Archive for category: At work!

“Mavinci is hard to top because of ease of use, consistency of product and reliability,” said Brent Manuel, Superintendent – Survey, BHP.

Brent Manual and his team at BHP are working on site at Mt Arthur, one of the largest producers in the Hunter Valley producing 19mt of product coal each year. The site’s geology is complex with over 120 seams in the mining area which are typically mined in 40 different composites dependent on product requirements.

“Currently we are mining down dip into a monocline which we don’t expect to pass in the next five years,” said Brent Manuel, Superintendent – Survey, BHP.

“This will result in more through seam blasting and challenge our operations to mine the coal as cleanly as possible.”

Why did BHP choose the Position Partners RPAS system with PPK?

BHP chose the RPAS system with PPK from Position Partners after Mr Manuel saw them in action at another of BHP’s sites. The team at BHP’s other site had chosen this particular system because of the quality of data that could be mapped and the cost and performance comparative to other systems was superior.

“I arrived at the Mavinci Sirius Pro and M210 solutions after viewing them at some of our northern operations,” Mr Manuel said.

“There had been a number of teething issues with different systems and for reliability, these were the two best options. The Mavinci is typically used for all of our larger scale mapping whereas the M210 is employed for smaller areas and where greater height accuracy is required.”

What drew Mr Manuel to the Mavinci was ease of use, consistency of data quality and reliability of the units. Mr Manuel found that the M210 offered his team the ability to map large tracts of high walls in short timeframes and at a quality far superior to their current methods of capture.

Benefits of using RPAS system with PPK

Previously, Mr Manuel’s team had relied on vehicle mounted scanner technology and RTK GPS and found that these systems could not compete with the RPAS system with PPK on the coverage, quality of resultant models and added benefit of supporting BHP’s site GIS system.

BHP mainly uses the RPAS system with PPK from Position Partners for thermal mapping, high wall mapping, inspections, photographing and filming of incident scenes and has noticed a range of benefits since implemented this system.

“Definitely coverage of areas, quality of the data and models produced from it are far superior than current capture methods. They also limit our interaction with mining fleets, so it also improves safety outcomes,” said Mr Manuel.

“In the current ‘Line of Sight’ world, Mavinci is hard to top because of ease of use, consistency of product and reliability.”

On implementation of the RPAS system with PPK from Position Partners, Mr Manuel’s team had to develop a couple macros to expedite the processing of the data.

“The user interfaces in the software are intuitive and all of my users have developed competency quickly,” said Mr Manuel.

“The final product from these processing software’s then translates across into our Mine Planning software without issue.”

The importance of service and support during purchasing and implementation

Mr Manuel has found that the local Position Partners team is important to his decision-making process when buying new technology because they always provide him with information on new developments and technology that his team should be considering.

“I always find our Position Partners representative easy to get a hold of and willing to help us work out any issues or provide support,” Mr Manuel said.

“We have called on several occasions for support and advice on training.”

About BHP

BHP is a world-leading resources company. BHP extracts and processes minerals, oil and gas, with more than 62,000 employees and contractors, primarily in Australia and the Americas.

Brent Manuel is Superintendent – Survey at BHP and has a team of five surveyors and 1 Reconciliation Officer. We are responsible for all survey requirements from set out of pit designs to calculation of monthly volumes. We are also responsible for the maintenance and supply of data to the Site GIS application.

Cairns-based construction firm chooses Topcon for accuracy, ease of use and flexibility

Kenfrost is a mid-sized construction company that specialises in residential building development in Cairns, with a civil construction division that offers road and other earthmoving services.

The company operates two graders and runs 3-4 construction and survey crews. Grader operator Matthew Byl has worked for the company since 2009 and explains why they opt for Topcon and how upgrading to the latest mmGPS machine control technology, along with a brand new CAT 120M AWD grader, has resulted in huge productivity improvements for the business. 

Why Topcon comes out Top

Mr Byl explained that although he’s been loyal to the Topcon brand for many years, he hasn’t done so just out of habit. “When we purchased this new CAT grader we were open minded and we did look seriously at upgrading the existing system that it comes with in place of Topcon,” he said.

