A year ago, we investigated the use of instruments and learned that views on their value varied considerably according to the size of the projects. Those who were frequently involved in big jobs (such as airports, highway construction or expansion, or extensive industrial development) were familiar with—and were users of—the impressive array of instruments available as add-on helpers to site workers who have spent most of their construction years with excavators, graders, loaders, and scrapers. They used to rely on their own skill and judgment, on stakes in the ground, or on other workers for precision. Has much changed since then? In the last few months we asked contractors, “When would you purchase lasers and instruments like those?” The most common answer still is, “When the scope of our work justifies them.” Contractor Attitudes Are Essentially Practical
An important aspect of the subject is revealed by Jim Hughes, CEO of Building Ventures Inc. based in Cartersville, GA. “As a small contractor, I have not found a need for the laser level,” notes Hughes. “I still use a Nikon line-of-sight level, and every now and then we need a transit. For that I use Topcon. The line-of-sight level does not require me to spend a lot of time training someone to use it, but the transit is another story. I am usually the one who uses the transit.” His company is frequently engaged in grading for drainage and site preparation. “I have a loader that I use for most of my work. If the job demands it, I rent excavators and scrapers, but none of the rentals has a laser level. We can bring a slab to within one-eighth to one-quarter of a foot and can create drainage falls in the same range. This is more than satisfactory for our needs. A laser would be nice, but it is still way too costly for me.” Other contractors, especially the one-, two-, or three-person companies, agree with him. “Many say they can’t buy new equipment just because it’s new; “especially in these difficult times for small contractors, they must need it.”
An important aspect of the subject is revealed by Jim Hughes, CEO of Building Ventures Inc. based in Cartersville, GA. “As a small contractor, I have not found a need for the laser level,” notes Hughes. “I still use a Nikon line-of-sight level, and every now and then we need a transit. For that I use Topcon. The line-of-sight level does not require me to spend a lot of time training someone to use it, but the transit is another story. I am usually the one who uses the transit.” His company is frequently engaged in grading for drainage and site preparation. “I have a loader that I use for most of my work. If the job demands it, I rent excavators and scrapers, but none of the rentals has a laser level. We can bring a slab to within one-eighth to one-quarter of a foot and can create drainage falls in the same range. This is more than satisfactory for our needs. A laser would be nice, but it is still way too costly for me.” Other contractors, especially the one-, two-, or three-person companies, agree with him. “Many say they can’t buy new equipment just because it’s new; “especially in these difficult times for small contractors, they must need it.”
A Cat 140H motor grader equipped with Topcon 3D-GPS automatic grade control system“Lasers are indispensable,” observes Maurice Piersol, president of Piersol Construction in Rosalia, WA.“Our on-the-ground personnel use them every day. We buy only self-leveling lasers—usually Topcon because we like their dealer support and price—but we do have some Spectra Physics [SP] equipment. I feel the quality of these old SPs is superior to any of the newer machines we own, but lack of local dealer support has prevented us from buying additional units.” Piersol Construction also has two machine-mounted receivers on dozers, or they can be mounted on a grader with machine controls. “For prebid work, I usually use a total station to verify jobs if I need additional information,” adds Piersol.“Some training is required for the operators to become familiar with the specific piece,” notes Barry Bender, president of Barry Bender Excavating in Wellesley, ON. “We keep our equipment as simple as possible to reduce the possibility of error. The equipment is only as good as the operator. We tried more complex laser equipment in efforts to become more efficient in our operations, but the operators didn’t like it and that actually slowed down our operations because the operators spent more time waiting for the equipment to catch up with them.” He cites an example of an instrument that was supposed to pick up the laser signal as the boom-mounted receiver passed through the beam. It then would calibrate itself to indicate cutting-edge elevation in any position. “The receiver wasn’t fast enough to pick up the beam, so the operator had to pass it through the beam several times till he caught it. That obviously slowed down operations.“My experience in 20-plus years of using laser equipment tells me to use the simplest system available for the most satisfactory results. We would never give up the laser equipment. We still try new pieces as they are introduced, and we upgrade when something superior comes along.” Bender’s comments echo those of many other contractors with whom we spoke.Combine Estimating and Layout for Competitive Efficiency
