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Intelligent Compaction

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California Asphalt Pavement Association
California Asphalt Pavement Association

Presentation by Don Matthews on Intelligent Compaction for the CalAPA Spring Asphalt Pavement Conference & Equipment Expo, April 20-21, 2016, in Ontario, CA.

Engineering
1 of 48
Intelligent Compaction (IC) for California Donald M. Matthews, PE Pavement Recycling Systems, Inc.
 Caltrans first required Intelligent Compaction (IC) on Cold In-place Recycling (CIR) project To date 15 completed, 14 in-process or planned  Now used on State projects for the HMA overlays on CIR  Soon for most HMA projects To date 15 completed, 22 in-process or planned  In the future on bases and sub-bases Overview
Intelligent Compaction (IC) FHWA Definition 1. Vibratory rollers with measurement/control system  Measurement system, ex. material stiffness and temperature  Control system automatically changes parameters (amplitude, force direction etc.) based on measurement 2. GPS based documentation systems corrected to survey level accuracy  Continuous recordation of materials stiffness and temperature  Continuous recordation of corresponding roller location  Color-coded mapping of location, stiffness and temperature
Vibratory roller with measurement/control system Roller has input sensors from accelerometers that measures reaction force Reaction force converts to resistance or stiffness Roller input sensors from infrared measured surface temperature Stiffness – Intelligent Compaction Measurement Value (ICMV)
Goal - Stiffness vs Density y = 6 x - 300 R2 = 0.94 200 210 220 230 240 250 260 270 280 290 300 84 86 88 90 92 94 96 98 100 Nuclear Density, % of Maximum StiffnessIndex,MN/m 2 But not sure we will get there Depth of stiffness measurements cannot be depth controlled. Measurement readings will change depending on frequency, speed and amplitude.
GPS Based Documentation Systems
GPS – Global Positioning System must be accurate to within 0.25 ft, 3 in, 7.5 cm Satellite direct only accurate to approximately 30 ft./10 m Must use one of following to improve accuracy:  Satellite - Based Augmentation Correction System  Network Real Time Kinematic (Network RTK)  GPS Base Station (RTK)
Satellite - Based Augmentation Correction System
Network Real Time Kinematic (Network RTK) Correction From Cellular Radio Towers Transmitted Via Radio Waves
GPS Base Station Onsite Transmitted Via Radio Waves Base Station Will Work in Poor Cellular Areas Less Issues with Lost Signal Due to Blocked Satellite View
IC Roller Requirements All with GPS Locations
Intelligent Compaction Roller w/ retrofit system GX-60 SL-R3 Receiver Infrared Temperatur e Sensor MCi-3 and Satel Radio Accelerometer
Automated machine guidance roller (AMGR) w/ retrofit system GX-60 SL-R3 Receiver Infrared Temperatur e Sensor MCi-3 and Satel Radio
Roller Display  Pass Count Mapping  Temperature  Stiffness  All Changeable by Roller Operator
IC/GPS Vendor Software Point Test and GPS Data GX-60 Roller Data IC/GPS Vendor Cloud USB IC/GPS Vendor Software Perform Analysis on How Well the Contractor Did (Quality Control)
Mapping – Pass Counts Using Cloud Can View Real Time At Our Desks 1,000 Miles Away or On a Cell Phone or Tablet on the Job
Temperature
Intelligent Compaction Specifications
Just In-Time Training (JITT) Required for All Projects January 1, 2017 Training Requirement for: IC Quality Control Technician IC Data Analysis Technician
GPS Site Calibration or Localization Grid 1 Grid 2 Established Provided By State Points With Known Coordinates Rover Recorder
 Evaluation of existing pavement conditions through pre-mapping  Use steel roller with low vibration and low frequency  Hope is will identify potential “soft” spots  “Soft” spots can be further investigated during coring and dynamic cone penetrometer (DCP) operations  Hesitation from manufactures to pre-map due to possible damage to rollers • An alternative to pre-mapping is perform a lot more coring and DCP CIR Pre-mapping For Stiffness
