Don B. Daily Memorial Fund Grant Progress Reports

Georgia Institute of Technology

Project Title; Real-time Pro-Active Equipment Operator and Ground Worker Warning and Alert System in Steel Manufacturing
Professor:  Dr. Jochen Teizer
Mentor:  Matt D. Moore, Gerdau Cartersville Mill, Cartersville, Ga., USA

On 10 November 2011, we conducted a basic project orientation and planning discussion via conference call. The action plan created during that meeting included a site visit to the Gerdau Cartersville Mill on 14 November. Our focus would be to identify opportunities to improve pedestrian safety around mobile equipment. On 14 November, we conducted a three-hour site visit and reviewed opportunities for the project by observing the mobile equipment operations at the plant. We focused on activities that are typical of steelmaking facilities to ensure that the outcome could apply to the largest possible market.
The area we reviewed included slag pot hauling, scrap bucket hauling, finished goods  hauling (on-site) and general forklift operations. During this time, the Georgia Tech group demonstrated some new technology that may be useful in creating a system to prevent pedestrian accidents with mobile equipment. Over the next few months, we will work to test different equipment at the site to determine its usefulness in steelmaking.

Milwaukee School of Engineering (MSOE)

Project Title: Design of Smart Lockout/Tagout Hardware for the Steel Industry
Professor: Dr. Joseph Musto
Mentor: Kevin Burg, Charter Steel, Saukville, Wis., USA
The student team visited Charter Steel on 18 November 2011 to share the proposal, tour the Charter Steel facility, and discuss the practical application of a lockout device and its usage. A student team was formed: MSOE seniors Heather Bobrowitz and Tim Johnson. MSOE sophomore Fred Karsten will be assisting the team. Background
research, including a patent search, was performed. References on lockout/tagout (LOTO) procedures were provided by the LOTO product manager at Brady Corp., Milwaukee, Wis.
Detailed design specifications for the device were developed. Preliminary design activities were performed:

  • A decision was made to provide lockout redundancy by designing a mechanism to attach to a standard lockout padlock.
  • A programming platform and an interface platform were selected (MATLAB/
  • Labjack).
  • An actuator was selected for the locking mechanism (9V DC solenoid).
  • Preliminary design configurations for the locking mechanism were synthesized, and one promising design alternative was selected for development.
  • A proof-of-concept software application was developed, simulating a short version of lockout procedure automation and driving a solenoid.


As part of their senior design course requirements, a detailed design proposal was written, summarizing all work to date and providing a detailed project plan for the remainder of the development effort.

Virginia Polytechnic University

Project Title: Fall Prevention Program for Flatbed Trailers and Flatbed Trucks
Professor: Dr. Alan P. Druschitz
Mentor: G. Lynn Akers, Steel Dynamics Inc., Roanoke, Va., USA
Three members of the Virginia Tech project team met with Dr. Alan Druschitz on 12 November 2011. The meeting started with a review of the purpose of the project and timeline for completion. The group toured the Steel Dynamics facility in order for them to get an understanding of the steel manufacturing process. The group plans to meet on site again to gather specific information about fall hazards at the truck and railcar loading areas.