“We often use laser instruments to do surveying on projects before we bid,” relates Bender. “Most of our employees use the instruments, in varying degrees. On the excavators, the operators need to know how to set up and use basic laser transmitters and receivers for foundation excavations and jobs like that. On the bulldozers, we use them for level or slope work. It certainly saves time by keeping the operators on their machines [instead of] having to get out to check grades or waiting for someone else to check the grades.”Preparing your bid has become both easier and more accurate since estimating software with computer-aided-design (CAD) file import has become available. Combining this accuracy with layout capability was a natural next step for software developers. Products that can be used for bidding, as well as for exporting data to the field, keep estimators and layout personnel on the same page for the project. An example of this type of program is InSite Sitework. “The program is designed to handle tough takeoffs with ease,” observes Steve Warfle, product manager at InSite Software Inc. in Rush, NY. “It uses common terms that are familiar to site estimators so that a time savings over a conventional hand takeoff of five to 10 times is easy to achieve. With a good CAD file, a complex takeoff can be done in a half hour or less.” InSite Software also supplies Field General, a product that gives the contractor control of site layout, data collection, and the machine all at the same time. Field General can interface in real time with a robotic total station or a global positioning system, or it can send point data to a conventional data collector. The system supports offset staking for even more time saved. “Using the CAD file, you can quickly stake the site with precision,” says Warfle. “Then you take your bids won with InSite Sitework right to the field.”
“We often use laser instruments to do surveying on projects before we bid,” relates Bender. “Most of our employees use the instruments, in varying degrees. On the excavators, the operators need to know how to set up and use basic laser transmitters and receivers for foundation excavations and jobs like that. On the bulldozers, we use them for level or slope work. It certainly saves time by keeping the operators on their machines [instead of] having to get out to check grades or waiting for someone else to check the grades.”Preparing your bid has become both easier and more accurate since estimating software with computer-aided-design (CAD) file import has become available. Combining this accuracy with layout capability was a natural next step for software developers. Products that can be used for bidding, as well as for exporting data to the field, keep estimators and layout personnel on the same page for the project. An example of this type of program is InSite Sitework. “The program is designed to handle tough takeoffs with ease,” observes Steve Warfle, product manager at InSite Software Inc. in Rush, NY. “It uses common terms that are familiar to site estimators so that a time savings over a conventional hand takeoff of five to 10 times is easy to achieve. With a good CAD file, a complex takeoff can be done in a half hour or less.” InSite Software also supplies Field General, a product that gives the contractor control of site layout, data collection, and the machine all at the same time. Field General can interface in real time with a robotic total station or a global positioning system, or it can send point data to a conventional data collector. The system supports offset staking for even more time saved. “Using the CAD file, you can quickly stake the site with precision,” says Warfle. “Then you take your bids won with InSite Sitework right to the field.”
Fran Cunningham’s company is not large, but he believes he saves many hours with the Field Generall Program.“I can set a hundred stakes in an hour with Field General,” relates Fran Cunningham, owner of Landmark Development in Auburn, NY. “Then I can go to the next job and set 100 more stakes. I don’t have any operators and equipment standing around waiting for layout stakes. The benefits are obvious.” Field General exports surface models to Trimble SiteVision 3-D, Leica 3D, and Topcon 3DMC systems. To verify work done, shoot the site and InSite will calculate the cut and fill to date. To handle the next phase, the contractor simply copies the proposed to the existing and imports the next shot, and the program calculates the new quantity. You can print cross sections, 3-Ds, and cut-and-fill maps to show actual excavation progress. Does this sound too complicated for you? We found it interesting and practical that InSite insists that potential purchasers of their systems try them for 30 days before commitment.
At this site, the grading controlled by Trimble instruments was good enough to make traditional fine gradingun necessary.What Do You Look For?
