Falling Weight Deflectometer Calibration Center and Operational Improvements: Redevelopment of The Calibration Protocol and Equipment

APPENDIX E. SPECIFICATIONS AND DRAWINGS

SPECIFICATIONS

1. General specifications

1.1 Description

The FWD calibration hardware set includes one accelerometer box assembly, one geophone calibration stand assembly, one seismometer calibration stand assembly, one reference load cell assembly, and one ball-joint anchor assembly. In some cases, only one of the stands is ordered for a hardware set. Drawings of each item are included by reference as part of this specification. Table 13 shows a list of drawings for each assembly.

1.2 Materials

The required materials are described in the referenced drawings (see table 13).

1.3 Manufacturing Requirements/Conflicts

The contractor should provide all materials needed to manufacture one complete hardware set unless otherwise noted.

Additional manufacturing requirements are listed with the specifications for each individual part or subassembly. If there is a conflict between the drawings and the specifications, the specifications should govern.

1.4 Surface Smoothness

An industrial quality surface finish is desired. All machined surfaces should have a smoothness of 63 μ-inches (0.0016 mm) or less.

1.5. Mill Surface Finish

The mill surface finish on aluminum extrusions should be inspected for nicks, cuts, and dings, and a reasonable effort should be made to smooth out the defects before anodizing. Avoid removal of excessive amounts of material in this process.

1.6 Anodizing

Where anodizing is required on aluminum parts, all parts should be thoroughly cleaned and anodized according to MIL-A-8625F Type 2 Class 2 (Black). All parts should have a cosmetically homogeneous appearance after being anodized.

If for any reason parts must be stripped to remove the anodizing, a phosphoric chromic solution should be used, followed by surface polishing to remove pitting and achieve a 63-μ-inch (0.0016-mm) smoothness.

1.7 Loctite®

Where Loctite® is required, medium strength #242 Loctite® should be used.

1.8 Delivery/Acceptance

The contractor should provide a guaranteed delivery time. All parts should be assembled and delivered to the address provided by the purchasing agency.

The purchasing agency should have 7 days after delivery to check parts for proper alignment and fit as well as finish, as required. If the part or parts are not acceptable, the contractor should replace them at no additional charge.

1.9 Method of Payment

Payment should be authorized upon acceptance of the complete order.

2.0 Accelerometer Box Assembly Specifications (Drawing CLRP-AB01)

2.1 Description

The accelerometer box assembly is designed to house a Silicon Designs Model 2220 accelerometer as well as to provide some EMI shielding and additional physical protection. The box assembly mounts on the calibration platter, the geophone calibration stand, and the seismometer calibration stand by means of two #10-24 knurled head thumbscrews through the lip on the box.

2.2 Materials

All of the materials for the accelerometer box assembly are described in the referenced drawing and the bill of materials.

2.3 Manufacturing Requirements

The accelerometer box top and bottom, the box assembly, and calibration platter should be assembled together to ensure proper alignment prior to delivery to the customer. The accelerometer box top and bottom should also be fitted into the geophone calibration stand and the seismometer calibration stand, and the fit should be a firm coupling to both stands without any gaps or interference between mating surfaces.

Each aluminum part should be cleaned and then anodized in accordance with section 1.5. Upon delivery, the customer should finish assembly of the box by mounting the accelerometer and the Amphenol receptacle, mating the box top and bottom, mounting the bubble level, and attaching the leveling screws to the calibration platter.

3.0 Ball-joint Anchor Assembly Specifications (Drawing CLRP-BJ01)

3.1 Description

The ball-joint anchor assembly is the means by which the calibration stands are coupled to the test pad during FWD calibration. The clamp provides a solid mechanical connection to the calibration stand, and the Techno/Sommer KG60 ball-joint provides some rotational freedom, making the stands easier to use as well as providing for some moment compensation.

3.2 Materials

All of the materials for the ball-joint anchor assembly are described in the referenced drawing and the bill of materials.

