2/14/2014 GOOD MORNING PROVOST CONTRACTING LTD. AUGUST 19,2013 WAWA ONTARIO CANADA HAWBAKER QUALITY MISSISSIPPI QUALITY ASPHALTCONFERENCE JANUARY 16-17, 2014 JACKSON, MISSISSIPPI 1 2/14/2014 39th OHIO ASPHALT PAVING CONFERENCE FEBRUARY `12TH,2014 FAWCETT CENTER THE OHIO STATE UNIVERSITY 34th WEST VIRGINIA ASPHALT PAVING CONFERENCE FEBRUARY 12TH,2014 C. W. CHUCK DEAHL FAT BOY ROLLER L.L.C. FAT BOY ROLLER L.L.C. CW CHUCK DEAHL cdeahl@fatboyroller .com ACHIEVING PROPER COMPACTION • WHY? • HOW? • DO’S DON’T’S • NEW DEVELOPMENTS WHY? • 1. COMPACTION IS THE LAST STEP IN ASPHALT PAVEMENT CONSTRUCTION • 2. COMPACTION NOT ONLY AGFFECTS PAVEMENT PERFORMANCE; BUT OFTEN DETERMINES IF WE GET BONUS DENSITY AND SMOOTHNESS 2 2/14/2014 IMPORTANCEOFCOMPACTION • IMPROVE MECHANICAL STABILITY • IMPROVE RESISTANCE TO PERMANENT DEFORMATION • REDUCE MOISTURE PENETRATION • IMPROVE FATIGUE RESISTANCE COMPACTION GOALS • DENSITY • SMOOTHNESS • BALANCED PRODUCTION BALANCED PRODUCTION PRODUCTIVE & PROFITABLE COMPACTION FOR ASPHALT PAVEMENTS BOTH HMA & WMA HOW ? DO WE COMPACT • Is a mechanical process: • ________ compresses HMA into a smaller denser volume after placement by applying one or more of the 4 forces of compaction • Increases mixture stability: I i bili • ________ forces asphalt coated aggregate particles closer together • ________ achieves particle to particle contact CONSISTENCY & COMMUNICATION 3 2/14/2014 FACTORSAFFECTING COMPACTION 4FORCESOFCOMPACTION PRESSURE: A DOWNWARD FORCE IMPACT: A HAMMER BLOW VIBRATION: A RAPID SERIES OF IMPACT BLOWS MANIPULATION: KNEADING IN A CONFINED MANNER NEEDEDFORCOMPACTION • • • • • • MIX DESIGN AGGREGATE AND ASPHALT CEMENT LAB DENSITY & FIELD DENSITY CLIMATIC CONDITIONS CLIMATIC CONDITIONS PAVER TYPE AND PAVING METHOD TEMPERATURE: MAT, BASE AMBIENT, DIRECTION OF SUN; WIND UNCOMPACTED EMBANKMENT •CORRECT MIX TEMPERATURE •CONFINMENT PARKINGLOTSOFTSUBGRADE 4 2/14/2014 COMPACTINGSUBGRADEWITHSTATIC TAMPINGFOOTROLLER TAMPINGFOOTGIVESYOUIMPACT PRESSUREANDMANIPULATION SELECTMATERIALCOMPACTEDINPLACETO PROVIDEINSULATIONLAYER Temperature 80OF Surface & Air Temperature, 5 mph wind Tem mperature, F 300 275 250 225 200 3” 175 1.5” 150 0 5 2” 10 15 20 25 30 35 40 45 50 55 60 Time, minutes 5 2/14/2014 Temperature Temperature 30OF Surface, 40OF Air Temperature, 15 mph wind 300 275 275 Temp perature, F Temp perature, F 50OF Surface & Air Temperature, 5 mph wind 300 250 225 200 175 1.5” 2” 3” 150 250 225 200 175 1.5” 2” 3” 150 0 5 10 15 20 25 30 35 40 45 50 55 60 Time, minutes 0 5 10 15 20 25 30 35 40 45 50 55 