What’s the menace that can interfere with any outdoor work (or recreation)? Both project owners and contractors assert that it’s the weather. If your site work involves people trudging through mud and unstable ground conditions, the job will slow down or stop. The right instruments can avoid that if you make sure your instruments match the bad weather you might experience. Can your controller and receiver survive being dunked in a typical construction-site puddle? Can they survive falling off a 6-ft. supporting pole or toppling from the top of a grader, a loader, or an excavator? Wind and rain have probably stopped more construction jobs than anything else has, but today’s best instruments are designed to shrug off the whims of the weather and carry on. A word you will find in many product descriptions is “rugged.” “Reliable” is another; that usually refers to the laser’s constant accuracy. For the Spectra Precision LL500 Slope Laser exterior horizontal laser level, for instance, the vendor claims “stable accuracy in even the most challenging environments.” This model offers easy setup via a three-screw leveling system with compensated electronic sensing. It is recommended by the manufacturer for roads and ditch banks with up to 25% grade, storm drains, septic beds, parking lots, and sloped floors. On the Snap laser receiver (a combination of a survey rod receiver and a machine-mounted receiver), the housing is made of Lexan to combat the most hostile weather and site environment, and the LCD has a built-in strobe-light rejection so the display is visible in all lighting conditions. The Snap receiver mounts on the machine with a magnet; it has been used on backhoes, box blades, skid-steers, excavators, and dozers.
What’s the menace that can interfere with any outdoor work (or recreation)? Both project owners and contractors assert that it’s the weather. If your site work involves people trudging through mud and unstable ground conditions, the job will slow down or stop. The right instruments can avoid that if you make sure your instruments match the bad weather you might experience. Can your controller and receiver survive being dunked in a typical construction-site puddle? Can they survive falling off a 6-ft. supporting pole or toppling from the top of a grader, a loader, or an excavator? Wind and rain have probably stopped more construction jobs than anything else has, but today’s best instruments are designed to shrug off the whims of the weather and carry on. A word you will find in many product descriptions is “rugged.” “Reliable” is another; that usually refers to the laser’s constant accuracy. For the Spectra Precision LL500 Slope Laser exterior horizontal laser level, for instance, the vendor claims “stable accuracy in even the most challenging environments.” This model offers easy setup via a three-screw leveling system with compensated electronic sensing. It is recommended by the manufacturer for roads and ditch banks with up to 25% grade, storm drains, septic beds, parking lots, and sloped floors. On the Snap laser receiver (a combination of a survey rod receiver and a machine-mounted receiver), the housing is made of Lexan to combat the most hostile weather and site environment, and the LCD has a built-in strobe-light rejection so the display is visible in all lighting conditions. The Snap receiver mounts on the machine with a magnet; it has been used on backhoes, box blades, skid-steers, excavators, and dozers.
The details of the project are clear and easily understood with InSite’s software.The words used to describe the Rugby 100LR, an automatic self-leveling laser for general construction from Leica Geosystems, are “rugged,” “reliable,” and “robust.” “The Rugby 100LR is a result of listening to our customers,” states Dan Dykhuis, program director for lasers in the Grand Rapids, MI, office. “It is built to be rugged yet easy to use and can make quick work of concrete forming, pad placement and framework, setting foundation and footings, as well as elevation indication for heavy equipment.” It has a working range of up to 2,500 ft., an automatic elevation alert function, and a manual grade up to +/-10% with cross-axis self-leveling. It levels automatically and quickly, has a simple five-switch keypad that controls all the functions, and features a low-battery and out-of-level indicator. “[The Rugby 100LR is built] along the same principles that guided the development of the earlier product [the Rugby 100], so customers can look forward to the same level of reliability and robustness,” adds Dykhuis. “The Rugby 100 has received an overwhelmingly enthusiastic response from both our dealers and customers worldwide. The co-molded housing of high-impact plastic and rubber is as rugged as it looks.” The Rugby100LR is the first Leica-branded product combining the heritage and expertise of Laser Alignment and Leica Geosystems.
Bullseye instruments attach to the earth-moving machine.Trimble (with mergers, that name now includes years of experience in this field with Spectra Precision, Laserplane, and Geotronics) makes an interesting and significant point: “Our customers are supported by the industry’s largest global service and support system, with partners who understand the technology, the applications, and your business needs.” What it is saying is that instruments are products that cannot be sold the way many other items for contractors are; they are not like hammers, pickups, or even most earthmoving machines. Contractors frequently mention that educated service personnel and knowledgeable sales staff are essential to instrument purchases. Lack of good local product support is a common reason for being disillusioned about instruments. “That’s a shame,” remarks Richard Shimota, a contractor in Bend, OR. “Poor support doesn’t necessarily mean poor product, except to the customer.”What Are the Main Advantages?