3.3 Manufacturing Requirements

Upon delivery, the customer should finish assembly of the anchor by attaching the base bar and the clamp base to the ball-joint. The clamp should be attached to the clamp base, and the rest stop should be mounted to the anchor assembly.

4.0 Geophone Calibration Stand Assembly Specifications (Drawing CLRP-GCS01)

4.1 Description

The geophone calibration stand assembly is designed to hold up to 10 geophones from the Dynatest®, Carl Bro, KUAB, or JILS FWD. The accelerometer box (see section 2.0) mounts to the middle shelf in the stand. The stand is attached to the ball-joint anchor (see section 3.0) during the calibration procedure.

4.2 Materials

All of the materials for the geophone calibration stand are described in the referenced drawing and the bill of materials.

4.3 Manufacturing Requirements

Prior to welding the stand, the parts should be cleaned and dry fitted together. A qualified Tungsten inert gas (TIG) welder should perform all of the welding. After welding, the stand should be cleaned and then anodized in accordance with section 1.5.

After delivery, the customer should finish assembly by adding handles and bubble levels as needed and use Loctite® to keep the connector pin in place.

5.0 Seismometer Calibration Stand Assembly (Drawing CLRP-SCS01)

5.1 Description

The seismometer calibration stand assembly is designed to hold up to 10 KUAB seismometers in a 2-column configuration. Additionally, the accelerometer box (see section 2.0) mounts to the middle shelf in the stand. The stand is attached to the ball-joint anchor (see section 3.0) during the calibration procedure.

5.2 Materials

All materials for the seismometer calibration stand assembly are described in the referenced drawing and the bill of materials.

5.3 Manufacturing Requirements

Prior to welding the stand, the parts should be cleaned and dry fitted together. A qualified TIG welder should perform all of the welding. After welding, the stand should be cleaned and anodized in accordance with section 1.5.

After delivery, the customer should finish assembly by adding handles and bubble levels as needed and use Loctite® to keep the connector pin in place.

6.0 Geophone Adapter Specifications

6.1 Description

The geophone adapters are used to couple three different types of geophones to the geophone calibration stand (see section 4.0) and allow for ease of movement of the geophones within the stand.

6.2 Materials

All materials for the geophone adapters are described in the referenced drawing and the bill of materials.

6.3 Manufacturing Requirements

The geophone adapters should be dry fitted into the geophone calibration stand sensor shelves to ensure a loose sliding fit in the slotted hole on each shelf.

7.0 Reference Load Cell Assembly (Drawing CLRP-LC01)

7.1 Description

The reference load cell is a custom load cell designed specifically for FWD calibration. The load cell allows all brands of FWD to be calibrated with a 11.7-inch (300-mm) load plate.

7.2 Materials

All materials for the reference load cell assembly are described in the referenced drawings and bill of materials.

7.3 Manufacturing Requirements

Prior to welding the base to the body, the parts should be cleaned and dry fitted together. A certified TIG welder should perform all of the welding. After welding, the load cell parts should be cleaned and anodized in accordance with section 1.5, with the exception of the measuring links (Drawing CLRP-LC04), which should not be anodized.

After delivery, the customer should have the measuring links gauged by a qualified strain gauge installer. Then, the load cell should be fully assembled, conditioned, and calibrated according to AASHTO R33-03.⁽¹⁰⁾

COMPLETE DRAWING LIST

Table 14 provides a complete drawing list for the accelerometer box, ball-joint anchor, geophone calibration stand, seismometer calibration stand, geophone adapters, reference load cell, and data acquisition cables. The drawings follow in the same order in this appendix.

ACCELEROMETER BOX

Figure 47. Photo. Accelerometer box.

Figure 48. Illustration. CLRP-AB01 accelerometer box assembly.

Figure 49. Illustration. CLRP-AB02 accelerometer box bottom.

Figure 50. Illustration. CLRP-AB03 accelerometer box top.

Figure 51. Illustration. CLRP-AB04 calibration platter.

