2/8/2019 Intelligent Compaction John Diel, United Contractors - - PDF document

2/8/2019 1

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

• nboard 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.

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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%)

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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

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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

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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

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Moving forward

• Commitment made in Summer of 16’
• Rented two pass mapping rollers to utilize in one
• f 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

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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

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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

• scillatory 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

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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

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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

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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

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Why do we need IC?

… sound judgment and rationality

Definition

Intelligent What is IC?

IC encompasses various products to measure, monitor and help in controlling both compaction and the compaction process

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Ultimate Goal for IC

Gain the knowledge needed to develop credible and productive IC Specifications for future projects Consistency

Shortcomings in the Compaction Process…

Limited “On The Fly” Feedback Over or Under-Compaction Can Occur

Why Intelligent Compaction?

FHWA IC Requirements

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40

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

41

IC Rollers

Bomag Caterpillar Ammann-Case Dynapac Sakai HAMM-Wirtgen

Single (Smooth) Drum Rollers

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Bomag Caterpillar Sakai HAMM-Wirtgen Volvo

Double Drum Rollers

Dynapac (Atlas Copco)

Roller Measurement Values

Caterpillar CMV, MDP Dynapac CMV Bomag EVIB Sakai CCV Ammann kb HAMM/Wirtgen HMV Passes

4 3 1 2 5 6 7 8 >8 Up to 15 passes

Up to 13 passes 1 pass 1-3 passes

Consistency

Example: Counting of Passes

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Frequency (Hz) Amplitude (mm) Type and weight Vibration drum Speed

Comparing ICMV-values

Consistent machine settings

Factors influenced on Asphalt

Factors: non-homogeneous subbase (antifreeze-layer, milled wearing-course, ...) changing layer-thickness patched spots Factors: changing layer-thickness extreme transverse camber non-homogeneous subbase (cobblestone-pavement)

Cool-down- behaviour

Time

Cooling-down

• f the Asphalt

Parameters of Asphalt Compaction

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Stiffness is not the same as Density!

Compaction Degree Data Analysis

WHERE ARE WE GOING WITH IC?

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Good ?

Pooled Fund Sates What are Other States Doing?

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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.

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HCQ Navigator Components

HAMM Compaction Meter

Measurement by means of the acceleration sensor on the drum Recording of drum acceleration Evaluation of soil reaction proportion Calculation of rigidity = Hamm Measurement Value (HMV)

HCQ Navigator – components

HAMM Temperature Meter

Measurement of asphalt surface temperature Measurement by means of infrared sensor Display in °C or °F

HCQ Navigator – components

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HAMM Temperature Meter

HCQ Navigator – components

Panel PC

Touchscreen Display, storage of all values Dust-proof and splash-proof Operating temperature range

• 36 °C to +60° C

Wi-Fi, Bluetooth Fast, high-capacity SSD disk

HCQ Navigator – components

Satellite receiver

Extremely accurate determination of drum position with the aid of correction signals

free of charge: Egnos (Europe), Waas (North America) requiring licence: Omnistar HP / XP

Plug & Play function if HCQ provision present Receives GPS & GLONASS No base station necessary Correction signals available in different accuracy classes by purchase of licence (via customer service)

HCQ Navigator – components

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Satellite receiver

Adapter kits for third-party receivers (Topcon HiPer II, Topcon HiPer SR, Leica) Other kits possible on submission of project request

HCQ Navigator – components

Overview

Project preparation Analysis functions User-friendly system interface Multilingual documentation Animations, tools and links Identical software on the panel PC and on the office computer

HCQ Navigator software

Visual representation

Panel PC – example: Split screen asphalt construction (passes, temperature)

HCQ Navigator software

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Data exchange via Wi-Fi

Networking of up to five machines Representation of the collectively achieved compaction progress

HCQ Navigator software

Machine 1 + Machine 2 + Machine 1 + 2

Software – two variants for data evaluation

HCQ Navigator office software VETA (standard analysis software used by US authorities)

HCQ Navigator software

VETA (from the USA)

Visualisation of compaction information with charts and maps

HCQ Navigator software

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VETA

Standardised display and analysis of area-wide dynamic compaction control Reference data obtained for example with a Troxler probe and supplemented with geo-data Standardised import format Standardised reports Comparison with existing planning data

HCQ Navigator software

• Rover Menu

Input of coordinates measured with external equipment (i.e. field rover) Direct comparison with HCQ checkpoints to determine distance between points Data export for daily GNSS accuracy verification

HCQ Navigation Software (new)

• Color Palettes

New, cleaned up design Possibility to save, rename and delete user defined palettes. VETA color palettes

HCQ Navigation Software (new)

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Roller Network

Machine 2 Machine communication Real time data transfer Automatic synchronization after connection loss

WITOS – HCQ (using the cloud)

WITOS HCQ integration

New license model (focused on HCQ cases machine number H900…) Live data transfer over WITOS SIM card

When you start recording data it is automatically sent up to the cloud This is also how we can see real time rolling on mobile device, tablet or office PC.

