2/8/2019 Intelligent Compaction John Diel, United Contractors Midwest Intro • Overview of Technology • Our Experiences • Benefits of Technology • Examples of Projects • Future of Technology IC - Overview • Intelligent Compaction (IC) refers to the compaction of road materials, such as soils, aggregate bases, or asphalt pavement materials, using modern vibratory rollers equipped with an integrated measurement system, an onboard computer reporting system, Global Positioning System (GPS) based mapping, and optional feedback control. IC rollers facilitate real-time compaction monitoring and timely adjustments to the compaction process by integrating measurement, documentation, and control systems. IC rollers also maintain a continuous record of color-coded plots, allowing the user to view plots of the precise location of the roller, the number of roller passes, and material stiffness measurements. 1
2/8/2019 Technology-Components • On board computer • Thermometer • GPS unit • Computer program – Real time monitoring – Create reports IC - Overview • For today’s discussion the primary point of focus will center on – Color-coded plots – Location – # of passes – Stiffness – Temperature – PASS MAPPING Our experience: The beginning • 2010 began PWL spec – Volumetrics: 60% of pay – Density: 40% of pay – Opportunity for bonus (3%) 2
2/8/2019 Our experience: The beginning • Initial focus was on volumetrics – DOT mandated minimum level of training – New investment in training and equipment to increase our level of success – Fear of the unknown • Pay based on road sample • Maintaining results in much tighter range than before History: How we got here • Density lacked improvement • Density became largest liability – Stuck in a rut of old practices • PWL puts emphasis on precision and accuracy • Needed real time quality control tools Our philosophy – “5 simple steps to successful PWL paving” • Start with a valid mix design • Asphalt plant that performs as it should • Properly managed stockpiles • Secure sample that is representative of the mix being made • Apply the correct amount of compactive effort at the appropriate temperature in the appropriate timeframe 3
2/8/2019 Our experience: The demo projects • 2012, first opportunity with “IC” – To Technical – Lack of interest on our part – Roller Issues • Still in early stages of development Our experience: The demo projects • 2015, opportunity to work with “ Moba Pave IR” system – Increased awareness – Temperature variability – Paver stops, paver speed – Truck exhanges • Increased interest in technology Our experience: The demo projects • Early 2016, second opportunity with IC – Increased Interest – Expectations to high – Focused on the wrong aspects – Tried to correlate stiffness to density 4
2/8/2019 The ahha moment • Did see an improvement in consistency of density – Operator was focused on pass mapping – Utilized that feature to increase level of coverage The ahha moment Back to Basics • Simple step #5 – Apply the correct amount of compactive effort at the appropriate temperature • Don’t overthink this thing 5
2/8/2019 Moving forward • Commitment made in Summer of 16’ • Rented two pass mapping rollers to utilize in one of our operating areas – Focus was on coverage and temperature – Impacts per foot – Roller speed – Noticeable improvement in density numbers Job Summary • Four IC rollers to start 2017 and three high profile jobs – Long haul early season PWL job – Night job w/ PWL Spec – PWL job w/density issues $$$ Job Summary • I-74 Bloomington- Long haul PWL – One hour to job – Early season start – Two pass mapping breakdown rollers – Rolling to the screed in echelon – Highest pay factor to date 6
2/8/2019 Job Summary • I-55 Springfield – Night paving – Two lift mill and fill – Two Hamm 120 with HQC as breakdown rollers – Rolled in tandem – Schedule was tight – Operator learning curve a little longer than expected Job Summary • I-55 Springfield – Night paving – First lift pay factor on par with average – Second lift schedule more fluid – Operators became more comfortable with system – Surface pay factor new company high – Pass mapping should be the law on night paving Job Summary • 336 Macomb Illinois – New construction, Full-depth asphalt pavement – Three mix types – Problem with density on first two lifts of base – Late fall work – Conventional rollers – Constantly changing roller configuration 7