In a practical vein, manufacturers point out that instruments can improve the quality of a contractor’s work, use less skilled labor (still in short supply and perceived in some regions to be the most important need in our industry), and minimize downtime and rework. They also say instruments can become significant tools from the very beginning of a project, at the concept stage before any blades have struck the ground or engines have been started. When estimates are accurate and the work follows suit, some of the not-so-obvious advantages to the contractor are better use of materials, lower labor costs, and fewer occasions when well-paid workers are wondering what to do next or how to correct a mistake just made.
In a practical vein, manufacturers point out that instruments can improve the quality of a contractor’s work, use less skilled labor (still in short supply and perceived in some regions to be the most important need in our industry), and minimize downtime and rework. They also say instruments can become significant tools from the very beginning of a project, at the concept stage before any blades have struck the ground or engines have been started. When estimates are accurate and the work follows suit, some of the not-so-obvious advantages to the contractor are better use of materials, lower labor costs, and fewer occasions when well-paid workers are wondering what to do next or how to correct a mistake just made.
Choose instruments that can work in all types of weather.An example of how you can save time and money recently occurred in the Netherlands. Dutch contractor Kuypers Kessel had to build a new ring road with several crossover sections, and there was railroad track nearby. That was nothing new for the contractors, except that they were also testing a new kind of sub-base material containing polluted soil. Kuypers Kessel installed a Blade Pro 3D machine control system with an ATS total station on a Caterpillar D6M dozer. The innovative sub-base material comprises lightly polluted earth mixed with chemicals and cement. The chemicals “store” the pollution while the cement sets the mix like concrete. But the work must be completed within a few hours and can take place only in dry conditions. The original plan was to use the dozer with the Blade Pro 3D system and then complete the fine work with a grader. In practice, the results from the instrument-guided dozer were so outstanding that the contract specifications were reached without the need for any further equipment. “We have used Trimble machine control laser systems for some years now to very good effect,” notes Harry Kuypers, managing director of the contractors. “On this project, we completed the contract quickly and accurately well within the set time frame.”
Both big and small projects can be faster and more accurate with the right instruments.Progress in Small Stages
One of the intimidating aspects of instruments in construction is that some vendors and contractors believe you have to go straight to the most advanced products available. Such products are also the most complicated and require the most training. “Visual-indicate machine control systems are a great first step into machine control,” comments Mike Bank of Apache Technologies in Dayton, OH, which makes and markets the Bullseye series of laser grade checkers, among other products. “They are a simple way for contractors to further save money using laser equipment they already own. Visual-indicate systems are similar to handheld laser detectors in that they show the operator the direction to move the cutting edge in order to be on grade. The difference is that a visual-indicate machine control receiver allows the operator to check the grade without leaving the cab. These systems are easy to use and relatively inexpensive.” To use a visual-indicate receiver on a bulldozer or a grader, a pole is welded to the blade. The cutting edge is then placed on-grade and the receiver adjusted to indicate on-grade. The operator can then check grade continuously during the earthmoving operation. When used on an excavator or a backhoe, the receiver is mounted on the dipper stick, with that mounting being either a pole welded in place or the magnetic mount many manufacturers offer. The operator would then dig to grade, place the bucket on the on-grade location, and attach the receiver. The receiver is then adjusted to show on-grade, and the operator continues his excavation. “When the operator wants to check grade, the bucket is placed in the same position as it was during setup,” adds Bank. “The dipper is placed in a plumb position, and the operator observes the indication given by the receiver. Some receivers automatically adjust for out-of-plumb, thereby increasing the digging range.”