Figure 52. Illustration. CLRP-AB05 accelerometer wiring.

BALL-JOINT ANCHOR

Figure 53. Photo. Ball-joint anchor

Figure 54. Illustration. CLRP-BJ01 ball-joint anchor assembly.

Figure 55. Illustration. CLRP-BJ02 clamp.

Figure 56. Illustration. CLRP-BJ03 clamp base.

Figure 57. Illustration. CLRP-BJ04 base bar.

Figure 58. Illustration. CLRP-BJ05 rest stop.

GEOPHONE CALIBRATION STAND

Figure 59. Photo. Geophone calibration stand.

Table 26. Hardware costs for BM-GCS geophone calibration stand.

Figure 60. Illustration. CLRP-GCS01 geophone stand assembly.

Figure 61. Illustration. CLRP-GCS02 geophone stand side rail.

Figure 62. Illustration. CLRP-GCS03 geophone top shelf.

Figure 63. Illustration. CLRP-GCS04 geophone stand bottom shelf.

Figure 64. Illustration. CLRP-GCS05 geophone stand sensor shelf.

Figure 65. Illustration. CLRP-GCS06 geophone stand accelerometer shelf.

Figure 66. Illustration. CLRP-GCS07 geophone stand handle holder.

Figure 67. Illustration. CLRP-GCS08 geophone stand connector pin.

SEISMOMETER CALIBRATION STAND

Figure 68. Photo. KUAB seismometer calibration stand.

Figure 69. Illustration. CLRP-SCS01 seismometer stand assembly.

Figure 70. Illustration. CLRP-SCS02 seismometer stand side rail.

Figure 71. Illustration. CLRP-SCS03 seismometer stand top shelf.

Figure 72. Illustration. CLRP-SCS04 seismometer stand sensor shelf.

Figure 73. Illustration. CLRP-SCS05 seismometer stand standoff.

Figure 74. Illustration. CLRP-SCS06 seismometer stand bottom shelf.

Figure 75. Illustration. CLRP-SCS07 seismometer stand handle holder.

Figure 76. Illustration. CLRP-SCS08 seismometer stand connector pin.

Figure 77. Illustration. CLRP-SCS09 seismometer stand shelf subassembly.

Figure 78. Illustration. CLRP-SCS10 seismometer stand accelerometer shelf.

Figure 79. Illustration. CLRP-SCS11 seismometer stand accelerometer shelf subassembly.

GEOPHONE ADAPTERS

Figure 80. Illustration. CLRP-GA01 geophone adapter assemblies.

Figure 81. Illustration. CLRP-GA02 Carl Bro adapter.

Figure 82. Illustration. CLRP-GA03 JILS adapter.

Figure 83. Illustration. CLRP-GA04 KUAB adapter.

REFERENCE LOAD CELL

For a photo of the reference load cell, see figure 104.

Table 36. Equipment and hardware items required for the BM-LC reference load cell.

Vendor Part Number	Item	Vendor	Quantity
92196A327	Socket head cap screw, 18-8 SS, ¼-inch 28 thread, 1¼-inch length	McMaster-Carr®	6
92196A323	Socket head cap screw, 18-8 SS, ¼-inch 28 thread, 7⁄8-inch length	McMaster-Carr®	6
92210A337	Flat head socket cap screw, 18-8 SS, ¼-inch 28 thread, 1¼-inch length	McMaster-Carr®	6
91737A072	Fillister head Phillips machine screw, 18-8 SS, #4-40 thread, ¼-inch length	McMaster-Carr®	4
654-MS3102A14S-5P	Amphenol box mount receptacle, MS3102A-14S-5P	Mouser Electronics	1
N2A-13-S054Y-350	Transducer-class strain gauges, general purpose 90-degree rosette, 1⁄8-inch gauge length, 350  resistance	Vishay Micro-Measurements	12
1 inch = 25.4 mm

Figure 84. Illustration. CLRP-LC01 load cell assembly.

Figure 85. Illustration. CLRP-LC02 load cell body.

