Computer Integrated Steel Bridge Design and Construction
Expanding Automation
Final Report

APPENDIX "E"
Brainstormed Topics

G-1 Brainstorming Ideas

This appendix documents the various ideas generated during the brainstorming sessions in the four breakout groups. Group 3 devised the subheadings herein as a preliminary step towards articulating the four Theme Areas that appear in Appendix A.

Group 1 Brainstorming Ideas

Facilitators: John Weston (TWI), Mike Beacham (NSBA)

Participants:

Owners/Gov't	Fabricators	Other
Lian Duan, Caltrans	Owen Sims, Augusta	Jack Jang, CEC
Ralph Anderson, ILDOT	Dave Johnson, PDM	Richard Sause, Lehigh U.
Milo Cress	Satoshi Tada, Kawada
	Kevin Lehr, Steelox

G1 - 1 (jj) Understand information flow

G1 - 2 (jj) Produce plans at speed of thought

G1 - 3 (ra) standardize details

G1 - 4 (os) reduce plan errors

G1 - 5 (jw) design and build contracts and creation

G1 - 6 (oa) combined fabrication and erection

G1 - 7 (ra) warehouse common plate sizes

G1 - 8 (tw) facilitate cash flow

G1 - 9 (os) reduce paper via electronic plan preparation review and approval

G1 - 10 (ra) standardize owner data format given to fabricator and contractor

G1 - 11 (sJ) simplify and speed fabrication drawing approval

G1 - 12 (os) standardize information flow (detailer / fabricator / contractor)

G1 - 13 (oj) detailer to work directly with engineer

G1 - 14 (jw) design build finance operate

G1 - 15 (rs) design for automation (detail)

G1 - 16 (os) simplify standards and detail options (for instance x-frames)

G1 - 17 converter to change any plans to details that fit any fabricators automated processes

G1 - 18 (dt) each state / owner establish practices details, products

G1 - 19 be competitive with steel and prestressed

G1 - 20 reduce labor intensiveness of steel fabrication and construction

G1 - 21 Decrease requirements / increase use of Ultrasonic test (how to record)

G1 - 22 Confidence and lower cost of NDT

G1 - 23 Weld sensing (smart) used instead of after the fact NDT

G1 - 24 Use parameters during process to enable acceptance (min after weld NDT)

G1 - 25 Quality control QA integrated in process

G1 - 26 Reduce cost of certification or use of Certification vs. NDT

G1 - 27 Standardize depth of intensity of inspection between steel and concrete and FRP

G1 - 28 Education (owner / consultant / shop drafting)

Group 2 Brainstorming Ideas

Facilitators: Ronnie Medlock (TXDOT), Geoff Booth (Mabey)

Owners/Gov't	Fabricators	Other
Ken Hurst, KSDOT	Jim DeLong, DeLong's	Tarsem Jutla, Caterpillar
Paul Rimmer, NYSDOT	Dan Moore, Industrial Steel	Tsuyoshi Sakura, Kawada
Lou Triandafilou, FHWA	Dennis Noernberg, AFCO	Toshio Omura, Kawada
		Dale Thomas, NSBA

G2 - 1 National standardization (Development and implementation)

G2 - 2 Bidding / Contracting system

G2 - 3 Customer Focus (include life cycle costs / values) (design / build) (DBFO)

G2 - 4 Performance specification instead of method specification / Contract alternatives

G2 - 5 Performance standards (shift to risk including fit / assembly)

G2 - 6 File transfer (DGN)

G2 - 7 CA Modelling

G2 - 8 Gather and inform about existing technology / training exposure

E-3

Group 3 Brainstorming Ideas

Facilitators: Karl Frank (U. Texas), Lynn Iaquinta (NSBA)

Owners/Gov't	Fabricators	Other
John Edwards, ILDOT	Jim O'Neill, Cleveland	N. Kannan, U. at Buffalo and Contour Steel
John Randall, OHDOT	Bob Graham, Steadfast
Tom Quinn, TNDOT	Alex Lowery, Pgn Coatings
	Richard Inserra, Stupp Bros.