“But when I had a demonstration and really compared the two, I wasn’t convinced that the other brand would offer any advantages and in fact there were a few key differences that made Topcon a clear winner from my perspective,” he added.

Mr Byl explained that Topcon is the only system on the market that can deliver fine precision grading using laser and GPS technology together at the same time. “What’s great about it is that even if you briefly lose line of sight with the laser, the GPS will keep you working so you don’t lose everything.

“Other systems rely on robotic total stations, which aren’t linked with the GPS technology so when you lose line of sight – which everyone does at some point as it’s just the nature of the job – you have nothing,” he added.

Mr Byl said he likes the fact that Topcon technology uses GPS at the core of its systems and supplements it with other technology such as lasers and robotics to increase accuracy.

“The fact the technology works together makes it more flexible for all sorts of different applications, without losing accuracy,” he said. “Other systems seem more cumbersome to me, as though you’re operating two types of technology independently from one another.”

A brief history lesson

Mr Byl has been using machine control technology since its early days and has experienced firsthand its evolution. Agtek, which was acquired by Topcon in the 1980s, invented the first 2D machine control system that enabled operators to grade cross slope and other complex designs. Later Topcon added Sonic Tracking technology that allowed the operator to follow the stringline with multiple grades and changes in level.

“I was working for a company in Western Australia when I started using machine control technology, the first being an Agtek System 4 which later evolved to the more sophisticated Topcon System 5 that is still popular today,” Mr Byl said. 

In 2009, Mr Byl relocated to Queensland and started working for Kenfrost. That same year the company purchased its first 3D machine control system, Topcon mmGPS. 

Commenting on the difference between 2D and 3D machine control, Mr Byl said: “2D is fantastic technology and it certainly makes your work a lot faster, but you are still reliant on others in the team for grade checking.”

“I find that with the 3D system I have everything I need to work independently without waiting for surveyors to peg out the design or check grade,” he added. “I can also start and finish the job where I want to, I don’t have to work areas that the surveyor has already set out as I have all the data I need on the screen in front of me.

“Personally I still run a stringline at the end just for my own peace of mind, but it’s not something I need to do!”

Yes you CAN

With the ability to connect directly into the machine’s CAN system, Topcon mmGPS delivers extremely high accuracy and rapid response to the machine’s every move.

An added advantage of direct connection to the machine’s CAN system is the ability to use the CAT joystick without adding additional controls.

“As an operator, I was impressed that Topcon could make use of this new joystick design. This way all the auto buttons and grade adjusters are part of the joystick, allowing me to keep my hands on the controls at all times,” Mr Byl said.

Automatic side shift is a new feature that Mr Byl explains makes road work significantly more efficient and accurate. “When boxing out curb, the system now has a feature that enables you to automatically side shift the position so that you follow the line of the curb exactly,” he said.

“Previously we would sometimes have problems when the team came to lay the curb and the line not being correct, which was usually an operator error somewhere along the way. This removes the risk of human error and makes it a lot more precise and faster to grade,” he added.

Other benefits of the new system include a faster, modern Topcon GX-55 control box that also features three integrated LED light bars for a quick visual reference to grade. “Our other system was five years old so as with any computer, the newer one is much faster,” he said. “I love the light bars as well, I’d got used to them on the 2D system and it’s great to have them back on this new version just to keep an eye on how I’m tracking to grade.”  

Single versus Dual Antennas

Topcon’s mmGPS solution has the option of using either a single or dual GNSS antenna setup. Kenfrost’s original system had a single antenna, but on the new one the company opted for twin GPS and is realising increased performance as a result.

“The single antenna system we had previously was extremely accurate, but I think the dual antenna setup has the edge especially if you’re working in tight spaces,” Mr Byl said.

“I love the fact that keeps up with you just as well in reverse as it does when you’re going forward”.

Although I don’t grade in reverse, with the single antenna you’d have to drive forward for a few metres before it would lock onto your position, whereas the dual system always knows exactly where you are, no matter how small an area you’re in or how often you switch direction,” he added.

