Computer Integrated Steel Bridge Design and Construction
Expanding Automation
Final Report

APPENDIX "C"
Pre-Workshop Survey
Summary of Responses

Summary of Responses Based on 15 responses

What is your primary area of interest/expertise:

Information Technology	1
Design	7
Fabrication (including Robotics & Welding)	6
Erection	1
Other Fabrication Inspection	1

What is your secondary area of interest/expertise, if applicable:

Information Technology	1
Design	2
Fabrication (including Robotics & Welding)	4
Erection	3
Other Servicing & Automation Eng- Shop Detail Drawings Administration	3

Identify the following:

High-Payoff (short term) Opportunities For Increased Automation	Gaps, Needs & Potential Obstacles to Implementing These Opportunities
Electronic Submittal of Shop drawings	a) ability to make designer comments during review on the electronic copy b) ability to stamp and approve shop drawings & provide approved & current copies to required personnel
Standardize details to enhance automation	a) getting all owners to agree upon common details
Electronic shop drawings:streamline drwg transfer, use for mat'l takeoffs/tracking	Must agree on standard file format(pdf, TIFF), authentication & protection
Improve shop documentation and info flow in shop (weld proc. NDT, paint, bar codes)	Educate users (ongoing process) and make available for smaller shops
Information transfer/storage/retrieval for shop owners, including exchange	Standard file format & protocol, insuring medium won't be abandoned in future
Nondestructive testing and production monitoring for both QC and QA	System cost, owner acceptance/trust in results, common stds, small shop access
Automated layout for cutting, NC cutting and drilling	Initial cost for new equipment is high, requires retraining of employees
Electronic Submittal/Approval of Shop Drawings	Liability & Security questions
Combining analysis, design & geometry software together	Weak link is current software
Repeat elements - cleats, stairs, supports	Design for repeat product
	IT knowledge and strategies Data-detail
Data Tracking	Low pay for Information
Web Management	Technology People
Shop Layout	Low Pay for Engineers Poor or no Management Support
Faster Construction Lower Costs	Communication between design software & fabricator software
Computer Based design and fabrication	Fabrication considerations at design stage, particularly at structural details
	Code requirements should be improved
Autonomous Welding (less supervision by welders) Automated inspections	Sensor Integration
Automation of Girder fit & weld CNC	Is the Equipment available?
Detailing software for bridges
Uniform Details	Varying state practices
Medium and Longer term Opportunities for Automation	Gaps, Needs & Potential Obstacles to Implementing These Opportunities
Using shop drawings for direct production control (mat'l select, cut, weld, paint)	Develop various systems; "cost" of shop errors, correcting errors found in field
Flexibility to handle wide range of work (beams, I-grdrs, tubs, haunches, curves)	System limits may exclude configurations and thwart innovative design concepts
Workers more productive and have broader responsibilities with automation	Fewer workers, older empl resist tech trng (or unable), lose knowledge/manual skills
For repair & widening jobs, integrate new and existing shop drawings	Major thrust in the next 50 yrs. Very labor-intensive unless "intelligent scanning"
Increased automation of all welding processes, automated fit-up and assembly (web to flange and stiffener assembly)	Variability of girder size and many changes in flange size is an obstacle to automation
Use of electronic design info in fabrication	Design software limitations. Enough interest in industry to see benefits
Automated contract drawing preparation	Lack of software
Changed connection design	Code acceptance Designer acceptance Appropriate equipment Design rules
Columns and beams	Product volumes
Modular buildings	Designs
Failing Infrastructure	Poor Scoping
	Lack of Timely use of resources
Bridge Programs
Synergistic considerations from structural design to fabrication/erection procedures - CAD/CAM	1) CAD/FEA design connecting? Not consider manufacturing effects in eng. Welding/cutting 2) E.g. welding sequence effects that significantly improve fatigue performance ????
Yes, Welding robot System	Engineering for integration of Welding System
Robotics for Welding	Software and Hardware not able to handle submerged arc welding process
Robotics for welding Conn & total CNC program @ Eng. Or shop floor
Fewer plate thickness variations which could lead to more uniform designs and details. Also this could lead to more advanced plate purchasing contracts which may speed up projects.	Designers wanting to "optimize" all portions of girder

Other comments, suggestions and questions:

• How does automation affect the design specification and procedures?
• "Automation" is a very generic term, so the panel must be cautious to avoid assigning inappropriate goals. Reducing labor costs with fewer, less qualified shop personnel is not applicable. Fabricators must also understand that this will be an evolutionary process, with changes, improvements and (inevitable) corrections occurring at irregular intervals. These modifications will have some negative effects on production and costs.
• We should see what is being done in the building industry.
• In order to implement Robotics in bridge building the expanded use of MIG, inner shield and or Dual Shield welding process will be required.

Appendix B | Table of Contents | Appendix D