PreMappingCIR Soft Spot?
23 Filter Data
Soft Spot? PreMapping Filtered Data ICMV < 10 Have to Hand Record Locations
Dynamic Cone Penetrometer (DCP) DCP Acceptable Marginal Poor Each Set of 10 Blows < 6 Inches <150 mm 6 to 10 inches 150 mm to 250 mm > 10 Inches > 250 mm Inches per Blow mm per Blow 0.6 15 0.6 to 1.0 15 to 25 > 1.0 > 25 So Far Not Great Correlation Will Not Miss Soft Spots – But If Pre- Mapping Shows a “Soft” Spot – Not Necessarily an Issue During Construction
During Construction  Passes  Temperature  Stiffness (Intelligent Compaction Measurement Value - ICMV)
Setting Analysis Parameters For Production Using VETA
AnalyzingOnly What’sNeeded
Filter Data By Hand on Screen By Rover via a Polyline By Alignment File
30 Importing Point Tests Use Layer Moduli for Temperature
 FIRST DAY ONLY  HMA => 0.15  All CIR TEST STRIPS
Intelligent Compaction Test Strips 500’ RollerCoverage RollerPass Steel Every Time Pneumatic Every Time Steel Recording - CIR CIR - 3 Nuclear Tests Per Coverage x 11 Coverages + Final 7 X 2 Tests Per Location = 80 Tests! HMA - 3 Nuclear Tests Per Coverage x 6 Coverages + Final 7 X 2 Tests Per Location = 50 Tests!
Steel Drum Roller Pneumatic Roller 110.0 112.0 114.0 116.0 118.0 120.0 122.0 124.0 126.0 128.0 130.0 132.0 134.0 0 2 4 6 8 10 12 Density(lbs/ft^3) Pass Count Break-Over Curve Data – Average of Locations IC Test Strip CIR Test Strip Final Vibe Does not correlate to break over as graphed
34
35
36 PassMapping
37
38
 Use the data to see how much over or under compaction that we have on projects Goal – Improve overall compaction during construction
We traditionally tested here Now want to test here at transition areas
41 Temperature Information Only for CIR HMA – If below specified temperature - Take Immediate Action
42
43 CCV-Stiffness Information Only for CIR & HMA < 0.15’ HMA => 0.15’ - 10% or below Target Value -Verify compaction with nuclear gauge 20% or below Target Value - Reestablish new value within 500’ section
Final Output To RE Electronic Data Files – Every Three Days PDF Reports - Daily
Caltrans’ Website CALTRANS INTELLIGENT COMPACTION FORMS CEM-IC05 Roller Operation JITT Review Checklist CEM-IC06 Geospatial Data and Analysis JITT Review Checklist CEM-IC07 JITT Attendance Sheet CEM-IC10 HMA Test Strip Submittals Checklist CEM-IC11 HMA Construction Daily Submittals Checklist CEM-IC12 HMA Intelligent Compaction Quality Control Report Checklist CEM-IC13 HMA With Density Requirement Intelligent Compaction CEM-IC15 HMA Method Compaction Intelligent Quality Control Report Summary CEM-IC16 HMA With Density Requirement Intelligent Compaction Control Report Summary CEM-IC19 CIR Intelligent Compaction Premapping Summary Report CEM-IC20 CIR Construction Test Strip Submittals Checklist CEM-IC21 CIR Construction Daily Submittals Checklist CEM-IC22 CIR Intelligent Compaction Quality Control Report Checklist CEM-IC24 CIR Intelligent Compaction Quality Control Report Summary CEM-IC25 CIR Intelligent Compaction Quality Control Report Summary INTELLIGENT COMPACTION GUIDELINES FOR CONTRACTORS Hot Mix ASPHALT (HMA) Intelligent Compaction Hot Mix Asphalt Test Strip Procedure Sample Intelligent Compaction Hot Mix Asphalt Test Strip Report Sample Intelligent Compaction Hot Mix Asphalt Compaction Quality Control Report COLD-IN-PLACE RECYCLING (CIR) Sample Intelligent Compaction Cold-In-Place Recycling Mapping Report Intelligent Compaction Cold-In-Place Recycling Test Strip Procedure Sample Intelligent Compaction Cold-In-Place Recycling Test Strip Report Sample Intelligent Compaction Cold-In-Place Recycling Compaction Quality Control Report http://www.dot.ca.gov/hq/construc/ic/
Conclusions and Recommendations  Appears to be a powerful tool to improve compaction – For QC Only  But IC is a work in progress  Still learning the most effective way to get better compaction and use information provided  Some improvements could make analyses more effective – VETA 4.0 Just Came Out Few Days Ago?
Thank You! Questions? dmatthews@pavementrecycling.com (951) 934-4753