Another advantage Mr Byl highlighted with the twin antenna setup is the ability to pitch the blade forward and still maintain good accuracy from the GPS. “With the single antenna, it needs to remain perpendicular to the blade to maintain accuracy, so you need to keep working at the same pitch,” he said. “But with the twin setup, I can adjust the pitch a bit to give me a sharper point on the cutting edge for work on hard surfaces, whilst still maintaining fine precision accuracy.”

High calibre install and support

Mr Byl highlighted the excellent service and support the company receives from Topcon’s Australian Distributor, Position Partners. “I was very impressed with the gentleman who installed this latest system. I worked with him whilst installing it, and I was very happy with the attention to detail that he had and to the overall presentation of the installation, particularly the wiring harnesses which can sometimes be challenging to get to looking neat and tidy.”

Kenfrost also utilises Position Partners’ Tokara Link remote support and diagnostics technology – a system that was developed specifically to meet the needs of the Australian construction market and provide industry-leading support capabilities.

“Just last week I ran into a problem whereby the control box froze on me,” Mr Byl said. “The support team in Brisbane was able to logon immediately to run some diagnostics and update the system to the latest software. Within the hour I was back up and running, so it saved a huge amount of time and I’ve had no problems since.

“It’s great to have the support of a professional team behind the technology that can assist us when need be,” he added.

Sydney-based sportsground and golf course specialists Flemming Golf are realising maximum productivity with Topcon’s latest dozer machine control.

Flemming Golf is a family owned company that works throughout Australia and overseas, constructing sports fields and golf courses. Having worked with Topcon laser and machine control technology for many years, manager Heath Flemming said they were keen to try out the latest addition to Topcon’s solutions, 3D-MCMAX, when they took delivery of their new CAT D6N dozer.

“We run a number of dual grade lasers, survey rovers, 3D dozer and excavator systems and a 2D tractor system, to eliminate pegs on site,” Mr Flemming said. “Once we’d ordered the dozer, we asked Position Partners [Topcon’s Australian distributors] what machine control system they’d recommend for it.”

The company recently bought a new CAT D6N dozer, which features a six-way blade ideal for the new 3D-MCMAX system.

“We find a 6-way blade more versatile than an SU blade for the work we do,” Mr Flemming said.

Topcon’s 3D-MCMAX is a fully integrated, mastless 3D dozer solution that utilises Inertial Measurement Units (IMUs) in place of GNSS receivers and cables connected to the blade via a mast.

With one IMU mounted to the back of the dozer blade and another on the undercarriage of the machine, Topcon’s dozer system processes positioning information up to 100 times per second. In contrast, a standard 3D system with only one positioning sensor updates position information only 10 times per second.

“We’ve had great success with the 3D-MC2 solution, which offers similar processing speed and responsiveness to the newer MAX option,” Mr Flemming said.

Although the machine has yet to be used full time on a project as its installation is still recent, Mr Flemming said it has some key differences to the older Topcon solutions they use.

“The responsiveness and reliability is still the same high standard you’d expect from Topcon, but not having the mast certainly makes visibility easier, especially when you’re grading tricky landscapes such as golf courses,” he said.

“The new Topcon screen with the integrated lightbars is also a great update, still very easy to use like the older style but just a bit faster and more modern. We’ve had no problems upgrading, even the old man who’s 68 has operated it and just picked it up without any additional training,” he added.

When asked why they opt for Topcon, Mr Flemming said: “We have tried other systems but they couldn’t keep up, so Topcon is a clear winner in our view.

“Grading a golf course is not like other applications where you could be working to the same level for quite a distance,” he added. “With the constant twists and turns and change of contours, we’ve found Topcon much more responsive technology.”

Another key reason for always choosing Topcon, is Flemming Golf’s relationship with Position Partners.

“As the first installation in Australia, there were bound to be a few teething problems with this new system,” Mr Flemming said. “But because we have a great relationship with Position Partners and have full confidence in the capabilities of their technical team, we knew we’d be up and running very quickly.”