One of the intimidating aspects of instruments in construction is that some vendors and contractors believe you have to go straight to the most advanced products available. Such products are also the most complicated and require the most training. “Visual-indicate machine control systems are a great first step into machine control,” comments Mike Bank of Apache Technologies in Dayton, OH, which makes and markets the Bullseye series of laser grade checkers, among other products. “They are a simple way for contractors to further save money using laser equipment they already own. Visual-indicate systems are similar to handheld laser detectors in that they show the operator the direction to move the cutting edge in order to be on grade. The difference is that a visual-indicate machine control receiver allows the operator to check the grade without leaving the cab. These systems are easy to use and relatively inexpensive.” To use a visual-indicate receiver on a bulldozer or a grader, a pole is welded to the blade. The cutting edge is then placed on-grade and the receiver adjusted to indicate on-grade. The operator can then check grade continuously during the earthmoving operation. When used on an excavator or a backhoe, the receiver is mounted on the dipper stick, with that mounting being either a pole welded in place or the magnetic mount many manufacturers offer. The operator would then dig to grade, place the bucket on the on-grade location, and attach the receiver. The receiver is then adjusted to show on-grade, and the operator continues his excavation. “When the operator wants to check grade, the bucket is placed in the same position as it was during setup,” adds Bank. “The dipper is placed in a plumb position, and the operator observes the indication given by the receiver. Some receivers automatically adjust for out-of-plumb, thereby increasing the digging range.”
Topcon RL-H2S rotating laser provides elevation control for grading. One of the simplest systems we came across was from LaserLeveling Inc. of Lutz, FL; it was developed from a three-point-hitch scraper (the Grademaster). This company has enjoyed particular success in recreational grading projects, such as golf courses and ballparks. For the construction grading package, LaserLeveling offers a three-part system: the grading system, the laser, and machine control. Setup takes only minutes. “We believe our system is simpler than most,” says Ray Joling for the manufacturer. “Unlike traditional three-point box scrapers, LaserLeveling’s scrapers use a unique rear-axle assembly where the rear axle controls the height or elevation of the cutting edge instead of the three-point hitch on the tractors [doing that]. This design increases the efficiency and control of the scraper and turns it into a precision grading attachment. Without this rear-axle system, we would probably not attain our tight grade tolerances.”
The operator can see exactly what he has done and what needs doing. “Plenty of tools have been available to measure grade, ranging from a simple pendulum to digital displays with remote sensors,” says Skip Gosnell, director of marketing at Rieker Inc. in Folcroft, PA. “While these instruments work well to indicate the grade of a surface, they only do one thing: indicate. It is up to the operator to control the machine moving the dirt.” Why don’t some instruments move the blade on a machine to keep a constant grade or the angle of a trench? In the past, it was difficult to have any one sensor do the job since conditions for trenching or grading would change. If a blade hit a rock, the sensor might send an elevated reading that would make the blade jump trying to react to the sudden input. Electronic sensors have been damped, among other things, to try to help alleviate some of the problems with jarring and vibration, but this has made tilt or grade sensors slow to react to changing surfaces—usually requiring the operator to make another pass.“The solution was not in the evolution of the sensors; it was in the invention of the microprocessor,” continues Gosnell. “A microprocessor can take information from a sensor and analyze it to see what it should or should not consider before giving a command to move or adjust a blade—much like a human understands that the sudden jolt of a rock is only a rock. It does this so fast that the blade remains on-grade.” Rieker’s RGC GradeControl system allows an operator to dial in a set angle in degrees, percent grade, or slope. Once in motion, the operator can fine-tune the controls, depending on the application. The RGC GradeControl Inclinometer package is designed to monitor slope and regulate both hydraulic and pneumatic systems. Adjustments of grade setting in manual and automatic control modes are done by simply pressing the “up” and “down” arrows; the operator adjusts the setting during operation for instant control. The “function” button allows the user to select among pulse width, dead band, and gain, then press the “up” and “down” arrows to calibrate the selection. “Using smart microprocessor-controlled systems like the Rieker GradeControl can increase productivity, but it can also allow someone with far less experience to produce masterful results,” concludes Gosnell.Whatever your level of interest, whatever your level of expertise, it seems that today’s instruments, independently or in conjunction with other tools, can increase the efficiency of your bidding, your productivity, and your profits.
