intelligent compaction
TRANSCRIPT
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?
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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?