Flemming Golf utilises Position Partners remote control and support technology, Tokara, to assist with sending design files to machines and getting technical help when required. “Tokara is a fantastic solution because it gives you peace of mind that no matter where the job is, the technical team can login to your machine and help with a software upgrade or to explain a new feature on the system, for example,” Mr Flemming added.

From L-R: Ed Kelly (Huntly Survey Manager), Jamie Nelson (Position Partners Sales Manager) and  Tony Dickens (Huntly Project Manager) 

Fulton Hogan, an international civil construction company specialising in transport, energy, mining and infrastructure projects, recently updated the firm’s project surveying methods in New Zealand by investing in a Remotely Piloted Aircraft System (RPAS).

Fulton Hogan & HEB Alliance is a joint venture project on the Huntly Bypass, a continuation of the Waikato expressway in between Auckland and Hamilton. This $458 million dollar project is set to transform the 15.2 kilometre stretch of the Waikato Expressway between Ohinewai and Ngaruawahia, between Auckland and Hamilton. Construction began in 2015 with the expressway due to be completed by 2019-2020.

Innovative Solutions

With such a large scale project at hand Fulton Hogan decided to look into new efficient ways to manage the survey aspect of the project.

“We were finding that conducting monthly survey measurements on large earthwork sites using traditional optical and GNSS survey methods were costly and involved out-sourcing the job to contractors,” said Ed Kelly, Fulton Hogan’s Survey Manager for the project. “So we decided to look at what else the market could offer to save time and money and increase safety,” he added.

After researching the various RPAS solutions available on the market, Ed met with Jamie Nelson, Position Partners New Zealand Sales Manager, who offered the perfect solution.

“When Jamie showed me the Sirius Pro with the RTK unit I knew I had found what I was looking for,” Ed said. 

Most RPAS solutions require the use of a series of ground control points to give reference locations for the images taken during a flight, so the photos can be collated into an orthophoto and subsequently a 3D model during post processing.

The Sirius Pro, however, uses a combination of on-board and ground-based GNSS technology to eliminate the need for ground control points, saving time and removing the dangers associated with surveyors working on hazardous terrain and near active machinery. Another very useful feature is the Terrain compensation in the flight panning Mavinci Desktop software. This allows the Sirius to maintain an even GSD (Ground sampling distance) for consistent and accurate results in mountainous terrain.    

“For a large road development project such as this, the use of ground control would add considerable time and expense to the end of month surveys, negating many of the benefits of this new technology,” Ed explained. “But I knew when I saw the Sirius Pro that it had the potential to drastically improve our workflow and offer a far more efficient, accurate and cost effective option.”

To make sure the Sirius Pro was up to the task and could deliver the results Fulton Hogan required, Ed undertook a series of test flights with the system. “There is always a degree of caution when investing in new technology as the results need to be proven, but when I saw the data produced from our trial flights, I was really impressed and knew it was the right tool for the job,” he added.

A good return on investment 

Since introducing RPAS technology Fulton Hogan has observed major time and cost savings on survey work for the Huntly Bypass Project. 

“Previously, we would contract four surveyors for a week each month to conduct an end of month survey. While the surveyors were collecting their data we would shut down sections of the site as it’s not safe to have anyone working near live machinery, but that of course has a knock-on effect to productivity and project costs.  

Now with the RPAS solution we can conduct the end of month surveys with two people in just 2-3 days. There is no need for the surveyors to work near machinery, which means there is no construction down time and the site is a lot safer overall.” Ed said.

Time savings and safety improvements have been a bonus to the Huntley Bypass survey team but they were also impressed by the quality of the RPAS data produced.

“I was surprised that the RPAS can produce higher quality data than traditional survey methods – I thought that at best it would match it, but never did I expect it to be better,” Ed explained.

Diversification of use – added bonus

Although purchased specifically for end of month surveys,  Ed’s team is now using the Sirius Pro on a number of other tasks because of its ease of use and the high quality data it produces.

“We now use the Sirius for jobs such as earthwork surveys and tree clearing – it’s probably used 2-3 times per week for survey work on site,” he said. “It’s proved a great return on investment.”

