MC3D is a geometry control program that is used to automate and improve the control of casting concrete segments using the short cell casting methodology.
“As-cast” curves are evaluated at every step of the process to verify that the actual superstructure geometry follows design documents.
With MC3D Geometry Control, bridge building can occur while the substructure is being constructed thereby accelerating the erection period. This reduces the effects of concrete creep and shrinkage and the time required to gain strength in the concrete is removed from the critical path.
Pre-stressed concrete segmental bridges can be used in almost any conceivable site condition and this bridge type has extended the practical competitive economic span range of concrete bridges. Its popularity has increased steadily over the years as engineers have developed a better understanding of the time-dependent behavior of the materials (i.e. concrete creep and shrinkage, steel relaxation, etc.)
Internationally respected consultants that use MC3D include IBT, Weidlinger, Corven Engineering, Parsons Brinckerhoff, and T.Y. Lin International as well as Fru-Con, PCL, AMEC Civil, Kiewit and many more. Notable bridge projects include the following: Maumee River Bridge in Ohio (USA), Tampa Hillsborough Expressway in Florida (USA), Vivekananda Second Crossing in India, Jahra Road Project in Kuwait, and Roslyn Viaduct in New York State (USA).
- Full 3D modeling which is critical for construction accuracy
- Easy input of a “casting-set” (a cantilever or a span), including number of segments, segment definition, joint definition and camber
- Allows match cast setup based on existing cast geometry
- Provides a form to easily input survey of match cast and wet cast markers
- Printable reports of theoretical and “as-cast” coordinates
- Corrects control point coordinates with final deflections to produce casting curves
- MS Windows-based providing input and output through the use of screen forms
- Editable joint coordinates and camber values can be input via “Excel-compatible” grids
- Export capabilities to MS Excel
The match cast joint method of pre-casting concrete segments has proved to be the most versatile and reliable way for a bridge builder to fabricate pre-cast segmental bridges.
With proper geometry control, the match cast method is ideal for building structures with complex geometry.
- Provides geometry control for pre-cast concrete segmental bridges
- Enables the user to ensure that the casting is done accurately
- Automatically provides accurate casting cell set-up data, regardless of complexity of geometry
- Enables curved structures to be built properly by accurately correcting for any systematic errors in the casting process. Corrections can then be made in the next phase of casting
- Monitors concrete segment casting according to casting-curves generated using IDS Bridge Designer™ analysis software
- Computes 3D setup and “as-cast” coordinates which are critical for accuracy and difficult to compute manually
- Creates a database and maintains proper records of theoretical coordinates, survey of control points elevations, and horizontal offsets as well as final “as-cast” coordinates
Each match cast segment must be placed correctly in order to fit the precise geometry of the bridge. In this process, a 3D curve along the box centerline must be accurately followed to accommodate both horizontal and vertical alignments. Cross-fall and predicted long-term structural deflections must also be accounted for.
The final geometry and degree of success of the entire erection process is determined by both the accuracy of calculations and the proper control of relative placement in the cell.
C3D generates the complete set-up* geometry for each segment being cast, whether it is for a “starter” (usually a pier segment) or “typical” segment.
* Set-up geometry refers to the local bolts elevations and horizontal offsets in the casting-cell.