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Intelligent Compaction

  • 1. Intelligent Compaction (IC) for California Donald M. Matthews, PE Pavement Recycling Systems, Inc.
  • 2.  Caltrans first required Intelligent Compaction (IC) on Cold In-place Recycling (CIR) project To date 15 completed, 14 in-process or planned  Now used on State projects for the HMA overlays on CIR  Soon for most HMA projects To date 15 completed, 22 in-process or planned  In the future on bases and sub-bases Overview
  • 3. Intelligent Compaction (IC) FHWA Definition 1. Vibratory rollers with measurement/control system  Measurement system, ex. material stiffness and temperature  Control system automatically changes parameters (amplitude, force direction etc.) based on measurement 2. GPS based documentation systems corrected to survey level accuracy  Continuous recordation of materials stiffness and temperature  Continuous recordation of corresponding roller location  Color-coded mapping of location, stiffness and temperature
  • 4. Vibratory roller with measurement/control system Roller has input sensors from accelerometers that measures reaction force Reaction force converts to resistance or stiffness Roller input sensors from infrared measured surface temperature Stiffness – Intelligent Compaction Measurement Value (ICMV)
  • 5. Goal - Stiffness vs Density y = 6 x - 300 R2 = 0.94 200 210 220 230 240 250 260 270 280 290 300 84 86 88 90 92 94 96 98 100 Nuclear Density, % of Maximum StiffnessIndex,MN/m 2 But not sure we will get there Depth of stiffness measurements cannot be depth controlled. Measurement readings will change depending on frequency, speed and amplitude.
  • 7. GPS – Global Positioning System must be accurate to within 0.25 ft, 3 in, 7.5 cm Satellite direct only accurate to approximately 30 ft./10 m Must use one of following to improve accuracy:  Satellite - Based Augmentation Correction System  Network Real Time Kinematic (Network RTK)  GPS Base Station (RTK)
  • 8. Satellite - Based Augmentation Correction System
  • 9. Network Real Time Kinematic (Network RTK) Correction From Cellular Radio Towers Transmitted Via Radio Waves
  • 10. GPS Base Station Onsite Transmitted Via Radio Waves Base Station Will Work in Poor Cellular Areas Less Issues with Lost Signal Due to Blocked Satellite View
  • 11. IC Roller Requirements All with GPS Locations
  • 12. Intelligent Compaction Roller w/ retrofit system GX-60 SL-R3 Receiver Infrared Temperatur e Sensor MCi-3 and Satel Radio Accelerometer
  • 13. Automated machine guidance roller (AMGR) w/ retrofit system GX-60 SL-R3 Receiver Infrared Temperatur e Sensor MCi-3 and Satel Radio
  • 14. Roller Display  Pass Count Mapping  Temperature  Stiffness  All Changeable by Roller Operator
  • 15. IC/GPS Vendor Software Point Test and GPS Data GX-60 Roller Data IC/GPS Vendor Cloud USB IC/GPS Vendor Software Perform Analysis on How Well the Contractor Did (Quality Control)
  • 16. Mapping – Pass Counts Using Cloud Can View Real Time At Our Desks 1,000 Miles Away or On a Cell Phone or Tablet on the Job
  • 19. Just In-Time Training (JITT) Required for All Projects January 1, 2017 Training Requirement for: IC Quality Control Technician IC Data Analysis Technician
  • 20. GPS Site Calibration or Localization Grid 1 Grid 2 Established Provided By State Points With Known Coordinates Rover Recorder
  • 21.  Evaluation of existing pavement conditions through pre-mapping  Use steel roller with low vibration and low frequency  Hope is will identify potential “soft” spots  “Soft” spots can be further investigated during coring and dynamic cone penetrometer (DCP) operations  Hesitation from manufactures to pre-map due to possible damage to rollers • An alternative to pre-mapping is perform a lot more coring and DCP CIR Pre-mapping For Stiffness
  • 24. Soft Spot? PreMapping Filtered Data ICMV < 10 Have to Hand Record Locations