From L-R: Alan Bullock (Emerging Products Specialist at Position Partners), Ed Kelly (Huntly Survey Manager), George Clemens  (Surveyor), Jono Halt (Head Surveyor) and Daniel Southall (Surveyor)

Support & Training

Prior to using the Sirius Pro on site, Ed and his team attended two RPAS operator training courses, provided by Position Partners Campus in conjunction with Massey University – School of Aviation.

 “I am really happy with the training and support we have received form Jamie and the Position Partners team,” Mr Kelly said. “On-boarding with any new technology has its challenges and they have been on-hand throughout to ensure everything ran smoothly.”

 Overall, Ed feels the introduction of the RPAS has been a great success.

“The Sirius has made a huge difference to our job and the productivity benefits have been noticed throughout the business. I certainly recommend this solution to colleagues and peers for a safer and more efficient way to survey, particularly on larger projects,” he added.

Brisbane-based Main Constructions specialises in both building and civil construction projects. With such a diverse service delivery, Project Supervisor Will Sylvester explains that Local Positioning System (LPS) machine control gives his team greater flexibility than using GNSS-based solutions.

The company has recently invested in Topcon’s new LPS excavator solution, adding to its existing suite of Topcon LPS solutions for dozers, graders and a compactor.

Main Constructions employs some 50 staff, owns around 100 machines and operates throughout Brisbane and surrounding areas, from Caboolture in the North, down to Byron Bay and as far West as Toowoomba.

The company offers earthmoving services for drainage, bulk earthworks, roads, councils, schools, sports complexes, housing developments and commercial buildings.

Because of the diverse nature of its work, Mr Sylvester explains that flexibility is key in deciding on what machine control and positioning technology to use. “Our projects range from small drainage work through to 3-4 hectare sites, so we find a total station solution is better suited to the variety of work we do,” he said.

“With LPS, we can use the total station on smaller sites just as a survey tool and to check grade, or on larger sites as a full-blown, automatic 3D machine control solution. I don’t have to worry about satellite coverage either, the system can be used in any environment, which suits our needs,” he added.

Without a crystal ball to predict what projects are on the horizon, keeping costs to a minimum is key for the business. “We could have the machines working in 3D for months on a big project, or they could be sitting idle for months. The fact that we can use the total station on any range of job keeps it working for us.”

Using 3D machine control on a range of equipment delivers better results and gives greater flexibility when it comes to selecting plant for a given job. “The Topcon system enables our dozers to fine trim like a grader,” he said. “We’ve used dozers to trim a football field before, covering 20,000 square metres at 1% slope, all within 10 millimetres. The technology frees up the machines on a wider range of projects, so a grader isn’t always required for final trim work.”

Mr Sylvester said that the company’s use of Topcon machine control has evolved over the years as the business has grown and the technology has developed. “We started off with grade lasers and pipe lasers, then moved into 2D machine control technology, before getting our first LPS 3D system for a grader about six years ago.”

Since the first grader was installed with machine control, Main Construction has gone on to fit another grader, two dozers and a compactor with the same technology.

“The only thing that was missing from the equation was an excavator solution,” he explained. “I asked the team at Position Partners [Topcon’s Australian distributors] to let me know as soon as one was available and I believe I’m the first customer in the country to have it!”

Topcon’s X-53i system utilises the PS robotic total station to provide precision measurements to the excavator via a combination of three slope sensors, the new MC-i4 GNSS receiver and new GX-55 control box and a robust Inertial Measurement Unit (IMU). The result is highly accurate bucket position and elevation awareness, even when working underground, amongst tall buildings, or under bridges or tree canopies, where GNSS solutions are limited or unavailable.

Mr Sylvester is very impressed with the new solution. “The benefits it delivers are huge, it increases productivity, saves on man power and gives the operator more control over his day so he’s not having to wait for the surveyor to check his levels.

“We’ve used it for trenching and drainage work, cutting batters and spreading topsoil and I’ve found it to be a very reliable and accurate system,” he added.

When asked why the company has always chosen Topcon, Mr Sylvester said “it’s really a combination of how easy it is to use and what I can only describe as phenomenal support that we receive from the local Position Partners team.”