Piling operations in marine environments have traditionally been labor-intensive, time-consuming, and prone to delays due to weather conditions, environmental constraints, and the need for precise alignment. However, with the integration of GPS machine control and real-time data-sharing platforms, the game has changed. These technologies are streamlining workflows, improving accuracy, and reducing costs, even on the most challenging projects.
A prime example of this transformation is the ongoing construction of the Alligator River Bridge in North Carolina. This $450 million project involves replacing an aging swing-span bridge with a modern, fixed-span high-rise structure. Despite its complexity and environmental challenges, the team has achieved unprecedented efficiency and precision in piling operations by leveraging cutting-edge technology. Here’s how they did it—and how you can apply the same principles to your projects.
1. Use GPS Machine Control for Precision and Efficiency
One of the standout technologies used in the Alligator River Bridge project is the Leica MC1 software platform, which integrates GPS machine control with 3D modeling. This approach eliminates the need for traditional survey-intensive methods, where crews manually position barges and rely on visual cues.
“Once the barge is in the right place, the tablet is then used as a guide to position the piles and get the right angles for their placement,” explains Jason, the project survey manager. “What is key to the success of this approach is the visualization that comes with using the tablet, as the crews see precise pile positions overlaid on the screen.”
This level of precision is critical, especially when working in muddy ground without a rock base. The technology ensures that piles are installed within defined tolerances, even in challenging conditions like rough waters. “We can now drive three to four piles a day, compared with just one or two under traditional methods,” says Luke, a superintendent with over 25 years of piling experience.
Takeaway: Invest in GPS machine control systems to improve accuracy, streamline workflows, and accelerate your piling operations.
2. Leverage Real-Time Data Sharing for Seamless Collaboration
Another key to the project’s success is the use of Leica ConX, a cloud-based platform that allows real-time data sharing between on-site crews, project managers, and even clients. This ensures that everyone works with “one version of the truth,” as Jason puts it.
“On a job like this, you can’t just drive back to the office, as all the action is on the water,” Jason explains. “With ConX, crews can download the latest model to the tablet and upload information from the barge. Similarly, if we need support from Leica, we can grant one of their experts access to the tablet for troubleshooting.”
This real-time connectivity has been a game-changer, enabling the team to address issues quickly and maintain progress despite the project’s remote and challenging location.
Takeaway: Use cloud-based platforms to enable real-time collaboration and troubleshooting, reducing downtime and ensuring alignment across all stakeholders.
3. Plan Around Environmental Constraints
Proactively addressing environmental regulations is key to maintaining progress on complex projects, especially in protected areas. For the Alligator River project, the team carefully planned their operations around the fish spawning season, which required a work stoppage during the summer. By integrating GPS technology and leveraging their expertise, they maximized productivity ahead of the July 15 moratorium.
“Because we knew we were going to lose a couple of months in the summer, we put on a big push to drive as many piles as possible before the moratorium,” Jason shares. This forward-thinking strategy not only minimized the impact of environmental constraints but also allowed the team to use the downtime for preparation, ensuring a seamless transition to the next phase of the project.
Takeaway: Use technology to optimize productivity within restricted timeframes and plan ahead to mitigate the impact of environmental constraints.
4. Train Your Team for Success
While technology is a powerful enabler, its success ultimately depends on the people using it. At Alligator River, the team invested in training to ensure operators could fully leverage the new systems.
“In the past, we relied heavily on surveyors with total stations to shoot in piles,” Luke notes. “Now we’ve eliminated that process by training our foremen and other operators directly on the system.” This not only improved efficiency but also empowered the team to adapt to the evolving demands of the project.
Preston, a piling team member, adds: “Everything is in this computer to get those piles exactly where they need to be. For us guys on the rig, it feels like working on dry land, even though we’re out here on the water.”
Takeaway: Invest in comprehensive training to ensure your team can effectively integrate technology into their workflows.
5. Combine Experience with Technology
Despite advances in GPS and real-time data sharing, experienced operators remain essential to successful piling operations. “Experienced operators and committed teams bring the skills and judgment needed to apply technology in real-world conditions,” Luke explains.
By pairing seasoned expertise with tools like Leica machine control, the team has significantly increased productivity, driving three to four piles per day compared to one or two using traditional methods. This synergy between technology and experience ensures precision, efficiency, and adaptability, even in challenging environments.
Takeaway: Pair experienced operators with advanced tools to maximize the benefits of technology in piling operations.
6. Harness Heavy Equipment and Technology for Maximum Impact
The Alligator River project showcases how the integration of cutting-edge technology with robust equipment can handle even the most demanding piling operations. The “Super Rig,” a triple-barge system carrying a Triple 8 ringer crane, provides the stability and lifting capacity needed to manage piles weighing up to 143,000 pounds and spanning up to 125 feet in length.
Preston, one of the piling team members, describes the process: “When you are ready to put in a pile, the process begins with what we call the driving cap. It’s a 10,400-pound block of metal that transfers the hammer’s force onto each pile. Between the hammer and cap sit cushion blocks, which absorb shock and protect the pile head.”
The Leica MC1 plays a pivotal role here, ensuring precise alignment of the pile’s head and toe. “The system displays both toe and head positioning of each pile, with operators adjusting until both align ‘in the green,'” Preston explains. This precision is critical for angled batter piles and other complex configurations.
Takeaway: Combine advanced machine control with heavy equipment to tackle large-scale projects efficiently and accurately.
7. Bridge Technology and Expertise for Superior Results
While technology has revolutionized piling operations, seasoned professionals remain indispensable. Their expertise ensures that technology is applied effectively in real-world conditions.
Luke, with 25 years of piling experience, emphasizes this point: “Experienced operators and committed teams bring the skills and judgment needed to apply technology in real-world conditions. The support and training we benefited from were critical to rolling out this approach.”
This sentiment is echoed by Jason, who credits the team’s success to a combination of advanced tools and the crew’s deep understanding of their craft. “Of course, it all comes down to having some very experienced team members on the rigs as they totally understand how to do this job and how to look after the equipment itself,” he says.
Takeaway: Pair experienced operators with advanced tools to maximize the benefits of technology in piling operations.
Building Bridges to the Future
The Alligator River Bridge project is a testament to what can be achieved when cutting-edge technology meets seasoned expertise. By integrating GPS machine control, real-time data sharing, and heavy equipment, the team has not only improved the speed and accuracy of piling operations but also set a new standard for efficiency and collaboration in the industry.
For companies looking to optimize their own piling operations, the lessons from this project are clear: invest in the right technology, train your team, and leverage the experience of seasoned professionals. By doing so, you can overcome environmental constraints, reduce costs, and deliver projects faster and safer than ever before.
As Luke aptly puts it, “Investing in these systems makes the whole industry better. It’s a whole lot better now than it was when I started out.”
To speak with a heavy construction expert who can guide you on your technology journey, contact us.
Contributor: Peter Haddock