Figure 86. Illustration. CLRP-LC03 base plate.

Figure 87. Illustration. CLRP-LC04 measuring link.

Figure 88. Illustration. CLRP-LC05 cover plate.

Figure 89. Illustration. CLRP-LC06 foot.

Figure 90. Illustration. CLRP-LC07 guide fingers.

Figure 91. Illustration. CLRP-LC08 interior connector wiring.

Figure 92. Illustration. CLRP-LC09 strain gauge layout.

Figure 93. Illustration. CLRP-LC10 bridge wiring.

DATA ACQUISITION SYSTEM

Table 39. Equipment and hardware items required for BM-DAQ.

Vendor Part Number	Item	Vendor	Quantity
Model 2310B	Vishay 2310 signal conditioner	Vishay Micro-Measurements	1
2310-A20 Kit	Vishay stabilizer bar and line cord accessory package	Vishay Micro-Measurements	1
KUSB-3108	Keithley 16-bit USB DAQ	Keithley	1
571-5-1634504-1	BNC panel mount radio frequency (RF) connector	Mouser Electronics	1
566-8723	Belden 8732, two-pair shielded cable, 25-ft sections	Mouser Electronics	4
654-PT06A-14-15P-SR	Amphenol PT06A-14-15P <SR> straight plug	Mouser Electronics	2
654-PT06A-10-6S-SR	Amphenol PT06A-10-6S <SR> straight plug	Mouser Electronics	1
654-MS3106F-14S-5S	Amphenol MS3106A 14S-5S straight plug	Mouser Electronics	1
2062325	Resistors, 2.2 k , ¼ Watt, 5 percent carbon film	Radio Shack®	2
2103233	Terminal strip, 5 position	Radio Shack®	1
2062543	Pushbutton, momentary, 1.5 A	Radio Shack®	1
278-0232	Enclosure, black plastic	Allied Electronics	1
91772A123	Pan head Philips machine screw, 18-8 stainless steel, #5-40 x 5⁄16-inch length	McMaster-Carr®	1
91841A006	Nut, 18-8 stainless steel, #5-40 thread, 7⁄64-inch height	McMaster-Carr®	1
510-0194	BNC to BNC cable, 10-ft length	Allied Electronics	1
523-T3324-501	Amphenol circular DIN connector	Mouser Electronics	1
546-1455T2202	Hammond enclosure, aluminum extruded, 8.66 x 6.3 x 2.1 inches	Mouser Electronics	1
523-T3327-100	Amphenol circular DIN connector, panel mount	Mouser Electronics	1
571-5-1634504-1	BNC panel mount RF connector	Mouser Electronics	1
523-T3327-100	Amphenol circular DIN connector, panel mount	Mouser Electronics	1
523-T3324-501	Amphenol circular DIN connector	Mouser Electronics	1
546-1455T2202	Hammond enclosure, aluminum extruded, 8.66 x 6.3 x 2.1 inches	Mouser Electronics	1
	Velcro, hook and loop, adhesive backed, industrial strength	Local hardware store
1 inch = 25.4 mm 1 ft = 0.305 m

Figure 94. Illustration. CLRP-DAQ01 Vishay 2310 to DAQ cable.

Figure 95. Illustration. CLRP-DAQ01A Vishay 2310B BNC to DAQ cable.

Figure 96. Illustration. CLRP-DAQ01B Vishay 2310B BNC to DAQ cable (stock parts).

Figure 97. Illustration. CLRP-DAQ02 Vishay to load cell cable.

Figure 98. Illustration. CLRP-DAQ03 accelerometer signal cable.

Figure 99. Illustration. CLRP-DAQ04 pushbutton to KUSB DAQ cable and cable wiring.

Figure 100. Illustration. CLRP-DAQ06 KUSB protection wiring.

Figure 101. Illustration. CLRP-DAQ07 KUSB enclosure rear panel.

Figure 102. Illustration. CLRP-DAQ08 KUSB enclosure front panel.