Pushing the Envelope

High Accuracy and Productivity: Key in South African Engineering Projects

-22- Technology&more; 2008-2
G
rowth and investment in South Africas infra-
structure are providing new challenges and
opportunities for surveyors and engineers.
Trimble technology is playing a key role on two of the
countrys largest and most visible projects. In Cape
Town, construction is underway on the new Green
Point Stadium. Scheduled for completion in 2009, the
Stadium will host several matches in the 2010 FIFA
(International Federation of Football Associations)
World Cup soccer tournament. In Gauteng Province,
the new Gautrain Rapid Rail Link is the largest civil
engineering project ever undertaken in South Africa.
When completed, it will connect Johannesburg,
Pretoria, and the O.R. Tambo International Airport
with over 80 km (50 mi) of high-speed commuter
railways. Both projects are publicly funded and have
drawn widespread attention.
Rising to the challenge is Julian Gray, Geomatics
Engineer for GNA Geomatics in Cape Town. Gray
was appointed as the Quality Assurance Surveyor
for the Green Point Stadium, where hes responsible
for checking the 3D accuracy of the stadiums struc-
tural elements. With required tolerances of less than
2 mm (0.08 in), Gray knew he needed a high-precision
surveying system. He selected the Trimble S8 Total
Station.
The versatile Trimble S8 immediately proved its
worth. Using low-density scanning techniques, Gray
conducted precise surveys on the 72 external pylons
surrounding the stadium structure that will support
the stadium roof. Te stadium roof extends out over
the grandstands, and designers must have precise
data on the supporting pylons. Using custom software
he developed that works in conjunction with Trimble
Geomatics Ofce software, Gray was able to check
the location, size, shape and rotation of the pylon
structures. The software computed the anticipated
location of the tops of the fnished pylons and moni-
tored construction progress to ensure that each pylon
was built correctly.
The stadium is a difcult place to survey. It is a relatively
small site, about 350 m x 350 m (1150 ft x 1150 ft), and
extremely busy. Crammed into the location are 14 tower
cranes, more than 1,800 workers, dozens of machines,
and dense scafolding. Gray politely describes the proj-
ect as Very Instrument Unfriendly. In its frst few hours
on the project, a dollop of concrete falling from an over-
head bucket splattered the instrument. Since then, the
Trimble S8 has endured dust, sand, cement and water
without difculty. After months of severe treatment, it
continues to work well, according to Gray.
Throughout the project, Gray has used forced-centering techniques and Trimbles high-precision prisms and
targets. Te instrument is mounted on concrete pillars, and mini-prism control points are placed in permanent
mounts. Measured distances are usually in the range of 4060 m (130200 ft) and never longer than 100 m (330 ft).
With this approach, Gray stated that he obtains standard errors of observation that are even better than the
instruments published specifcations. Trimbles narrow-beam EDM technology provides an important beneft
on the project. It lets Gray measure through scafolding and narrow openings with speed and confdence.
The project recently reached the stage of placing embedded plates onto the tops of the pylons. Tis requires
the positioning of a large, complex plate onto each pylon table. Te table measures 4 m x 80 cm (13 ft x 31 in) and
is 50 m (160 ft) above the ground. Gray checked the work using the Trimble 360 prism in a specially manu-
factured prism mount as the target for the Trimble S8 AutoLock measurements. Gray is achieving accuracy of
better than 2 mm (0.08 in), and the work, he says, is proceeding to the satisfaction of all concerned.
In the second project, the trains of the Gautrain Rapid Rail Link will travel at over 160 kph (100 mph),
connecting three main terminals and seven intermediate stations. Gray was appointed to check the above-
ground structures with high precision and accuracy. A key part of his work was verifying the geometry and
location of all of the bridge piers.
Gautrains contractor had selected a pre-cast segment approach for constructing overhead viaducts. This is the
frst time this method has been used in South Africa, and its receiving a lot of attention. Te approach uses a
launching girder system to lift pre-cast concrete segments into place. The segments are locked together to form
the deck of the viaduct between the piers. Each segment is about 2.5 m long x 10.1 m wide (8.2 ft x 33 ft) and
weighs up to 55,000 kg (61 US tons). With spans between piers as long as 50 m (164 ft), the geometry of the pier
heads must be checked and confrmed before the frst segment can be placed. Te distance between pier heads
must be accurate to within 2 mm (0.08 in). Taking advantage of the Trimble S8 speed and precision performance,
Gray was able to check the all of the 3D elements of 36 piers on 4 separate viaducts in less than 5 days.
Gray has several uses for the Trimble S8 Total Station on the Gautrain project. Te instrument is used to check
the control points used by the project teams in setting out for construction. In the tunnels, Gray scanned
cross-sections, using the built-in laser pointer and Direct Refex EDM. And he has proposed to use the Trimble
S8 as a monitoring system to check for possible subsidence of viaduct piers. Some piers are difcult to access,
and the accuracy of the Trimble S8 will let the teams watch for any vertical settlement.
Julian Gray and both project teams are pleased. Te accuracy and versatility of the Trimble S8 plays a crucial
role in both projects. Te instrument is performing well under extremely adverse conditions, Gray says, and
the results are exceeding manufacturers specifcations. Gray says that the team has taken great satisfaction
in pushing the envelope with the Trimble S8. As a result, the project managers will be fnding more and more
uses for the Trimble S8 Total Station as a solution to their high-precision measurement needs
-23- Technology&more; 2008-2