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Tracking precast tunnel liner segments
Tracking Precast Tunnel Liner Segments
NRC Pre-Con Project
Ajit Pardasani, Qi Hao
Centre for Computer Assisted Construction Technologies
London, Ontario
Transportation Research Board (TRB) 90
th
Annual Meeting 2011
Project Team
National Research Council
• Engler, Chris
• Hao, Qi
• Kopp, Brock
• Kruithof, Steve
• Laborde, Vincent
• Murray, Niall
• Neutel, Denise
• Pardasani, Ajit
• Puurunen, Elias
• Vantorre, Laurent
Armtec/Pre-Con
• Galan, Israel
• Hines, Duncan
• Knelsen, Henry
• Sheldon, Phil
• Slosarcik, Paul
PreCast Concrete Production
-Inefficiencies
• Precast Industry Scenario:
–
Pieces
cast months ahead
– Storage time: 1 day to several months
– Paper based tracking systems
• Areas of Pain:
– Re-entry and duplication of data
– Poor access and visibility of data
– Upto1/3
rd
time wasted searching
– High variability in quality
– Handover of Product Quality Data
Pre-Con, Armtec
Infrastructure Fund
• Armtec: Manufacturer for range of
infrastructure products
• 48 plants across Canada
• Pre-Con has two plants:
– Brampton and
Woodstock
• Designs, manufactures, delivers
and erects:
– Precast and pre-stressed concrete
– Bridge components
– Parking structures
– Wall cladding systems
– Tunnel liners
Pre-Con: Current State
• 60 acres yard
• Some pieces made months ahead
• Dwell time: 24 hrs to 9 months
• Average dwell time: 110 days
• Inefficiencies:
– Time to locate a component: several minutes to hours
– Frequency of incidents of missing pieces ~ every 2 weeks
– When a piece cannot not be found, it is cast again
Life Cycle Tracking
Project
• Objective: To develop
computer-assisted life cycle tracking/traceability
system to reduce wasted effort and
improve quality
• Collaborator:
Pre-Con, Armtec,
Brampton and Woodstock Plants
– Part of Armtec Infrastructure Fund
• Project Duration:
– Phase 1: Oct 2009 – June 2010
– Phase 2: Sept 2010 – Aug 2011
Pre-Con supplied I girders for Perley bridge replacement
Tracking
Requirements (1)
AS-IS
TO-BE
(2010-11)
Paper based
Manual updates
Not integrated
Duplication of information
No data transparency
Computer based
Semi-automatic- Utilizes RFID
Integrated with work flow
One data source
Visible across all departments
Location tracking
Inventory management
Traceability of quality data
Traceability
Requirement (2)
“A key element to be addressed in the CQC plan will be
procedures to maintain traceability
between manufactured
segments and methods and materials used in the manufacture
including and not limited to material quality test results,
fabrication, date and time of manufacture, moulds used and
material sources.
A UPC (Universal Product Code) system will
be implemented by the Contractor to ensure traceability of the
above listed items to stored and installed segments
.”
Excerpt from Toronto Transit Commission Contract A35-18
NRC’s Tracking System would help Pre-Con fulfill the traceability
requirements stipulated in the contract
Tracking of Tunnel
Liner Segments
• TTC Toronto-York Spadina
Subway Extension
– 2 tunnels ~ 6.5 KMs each
– $43 Million contract for Pre-Con to
fabricate 58,000 segments
– August’10 - Nov’12
• Pre-Con is using NRC’s system
to maintain traceability of data
from production to shipping
– RFID and quality data will be used
for tunnel maintenance by TTC
• System is deployed at
Pre-Con’s Woodstock’s plant
Pre-
Con’s tunnel segment production facility
Integrated Life Cycle
Tracking
Shared
Data
Model
Storage
(Location)
Manufacturing
(Schedule, Attach
RFID tag, Date,
Casting Bed)
Quality Control
(Defects,
Deficiencies)
Maintenance
& Rehabilitation
(Inspection,
Repairs)
Ship
(Load & Ship)
Scan RFID tag and link data
