Moving construction forward with faster layout: Concrete contractors speed up site work with the Leica AP20

Work delays caused by labor shortages often block productivity on construction sites, including concrete layout work. With every challenge, however, an opportunity for innovation arises. Technology that speeds up on-site workflows and task completion, from layout to as-built checks, makes a huge difference in finishing projects on time. This is more important than ever in environments with tight timelines and multiple trades working at once.

The Leica AP20 AutoPole is an innovation transforming one-person productivity for concrete and other building construction contractors. A blend of game-changing features makes the AP20 a powerful ally for all Leica Geosystems iCON robotic total station operators with:

• Tilt compensation, for faster, flexible, and safer measuring and layout.
• Automatic pole height adjustments – simply adjust the height and the changes are automatically recorded in the software.
• Automatically relock to the right prism if the connection to the total station is interrupted (TargetID).

"I would say the time savings using the Leica AP20 AutoPole are up nearly 60%"

In this interview, Nate Bush, a layout expert and Leica iCON technology consultant, shares how the AP20 speeds up layout workflow for concrete contractors and other trades, even on the busiest sites where multiple groups are working at once. Bush discusses the biggest gains contractors can expect to see when adding the AP20 to their iCON site layout workflow, and shares bonus highlights like safety and QA/QC benefits.

Nate Bush: Career and technology development in concrete layout

Tell us about your career journey from first job on a site to concrete layout expert and construction technology consultant.

I started my career fresh out of high school doing concrete layout work for Baker Concrete, and although it was completely new to me, I enjoyed what I was doing – calculating things, taking them to the field, and watching everything get built from the layout I gave. I took pride in making sure things were correct and I had a good track record of minimal mistakes and rework, and I became the lead layout person for projects.

The first instrument I used was a Wild/Leica T1 transit. Nothing digital, so everything was done with a 100’ tape, and plumb bobs. Over the years, I eventually got a manual total station with data collector and then into robotic total stations.

I have worked on just about anything concrete related, like schools, hospitals, power plants, parking garages, and high-rises, just to name a few. The work on these projects included footer layout, large pits, elevated decks, tilt up panels, embeds, and vertical elements such as walls, elevator shafts, and columns. For most projects, our layout team supplied the project with control and as-built data.

In my last 5 years with Baker Concrete, I was the Layout Regional Manager in charge of all the field layout personnel when it came to scheduling, developing, and training. I oversaw layout on all the projects to make sure things were getting done correctly and contractually.

I started using Leica iCON robotic total stations in 2017, and over the next four years I got to know the Leica team. Through them, I learned about the opportunity for a sales engineer focusing on training customers. I knew I could share my experiences with other contractors and help them become more efficient and so, after 27 years with Baker Concrete, I joined Leica Geosystems in 2022.

I really enjoy talking and learning about all the different ways other contractors perform layout and exchanging knowledge, and I know that Leica iCON technology, including the AP20, is there to help them achieve higher efficiency.

Common concrete layout challenges and tech solutions

What are the challenges of laying out on a formed concrete deck, including plywood or pre-pour?

Normally layout in these cases is in a fast-paced environment where many other trades are working in the same area, and time is the biggest challenge. It’s all about getting the slab prepped to pour to stay on schedule. You’re trying to get work done quickly so the crews can start forming and the rod busters can start laying the rebar.

Often the rod busters, electricians, and plumbers start at the same time as you. Most of the time, the electricians and plumbers have robotic total stations as well, so having the AP20’s automatic target relock with TargetID eliminates the possibility of locking on to another prism. This saves time and frustration when you’re searching for your prism.

How has the AP20 helped you perform this task faster?

Using the AP20, points can be laid out faster by not having to worry about plumbing the rod (levelling the pole). Really, as fast as you can move the rod and process the data, you can get to your point. I would say the time savings are up nearly 60%.

Using the AP20 with the Auto point/line selection tool in Leica iCON build is also a nice workflow to speed things up. The Auto Point/Line selection tool automatically selects the most efficient next point for you, allowing you to get to the point faster.

Benefits across tasks and trades

After the concrete is poured, what other tasks do you need to perform and how does the AP20 help get these jobs done quickly?

After the concrete is poured, it's time to layout the columns and walls and take as-built shots for the slab edge, and topo the top of slab.

Just like before, when using the AP20, points can be laid out faster by not having to worry about plumbing the rod. You can get the shots by tilting the pole around the vertical rebar that may be in the way. When it comes to the slab topo, working with auto-logging based off time, you can collect the points as fast as you can walk. If set up correctly, it’s like having a walking stick while you walk across the slab.

Plus, you don’t have to worry about the rod height, the AP20 takes care of that for you. This will help eliminate any elevation errors due to wrong pole height. If you’ve been around long enough, you know what I’m talking about.

Besides the concrete contractor, who else do you see benefiting from the AP20?

The electricians and plumbers for sure. They have a lot of points to layout for hangers and sleeves. I would say they can cut their layout time by at least half. They sometimes have the most layout to do on a deck.

Improved safety and efficiency on construction sites

What other ways can the AP20 help on construction sites?

The AP20 can definitely help with construction site safety. There are times where we have to get in some tricky places to layout or as-built check a point. One example is if you need to collect a slab edge on a steel deck that has a handrail around it. You don’t have to cross the handrail to collect a point. Another would be collecting a point on a wall, whether it’s an embed or sleeve, it may eliminate the use of a ladder.

There are many use cases, and everyone does things a little differently. I think you will discover many applications where this can help you with your daily routines, and overall, you will become faster, more efficient, and in some cases, safer.

Quick takeaways

• The AP20 is revolutionising one-person layout productivity for concrete contractors in the construction industry with advanced features including tilt compensation, automatic pole height adjustments, and the ability to automatically relock to the correct prism.
• Even in busy, multi-trade environments, the AP20 enhances workflows and alleviates common concrete layout challenges.
• With the potential for broad use across different trades like electricians and plumbers, the AP20 offers a significant leap towards enhancing efficiency, reducing potential for errors, and improving safety standards on construction sites.