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Fundamentals of Intelligent Compaction (IC)
By Rafiq Darji, P.E.
FHWA, FL
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What is Intelligent Compaction (IC) ?
• IC in simple form: “ it is nothing but addition of
Science and Technology into the Art of Compaction”
• Compaction is one of the most important processes in roadway construction
• It plays very critical role in achieving long lasting pavements
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FHWA Pooled Fund IC Project 2008-11
• Demonstrate HMA IC Technologies to Agencies and Industry
• Develop Experience and Expertise within DOT Organizations
• Assist the DOT’s in the development of Quality Control Specifications
• Identification and prioritization for further research and data analysis
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IC-TPF States
MN
KS
TX MS
IN
NY
PA
VA
MD
ND
GA
WI
2008 2009 2010
Mini demo
2 demos
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Why Intelligent Compaction?
• Compaction is one of the most important processes in roadway construction.
• It is essential in achieving high quality, uniform compacted materials, which better ensures long-lasting performance.
• Efficiency of operation: Compaction effort only applied when and where needed.
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Why Intelligent Compaction?
Shortcomings in Conventional Compaction
Limited On-The-Fly Feedback
Over- Compaction
Under- Compaction
Leads to Distresses
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Why Intelligent Compaction? Shortcomings in Conventional Acceptance
Limited Number of Locations
After Compaction is Complete
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100 % Coverage
1 / 1,000,000
Courtesy of Caterpillar
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• How IC Rollers Work: IC machines are vibratory rollers with accelerometers mounted on the axel of drums, global positioning system, Infra-red temperature sensors (for asphalt), and on-board computers that can display color-coded maps in real-time to track roller passes, asphalt surface temperatures, and stiffness of compacted materials.
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Intelligent Compaction
Continuous Measurement
System
Global Positioning
System GPS
Onboard Report System
Courtesy of Bomag
Temperature Sensors
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HAMM Double Drum IC System
Accelerometer
GPS Receiver
HCQ GPS Navigator
Temperature Sensors Control Panel
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Color-Coded On-Board Display
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GPS Precisions
• Autonomous:10 -15m • DGPS: 0.5 - 5m • Float : 1 m • Fixed :1-3 cm
Courtesy of Trimble
Not to scale
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GPS Accuracy for IC
Unspecified Source
1 2 3 4
IC Pass
Counts
Poor GPS Good GPS
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Single Drum IC Rollers
Bomag
Caterpillar Ammann-Case
Dynapac Sakai
HAMM-Wirtgen
Soils and Subbase
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Double Drum IC Rollers
Bomag
Caterpillar Sakai
HAMM-Wirtgen
Asphalt
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Auto-Feedback System
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Improved Rolling Pattern Before
After
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Test Sections/Target Values
• Dimensions of Test Sections • 75 m X 6 m for Soils • 300 – 500 Tons for HMA
• Evaluations for Each Lift Materials with cores
• Fixed Settings of IC Compaction
• Determination of Target Roller Passes and IC-MV
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Benefits Observed by Contractors Real-time feedback to operators
GPS System Transferrable
• Increased Accountability • Coverage
• Prevent Gaps between passes
• Compaction Curves • ↓ Number of Passes
• Identify Weak Areas • Moisture Control (Grading Applications)
• View Temp (HMA applications)
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Benefits of IC Continuous record of material stiffness, coverage and temperature
Improved uniform and consistent densities
Identification of soft or non-compactable areas
Increased productivity (knowing when and where to apply what effort of compaction)
Reduction of over compaction and under compaction
Encourages best roller compaction practices
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How IC Works
Courtesy of HAMM/Wirtgen
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Intelligent Compaction (Total of 25 Projects)
2004 – Mn/ROAD, Demo
2005 – US 53, Granular (Taconite)
– US 14, Non-Granular, Granular
– US 12, Base
2006 – TH 64, Granular
– Mn/ROAD, Misc – Non-Granular
– I-494 Valley Creek Road, Granular Shoulders
2007 – US 10, Staples, Granular
– US 10, Detroit Lakes, Non-Granular, Granular
– TH 60, Non-Granular, Granular
– TH 36, Non-Granular, Granular
2008 – CSAH 2, Non-Granular, Base
– CSAH 4, Base, HMA (Breakdown)
2008 (cont) • CSAH 40, HMA (Breakdown)
• Mn/ROAD, Non-Granular, Granular, Base, Base, FDR, SFDR
• TH 60, Non-Granular, Granular
• TH 71, HMA (Breakdown)
2010 • TH169, HMA (Breakdown)
• TH 13, HMA (Breakdown)
• TH16, SFDR
• TH 610, Granular
• CSAH 10, Granular (Compactor Rejected)
2011 • TH35, HMA (Pneumatic, Static, Vibratory)
• TH 30, FDR, SFDR (Padfoot)
• TH 83, FDR (Padfoot)
• TH 212, FDR (Padfoot)
• TH 23, Granular (Compactor Rejected)
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IC Retrofit
Presently only one manufacture who supplies retrofit equipment Retrofit can be installed on any compactor from any manufacturer, used or new machines Can be transferred between many machine types
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Retrofit Single Drum IC Roller
Volvo with Trimble Retrofit
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Retrofit Double Drum IC Roller Conventional Roller
with Trimble Retrofit
Printer
Control Box GNSS Receiver
Temperature Sensor
Temperature Sensor
Courtesy of Trimble
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CA
AZ
CO
NM
TX
OK AR
LA
MO KY
AL GA
FL
VA
OH
MI
VT AK
MT
NV
ME
WA
OR
UT KS
ID WY
ND
SD
MN
NE
WI
IA IL IN
MS
TN SC
NC
WV
PA
NY
CT NJ DE MD DC
MA NH
RI
CA
HI
PR
Committed
National Leader
Source: EDC 2 Implementation Plans (June 6)
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More information
• Every Day Counts – http://www.fhwa.dot.gov/everydaycounts/
• Intelligent Compaction – http://www.intelligentcompaction.com/