  • 25. Dynamic Cone Penetrometer (DCP) DCP Acceptable Marginal Poor Each Set of 10 Blows < 6 Inches <150 mm 6 to 10 inches 150 mm to 250 mm > 10 Inches > 250 mm Inches per Blow mm per Blow 0.6 15 0.6 to 1.0 15 to 25 > 1.0 > 25 So Far Not Great Correlation Will Not Miss Soft Spots – But If Pre- Mapping Shows a “Soft” Spot – Not Necessarily an Issue During Construction
  • 26. During Construction  Passes  Temperature  Stiffness (Intelligent Compaction Measurement Value - ICMV)
  • 29. Filter Data By Hand on Screen By Rover via a Polyline By Alignment File
  • 30. 30 Importing Point Tests Use Layer Moduli for Temperature
  • 31.  FIRST DAY ONLY  HMA => 0.15  All CIR TEST STRIPS
  • 32. Intelligent Compaction Test Strips 500’ RollerCoverage RollerPass Steel Every Time Pneumatic Every Time Steel Recording - CIR CIR - 3 Nuclear Tests Per Coverage x 11 Coverages + Final 7 X 2 Tests Per Location = 80 Tests! HMA - 3 Nuclear Tests Per Coverage x 6 Coverages + Final 7 X 2 Tests Per Location = 50 Tests!
  • 33. Steel Drum Roller Pneumatic Roller 110.0 112.0 114.0 116.0 118.0 120.0 122.0 124.0 126.0 128.0 130.0 132.0 134.0 0 2 4 6 8 10 12 Density(lbs/ft^3) Pass Count Break-Over Curve Data – Average of Locations IC Test Strip CIR Test Strip Final Vibe Does not correlate to break over as graphed
  • 34. 34
  • 35. 35
  • 37. 37
  • 38. 38
  • 39.  Use the data to see how much over or under compaction that we have on projects Goal – Improve overall compaction during construction
  • 40. We traditionally tested here Now want to test here at transition areas
  • 41. 41 Temperature Information Only for CIR HMA – If below specified temperature - Take Immediate Action
  • 42. 42
  • 43. 43 CCV-Stiffness Information Only for CIR & HMA < 0.15’ HMA => 0.15’ - 10% or below Target Value -Verify compaction with nuclear gauge 20% or below Target Value - Reestablish new value within 500’ section
  • 44. Final Output To RE Electronic Data Files – Every Three Days PDF Reports - Daily
  • 45.
  • 46. Caltrans’ Website CALTRANS INTELLIGENT COMPACTION FORMS CEM-IC05 Roller Operation JITT Review Checklist CEM-IC06 Geospatial Data and Analysis JITT Review Checklist CEM-IC07 JITT Attendance Sheet CEM-IC10 HMA Test Strip Submittals Checklist CEM-IC11 HMA Construction Daily Submittals Checklist CEM-IC12 HMA Intelligent Compaction Quality Control Report Checklist CEM-IC13 HMA With Density Requirement Intelligent Compaction CEM-IC15 HMA Method Compaction Intelligent Quality Control Report Summary CEM-IC16 HMA With Density Requirement Intelligent Compaction Control Report Summary CEM-IC19 CIR Intelligent Compaction Premapping Summary Report CEM-IC20 CIR Construction Test Strip Submittals Checklist CEM-IC21 CIR Construction Daily Submittals Checklist CEM-IC22 CIR Intelligent Compaction Quality Control Report Checklist CEM-IC24 CIR Intelligent Compaction Quality Control Report Summary CEM-IC25 CIR Intelligent Compaction Quality Control Report Summary INTELLIGENT COMPACTION GUIDELINES FOR CONTRACTORS Hot Mix ASPHALT (HMA) Intelligent Compaction Hot Mix Asphalt Test Strip Procedure Sample Intelligent Compaction Hot Mix Asphalt Test Strip Report Sample Intelligent Compaction Hot Mix Asphalt Compaction Quality Control Report COLD-IN-PLACE RECYCLING (CIR) Sample Intelligent Compaction Cold-In-Place Recycling Mapping Report Intelligent Compaction Cold-In-Place Recycling Test Strip Procedure Sample Intelligent Compaction Cold-In-Place Recycling Test Strip Report Sample Intelligent Compaction Cold-In-Place Recycling Compaction Quality Control Report http://www.dot.ca.gov/hq/construc/ic/
  • 47. Conclusions and Recommendations  Appears to be a powerful tool to improve compaction – For QC Only  But IC is a work in progress  Still learning the most effective way to get better compaction and use information provided  Some improvements could make analyses more effective – VETA 4.0 Just Came Out Few Days Ago?

Editor's Notes

  1. Intelligent Compaction