intelligent compaction

Intelligent Compaction (IC)

for California

Donald M. Matthews, PEPavement 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 measurement2. 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 - 300R2 = 0.94

200210220230240250260270280290300

84 86 88 90 92 94 96 98 100

Nuclear Density, % of Maximum

Stif

fnes

s In

dex,

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 RequirementsAll with GPS Locations

Intelligent Compaction Roller w/ retrofit system

GX-60

SL-R3 Receiver

Infrared Temperatur

e SensorMCi-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 1,000Miles 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, 2017Training Requirement for:

IC Quality Control TechnicianIC Data Analysis Technician

GPS Site Calibration or Localization

Grid 1

Grid 2 Established

Provided By StatePoints With Known

Coordinates

Rover Recorder

Each Point’s GPS Location Measured and Recorded

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

Pre

Map

ping

CIR

Soft Spot?

23

Filter Data

Soft Spot?

Pre

Map

ping

Filtered DataICMV < 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 Blowmm per Blow

0.615

0.6 to 1.015 to 25

> 1.0> 25

So Far Not Great CorrelationWill 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 ParametersFor ProductionUsing VETA

Anal

yzin

g On

ly

Wha

t’s N

eede

d

Filter Data

By Hand on ScreenBy Rover via a Polyline

By Alignment File

30Importing Point Tests

Use Layer Moduli for Temperature

FIRST DAY ONLYHMA => 0.15All CIR

TEST STRIPS

Intelligent Compaction Test Strips500’

Roller Coverage

Roller Pass

Steel Every Time

PneumaticEvery 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

0 2 4 6 8 10 12110.0

112.0

114.0

116.0

118.0

120.0

122.0

124.0

126.0

128.0

130.0

132.0

134.0

Break-Over Curve Data – Average of Locations

IC Test StripCIR Test StripFinal Vibe

Pass Count

Dens

ity (l

bs/ft

^3)

Does not correlate to break over as graphed

34

CIR & HMA < 0.15’ Information

Only

HMA = > 0.15’ Used to Establish

Target Value

35

CIR & HMA < 0.15’ Information

Only

HMA = > 0.15’ Used to Establish

Target Value

36

Pass

Map

ping

37

38

Required 90%

CIR & HMA

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

Tem

pera

ture

Information Only for CIR

HMA – If below specified temperature - Take Immediate Action

42

CIR Information Only

HMA 95% Required

43

CCV-

Stiff

ness

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’ WebsiteCALTRANS INTELLIGENT COMPACTION FORMS CEM-IC05     Roller Operation JITT Review ChecklistCEM-IC06     Geospatial Data and  Analysis JITT Review Checklist CEM-IC07     JITT Attendance SheetCEM-IC10     HMA Test Strip Submittals ChecklistCEM-IC11     HMA Construction Daily Submittals ChecklistCEM-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 SummaryCEM-IC16     HMA With Density Requirement Intelligent Compaction Control Report SummaryCEM-IC19     CIR Intelligent Compaction Premapping Summary ReportCEM-IC20     CIR Construction Test Strip Submittals ChecklistCEM-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 CONTRACTORSHot 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 ReportIntelligent Compaction Cold-In-Place Recycling Test Strip ProcedureSample 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