Simplified Panel-PC Installation

No direct customer access to windows functionalities Faster and easier PC setup Better HCQ integration

HCQ Navigation Software

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Live data transfer from HCQ Navigator Panel PC to WITOS HCQ

Transmission via WITOS SIM-Card

Administration

License and user administration according to WITOS standards

Machine license Multiple User roles available

Access over Wirtgen Group Portal (single sign-on with FleetView possible)

All servers within WITOS cluster

WITOS Support

Wirtgen America - Nashville

General

Overview map

Enter through www.witos.com Enter user name & password Simple project and status

• verview according to the

projects location Different search options also available

WITOS HCQ Portal

Overview table

Project and status administration Multiple search options Column sorting Set project visibility for restricted users (~DOT)

WITOS HCQ Portal

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• Live Monitor

Real-time monitoring

• f work in progress

Display of: drum positions Pass count Temperature HMV Can also select which roller to see if more than

• ne are set up to record to

the same job through WITO HCQ

WITOS HCQ Portal

• Live Monitor

VETA Export possible at any time

WITOS HCQ Portal VETA

Single Software for uniform display and analysis

• f CCC and Paver temperature data.

Specification of a uniform import format for all system vendors Combination of reference data taken by load plates, Troxler probes, insertion thermometers,

• etc. and their corresponding geo data

Alignment with existing planning data Creation of uniform reports New Cloud connectivity for direct data import Software is available for free download www.intelligentcompaction.com Developer: The Transtec Group

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VETA Statistics HCQ VRS Modem Components

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Process Data Gateway Process Data Gateway

Overview

Standardised CAN interface Provision of sensor data for integration into external compaction documentation systems Central power supply for external compaction documentation systems Measurement data capture with HAMM sensor technolog

Process data gateway (option)

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Process data gateway (option)

Process Data Gateway

Customer benefits

Independence from the roller manufacturer A system that also works for mixed roller fleets Easy integration into telematic systems, online portals and existing continuous compaction control systems

Process data gateway (option)

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Data Extent

Amplitude Frequency HMV Vibration Status Asphalt surface temperature Machine speed Driving direction

Process Data Gateway

Overview Data transmission  Data provided: Amplitude & frequency Rigidity value HMV Vibration on/off Asphalt surface temperature Direction of travel Travel speed Machine data, fleet management data, such as consumption or tank levels, are not transmitted. Data transmission only locally to the machine

Process data gateway (option) HCQ Options

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The Future of IC Topcon

• MC-i4

– GNSS included – Radio included (DUHF / FH915) – Cell included (Sitelink)

• Display

– GX-55 – GX-75

• Sensor kit

– IR temperature sensors – Accelerometer

Compaction kit - Topcon

• MC-i4

– GNSS included – Radio included (DUHF / FH915) – Cell included (Sitelink)

• Display

– GX-55 – GX-75

• Sensors:

– OEM connection (CAN-bus)

Compaction kit for OEM (Hamm, Bomag)

OEM connection

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Enabling Shortcuts

ICMV indictor Configurable bar Configurable text

• verlay

Customizable as-builts mapping colors, showing updates of ALL rollers live Automatic forward/reverse detection with

• verride

Cycle as-built type (ICMV, Temp, Passes) Toggle as-built mapping Other roller

• 6.5”

GX-55 and GX-75

• 10” @ higher resolution
• Built-in light bars
• Common buttons next to the display

New reports

Based on station range Pass fail analysis Reports per lot SiteLink

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Task Compaction Pass count report

Task Compaction Pass count report

Coverage %

• Min. pass

condition Area covered with just pass count Pass / Fail analysis

• Max. pass

condition Cumulative pass count

The Future of IC Trimble

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The Application

Trimble Machine Manager wirelessly communicates to one or more machines to deploy jobs, check progress on running machines, and get alerts from machines that have encountered obstacles. It is the central location that allows one person to control many machines.

Trimble Machine Manager Application

Technologies

TRIMBLE MACHINE MANAGER BRAIN LIDAR CAMERA CAMERA RADAR RADAR GNSS AUTOSENSE SPEED CONTROL ECM MOTORDRIVE

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IC Enhancements

Aftermarket and OEM Integration

Aftermarket IC systems working with factory sensors Makes working with a mixed fleet easier with standardized technology Manage coordinate systems in more flexible ways

Training

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Training

Critical to the success of the project and future projects Both State & Contractors Manufacturers Software Downloading Data VETA Software

Up the Version 5.0

For More Info on IC…

IntelligentCompaction.com info@IntelligentCompaction.com

Website Email

(512) 451-6233

Phone

Summary

Why IC?

QC Tool Consistency Permanent Record Pre-mapping

IC Rollers

Several Manufacturers Different values

FHWA Requirements

System Requirements VETA software for States

States Involved

33 Total (more getting involved)

Training (Key) Overall Benefit:

Improved Pavement performance!

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Thank you very much! Thank You

Session Evaluations/PDH’s

• Complete session feedback in

mobile app, your comments appreciated.

• Professional Development

Hours logged in session feedback.

See you again at:

• CONEXPO-CON/AGG 2020

– March 10-14, 2020 – Las Vegas, NV – 140+ education sessions

• World of Asphalt 2021

– March 16-18, 2021 – Atlanta, GA – 120+ education sessions

#WorldofAsphalt