal Descriptions for Parcels Easements
• Settlement Surveys
• Site Design
• Subdivision Mapping Planning
• Topographic Surveys

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HDS Laser Scanners

• Gather 3-dimensional information in point clouds
  without hands on contact.
• Get information from unsafe working environments
  without entering the environment
• Get information on unreachable objects
• Gather mass information for an area.
• As-built verification on piping, structural
  steel, and equipment.
• Reduce re-work to 1 or less.
• Fast and Accurate
• Accurate to within /- 1/8 inch

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How Scanners Work

• There are 2 main types of High Definition
  Scanners Pulse Based and Phase Based
• Pulse based scanners measure the angle and time
  of flight for the laser beam to reflect off an
  object and return to the scanner measuring up to
  50,000 points per second.
• Phase based scanners measure the angle and phase
  shift of the laser beam measuring 500,000 points
  per second.

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A Typical Scan Job

• Determine what the client needs/wants done.
• Use scan targets for tie-in to local coordinate
  system and verify position of scanner is good
  from start to finish.
• Use Leica or Trimble total station
• Set control on job site
• Tie-in to local coordinate system
• Leica Cyclone
• Creates registration between scanner and total
  stations
• 3D modeling of point clouds

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Typical Scan Work

• Commercial/Civil Work
• Bridges
• Roadways
• Commercial Properties
• Historical Renovation
• Industrial Work (Mills)
• Blast Furnaces
• Crane Rails
• Fabricated Pipe Verification
• Interference Verification
• Retro-fit Pipe Verification

• Industrial Work (Refineries)
• Fabricated Pipe Verification
• Interference Verification
• Oil Rigs (Offshore)
• Retro-fit Verification
• Other
• Flange Location Orientation
• Cut-lines for Piping/Ductwork
• Pipe Routing
• Clash Detection
• Accident Investigation/Recreation

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Faro Laser Trackers

• Utilize Five Faro Trackers
• Measure /- 0.001
• Allows 3D alignment survey from one position
  relative to level, reference lines, planar
  reference lines, or radial reference lines.

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How Laser Trackers Work

• Emit a laser that locks onto the center of an
  SMR
• The tracker has the robotic ability to follow the
  SMR as long as the SMR is aimed at the tracker
  and there is no direct inference in the beam
• Use of nests for tracker positioning
• 3 points of contact
• Best-fit (least squares) position determination

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Advantages of Laser Trackers

• Repeatability
• Accuracy
• Measures 10,000 samples per second
• Dynamic Surveying
• Can gather information as the SMR is moving
• Assists in adjustments
• Determination of high/low points along a path
• Gather information for 3D alignments from one
  setup
• Fast re-survey after adjustments
• Ability to work in multiple coordinate systems
  simultaneously with no additional setups

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Example Projects
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Sample Scan Work

• Oil Rig
• Structure to Survey

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Sample Scan Work

• Oil Rig
• Falk PLI was asked to gather structural
  information to determine current condition of
  damaged structure from Hurricane Rita.
• Laser Scanning was to be used for the survey in
  order to gather data in inaccessible locations.

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Sample Scan Work

• Oil Rig
• Scan Locations

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Scan Images

• Oil Rig
• Comparison of picture scan results

3-Dimensional point cloud of the Oil Rig
comprised of approximately 24.3 million
individual observations each with an X,Y,Z
coordinate. (right)
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Scan Images

• Oil Rig
• Comparison of picture scan results

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Scan Images

• Oil Rig
• Comparison of picture scan results

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Results

• Chord A Y Direction
• (Lean)

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Results

• Chord A Trend Line Deviations Y- Direction
• (Straightness)

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Sample Scan Work

• Plumbness/Flatness Survey
• Existing Buildings had settlement concerns.
• Exterior Walls were surveyed using an HDS Laser
  Scanner to determine the condition of the
  buildings.
• 9 Buildings were surveyed over the course of 3
  days.

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Sample Scan Work

• Plumbness/Flatness reports
• The points gathered from scanning are made into a
  3D surface, from which, a grid is generated to
  report the deviations of the wall.
• A color map was made for each wall of each
  building to report the deviations.

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Sample Scan Work

• Blast Furnace Duct Replacement
• Existing Duct work was in need of replacement.
• Existing Duct was Surveyed, and a 3-D model made
  to verify the existing location and alignment.

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Sample Scan Work

• Blast Furnace Duct Replacement
• Existing Duct was removed, and tie points
  resurveyed.
• New Duct pieces were surveyed on the ground, and
  a 3-D model was made.
• The 3-D model was Fit into position to the
  existing tie points.
• Modifications to the New Duct pieces were made in
  order to fit the existing tie points.

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Sample Tracker Work

• Continuous Caster Alignment
• Produces Steel Slabs
• Slabs must meet specifications for quality of
  product
• Continuous Casting Machines must be well aligned
  in order to meet quality specifications

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Sample Tracker Work

• Caster Alignment
• Set oscillators
• Segment verification
• Determine best-fit radius point of caster based
  on segment pads
• Verify rolls, cams, pins
• Set permanent control (tracker plugs) for future
  verification surveys or adjustments

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Primary Project Goals

• We pride our self on continuing to meet the
  demands of our clients through traditional
  surveying techniques and by continuing to plan
  and develop for a clients future surveying needs.
• Reduce re-work and expedite maintenance/constructi
  on on all jobs.

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5979 McCasland Ave. Portage, IN
46368 (219)-762-7024 falk_at_falk-pli.com www.falk-pl
i.com