Level up your dozer with grade control


Here’s why grade control is a must-have for today’s construction projects

Imagine trying to level dirt and relying on guesswork to get it perfect. In the past, many construction projects struggled with accuracy and delays because of manual grading errors. But today, grade control systems for dozers are readily available.

Contractors may select a basic two-dimensional (2D) grade control system or a more sophisticated three-dimensional (3D) grade control system. With the power of GPS, sensors and smart technologies, grade control can help improve accuracy, efficiency and productivity on rough or fine-grading projects.

A 2D grade control system is like using a high-tech level. It helps dozers stay at the right height and slope as they move across a job site. The height and slope measurements are typically achieved with lasers, although 2D systems can also be used without lasers.

“The 2D systems allow operators to work off a single plane — either flat, single or dual-slope,” said Moo Young Park, Senior Product Manager at Develon North America.

“They help to ensure that the blade is at the correct height and angle for the job. However, since it only measures two dimensions, height and angle, it doesn’t account for the overall terrain or changes in elevation over the entire site.”

Basic 2D is ideal for projects where general depth and slope are needed, such as grading a road or levelling a site. A 3D grade control system takes things to the next level. It uses GPS or other positioning systems to track the dozer’s exact position on the site and compares it to a digital model of the project.

“Grade control systems use information gathered from global navigation satellite systems (GNSS), GPS, laser, sonic or total station technology,” Park said. “This allows for adjustments in real-time based on both height and the entire terrain’s layout.”

A 3D system is typically used for more complex projects where precise work is needed, like elevation, slope and terrain. A 3D system is ideal for tasks, like grading for road and highway construction or earthmoving projects.

An additional monitor may be required in the cab for 2D and 3D grade control systems to display real-time visual data, such as machine positioning and elevation, enabling the operator to make precise adjustments. This second monitor helps enhance workflow by providing separate views for machine performance and grade control information, reducing the need to toggle between screens. Some 2D grade control systems, including those without lasers, use the standard monitor in the dozer.

Boosting efficiency

With modern 2D and 3D grade control systems, operators no longer must stop and adjust their dozer constantly to rely on surveyors to measure elevations. You can automatically adjust the dozer blades in real-time based on precise digital data. 

“By using GPS, lasers or sensors, these systems provide real-time feedback, allowing for more accurate grading,” Park said. “In a 2D system, automatic adjustments based on sensor data ensure that the blade maintains the correct height and slope throughout the grading process.” 

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3D grade control systems integrate GPS technology and digital terrain models (DTMs) that show the planned surface shape, so the machine knows exactly how to move to achieve the correct grade.

“By comparing the dozer’s position and blade settings to a detailed 3D model of the site, these systems ensure that grading aligns accurately with the project’s design specification,” Park said. “This real-time feedback and automatic adjustment mean that the grading can be completed to the required standards in fewer passes. As a result, operators can avoid the need for extensive rework.”

Enhanced safety

By using grade control systems, it can reduce the likelihood of errors. A 2D system improves safety by automating the grading process. It ensures precise adjustments to the blade’s height and slope, minimizing the risk of creating unstable or uneven surfaces.

3D grade control systems enhance safety by leveraging advanced technologies like GPS and geofencing. 

“GPS tracks the dozer’s exact location, while geofencing creates virtual boundaries to keep the equipment away from restricted or dangerous areas,” Park said. “This helps ensure the dozer operates within a safe, designated zone.”

Collision avoidance systems, commonly integrated into 3D grade control systems, detect potential obstacles and issue alerts. Digital Terrain Models (DTM) provide detailed site data to help operators safely navigate complex job sites and avoid hazardous areas.

Training advice

Before implementing 2D and 3D grade control systems, Park recommends operators follow proper training. It helps dozer operators learn how to input the correct settings, so the dozer works as intended, leading to more precise grading and fewer errors.

“Operators need to learn how to set up and calibrate these components and how to adjust the blade’s height and angle to achieve the desired grade,” Park said. “Instruction typically includes both manual and automatic modes and how to switch between them.”

Training is more complex for 3D grade control systems due to the integration of GPS technology and DTMs. 

According to Park, the learning curve varies depending on the technology, but spending at least two hours a day for about two weeks will give operators a general understanding of 2D and 3D grade control systems.

Maintenance 

Since 2D and 3D grade control systems have highly sensitive sensors, GPS equipment and electronic components must be in good working condition to function accurately, it’s essential to follow proper maintenance.

“For 2D grade control systems, maintenance involves checking and calibrating sensors and lasers,” Park said. 

“Clean and properly align sensors and lasers to ensure accurate measurements. Then inspect the mechanical components of the system, such as the blade and hydraulic controls, to confirm they are functioning correctly and are free of wear or damage.”

For 3D grade control systems, maintenance is crucial because they integrate complex software, DTMs and multiple data sources. Failure in any one component can throw off the entire system’s functionality.

“Inspect the GPS receivers and antennas for signal integrity and connectivity, as any issues can affect positional accuracy,” Park said.

“The software that manages DTMs and provides real-time data also requires regular updates to make sure it operates effectively and integrates correctly with the hardware.”