AUTOMATED SHOP

G3 - 2 acceptance of virtual laydown

G3 - 6 standard acceptance of automated fabrication methods

G3 - 7A automated NDT with document support (with high reliability)

G3 - 9 designers flexibility during fabrication to change details to fit automation of selected shop

G3 - 23 automated record keeping of quality parameters in shop and acceptance by owner

G3 - 33 how do we qualify robotic-weld in bridges?

G3 - 38 Training of workforce for automated positions

G3 - 39 Continuing Advancement of automated processes creates a barrier (my investment is given free to next guy)

DEVELOPMENT OF STANDARD BRIDGE SYSTEM

G3 - 1 standard bridge complete package

G3 - 3 standard bridge deck prefab system and design

G3 - 4 modular construction (snap or connect standard parts) (reduce construction time)

G3 - 18 short span standard rural stock bridges (drop in place)

G3 - 19 strategic initiatives with precast concrete industry

G3 - 20 acceptance of material that is pre-fabricated

G3 - 21 letting of multiple bridge fabrication packages (1 year of work vs. 1 bridge)

ELECTRONIC DATA SYSTEMS

G3 - 7 acceptance of electronic documentation in lieu of traditional paper documents

G3 - 8 communication links between fabricators and designers

G3 - 30 archivable medium for future use of electronic documents

G3 - 42 Standard Protocol for Electronic Data Transfer

G3 - 43 Life cycle cost database for future maintenance program

DESIGN AUTOMATION STEPS

G3 - 5 common national steel details

G3 - 7 acceptance of electronic documentation in lieu of traditional paper documents

G3 - 8 communication links between fabricators and designers

G3 - 13 designers need to be aware of mill rolling availability

G3 - 14 steel interchange site to exchange information on steel availability (AISI)

G3 - 15 cost data base (idea of cost / sq ft or lb/ sq ft to designers

G3 - 25 incentive program for designer, - economy, life-cycle quality (value)

G3 - 26 designer training in fabrication and construction (on-site)

G3 - 28 designer / detailer / fabricator / contractor to use one accepted computer model

G3 - 35 standard plate products to create fewer rolling sizes (allow some stock piling) (lump sizes)

G3 - 36 Database of upcoming events by year and type to allow fabrication / production some project planning (market forecast)

SPECIFICATIONS & CONTRACTS

G3 - 6 standard acceptance of automated fabrication methods

G3 - 7 acceptance of electronic documentation in lieu of traditional paper documents

G3 - 9 designers flexibility during fabrication to change details to fit automation of selected shop

G3 - 10 revise contractual arrangements to allow flexibility

G3 - 11 certification program acceptance (Requiring Certification)

G3 - 12 improve certification process with more categories (higher standards)

G3 - 20 acceptance of material that is pre-fabricated

G3 - 23 automated record keeping of quality parameters in shop and acceptance by owner

G3 - 29 comprehensive as built plans with details as constructed

G3 - 31 National acceptance of coating systems

Group 4 and Unattributed Brainstorming Ideas

Facilitators: Tom Siewert (NIST), Bill McEleney (NSBA)

Owners/Gov't	Fabricators	Other
Henry Pate, TNDOT	Tom Guzek, Trinity	Dave Mackey, CEC
Krishna Verma, FHWA	Bob Smith, Mabey	Yoshihiro Kanjo, NKK
Todd Niemann, MNDOT	James Tyvand, Addison	Chitoshi Miki, Tokyo Inst. of Technology
George Christian, NYSDOT

G4 - 1 Need to increase SPEED of construction

G4 - 2 Reduce initial COST of structures

G4 - 3 Certification based on quality of work and work force

G4 - 4 Standardize transport requirements across country for oversize, overweight loads

G4 - 5 Elimination of fabricator weld acceptance testing (PQR's)

G4 - 6 Cost of robot - savings (research data)

G4 - 7 Deliver man-hours per ton through automation

G4 - 8 Research on entire cycle of bridge construction (initiation of design through final punch list); Evaluate ability to change time of process

G4 - 9 Standardize repair details

G4 - 10 Coating system suitable for automation

Appendix D | Table of Contents | Appendix F