2/8/2019 Job Summary • 336 Macomb Illinois – Pave surface 24’ wide – Breakdown with 4 Cat rollers – One pass mapping and one conventional vibratory roller per 12’ lane – Finish with Hamm oscillatory roller Job Summary • 336 Macomb Illinois – Roll to screed to take advantage of temperature – Roll in echelon with breakdown rollers – Density pay factor of 102.8% out of possible 103% Benefits of IC - Compaction • Operator has real time information as to coverage, temperature, impact spacing and roller speed • Rolling to the screed – Thin lift pavements – Highly modified PG graded pavement – Cool weather paving – More consistency 8
2/8/2019 Benefits of IC – Real Time Quality Control • Alerts to changes in compaction conditions – Temperature – Stiffness? – Speed/Impacts per foot • Helps narrow down causes of issues – “Must identify a problem before you can fix it” • Less time spent “monitoring density” – Spend more time on proactive QC activities Benefits of IC - Personnel • Operation – Some training required, but minimal. – A couple of hours to get used to screen output – Overall, extremely well received • Utilization of younger/inexperienced workforce – Operators – QC Personell • Sense of involvement from operators Benefits of IC – Data Utilization • Post paving teaching tool – Operators – Management – Agencies • Mapping reports – Helps get to the root of a problem 9
2/8/2019 Benefits of IC - Opportunities • Help industry and agencies move forward with technology – Experimental contracts – Help develop manageable specifications Future of Technology • “Smart Technology” – More digital/wireless feedback to outside users – Alert to changes rolling conditions • Coverage • Temperature • Communication between systems – Pave IR? – Other rollers Future of Technology • Improvements on existing technology – Thermometers – GPS 10
2/8/2019 Summary • 2016: 2 rental units • 2017: 4 rental units • 2018: 4 rental units/4 owned units • 2019: 14 owned units • Best real time density quality control tool to come along since the Nuclear Density Gauge Thank You John Diel United Contractors Midwest 217-622-5967 john.diel@ucm.biz Outline Why do we need IC? FHWA IC Requirements IC Rollers What States are doing HCQ Navigator WITOS HCQ (cloud) Gateway portal Topcon & Trimble Summary 11
2/8/2019 Why do we need IC? Intelligent Definition … sound judgment and rationality What is IC? IC encompasses various products to measure, monitor and help in controlling both compaction and the compaction process 12
2/8/2019 Ultimate Goal for IC Gain the knowledge needed to develop credible and productive IC Specifications for future projects Consistency Why Intelligent Compaction? Shortcomings in the Compaction Process… Limited “On The Fly” Over or Under-Compaction Can Feedback Occur FHWA IC Requirements 13
2/8/2019 IC Roller Requirements (FHWA) IC Measurement Value (ICMV) GPS-Based Documentation System On-Board, Color-coded Display Surface Temperature Measurement System Need to be able to download data to Veta 40 IC Rollers 41 Single (Smooth) Drum Rollers Ammann-Case Caterpillar HAMM-Wirtgen Bomag Dynapac Sakai 14
2/8/2019 Double Drum Rollers Sakai Bomag HAMM-Wirtgen Caterpillar Dynapac (Atlas Copco) Volvo Roller Measurement Values Ammann Caterpillar HAMM/Wirtgen k b CMV, MDP HMV Dynapac Sakai Bomag CMV CCV E VIB Example: Counting of Passes 1-3 passes Up to 13 passes Consistency Up to 15 passes 1 pass 1 2 3 4 5 6 7 8 >8 Passes 15
2/8/2019 Comparing ICMV-values Consistent machine settings Vibration drum Type and weight Frequency (Hz) Speed Amplitude (mm) Factors influenced on Asphalt Factors: changing layer-thickness extreme transverse camber non-homogeneous subbase (cobblestone-pavement) Factors: non-homogeneous subbase (antifreeze-layer, milled wearing-course, ...) changing layer-thickness patched spots Parameters of Asphalt Compaction Cool-down- behaviour Cooling-down of the Asphalt Time 16
2/8/2019 Compaction Degree Stiffness is not the same as Density ! Data Analysis WHERE ARE WE GOING WITH IC? 17
2/8/2019 Good ? Pooled Fund Sates What are Other States Doing? 18
2/8/2019 What are Other States Doing? HCQ Navigator HCQ Navigator • System for Continuous Compaction Control • Satellite based & area wide Measurement Display Electronic Documentation • Of all relevant parameters Number of Passes Stiffness Temperature Global Position, u. v. m. 19
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