60 Time, minutes Paving24’‐0”WideInterstate I64 So. Indiana 4‐71 GM Engine 3’‐0” Extensions 12’‐0” Basic Screed 6 2/14/2014 HOWDOWEBALANCE PRODUCTION • DETERMINE PAVER SPEED • NUMBER AND TYPE OF ROLLERS NUMBER AND TYPE OF ROLLERS • NUMBER OF PASSES WITH ROLLERS TO COVER THE MAT AND OBTAIN DENSITY PAVERPRODUCTION FORMULA • • • • S= Paver Speed (ft./min.) W= Lane Width (ft.) L= Lift Thickness (ft.) D= Density (lbs./ft.3) FORMULAEXAMPLE • • • • Paver Speed= 40 ft./min. Lane Width= 12 ft. Density= 135 lbs./ft.3 Lift Thickness= .166 ft. = 2 inches • Tons/Hour= S x 60 min. in1 hr.x 1 ton in 2000 lbs.x W x L x D • Tons/Hour = 40 x 60 x 12 x .166 x135 divided by 2000= 322 Tons/ Hour BALANCINGROLLERSWITH PAVERSPEED 3PHASESOFROLLING • Breakdown Roller: 84” Double Drum Vibratory 4000 vpm • Roller maintains a min. of 10 impacts per foot (IPF) = 400 fpm • 400 fpm has to be reduced by # of passes to cover 400 fpm has to be reduced by # of passes to cover paving ; # of passes to obtain density=2; 2PLUS 2=4plus 1 return pass total passes = 5 • 400 fpm divided by 5 passes = 80 fpm • 80% efficiency factor x 80 fpm= 64 fpm • This 84” double drum vibratory roller will match 40fpm paving speed • BREAKDOWN • INTERMEDIATE • FINISH INISH 7 2/14/2014 3PHASESOFROLLING • EACH PHASE OF ROLLING IS A: TIME, • TEMPERATURE, AND DISTANCE ZONE • BREAKDOWN ROLLING: DOUBLE DRUM VIBRATORY 1 OR 2 DISTANCE: O O 2 S • 200’ FROM SCREED, TEMPERATURE: 200 F‐ 290F TIME: 10 MINUTES 3PHASESOFROLLING • INTERMEDIATE: SECOND OR THIRD DOUBLE DRUM VIBRATORY OR 20 TON AND ABOVE PNEUMATIC ROLLER 200 TEMPERATURE: 170 F – • DISTANCE: 200’ 200F TIME: 5 MINUTES • FINISH: DOUBLE DRUM VIBRATORY RUN IN STATIC • DISTANCE 100’ TEMPERATURE 100F150-170F TIME 10 MINUTES PRESENTATION REVIEW • 3. REVIEW COMPACTION BEST PRACTICES • 4. REVIEW TYPES OF ROLLERS: SET UP, UP APPLICATION APPLICATION, AND ROLING PATTERNS TO ACHIEVE; PRODUCTION, DENSITY, AND SMOOTHNESS IN A SAFE MMANNER. OUTLINEOFPRESENTATION 1. WHAT IS COMPACTION? 2. WHAT ARE THE GOALS OF COMPACTION? 3. WHAT ARE THE FOUR FORCES OF CO COMPACTION? C O ? 4.WHAT FACTORS AFFECT THE COMPACTION OF HMA? 5. HOW DO WE GET COMPACTION PERFORMANCE AND PROFIT? 8 2/14/2014 9 2/14/2014 10 2/14/2014 11 2/14/2014 OWNEROFCOMPANYROLLINGWITH3TON ROLLERTOACHIEVE94%DENSITY FINISHEDPARKINGLOT;KEPTTRUCKSOFF AREASWITHSOFTSUBGRADEFORTWODAYS PARKINGLOTHASBEENIN4YEARSWITHNO REPAIRS GRACE PACIFIC • • • • • • 3 IN 1 TRAINING COMMUNICATION QUALITY CONTROL PAVING FOREMAN ROLLER OPERATOR 12 2/14/2014 PRESENTATION REVIEW • 3. REVIEW COMPACTION BEST PRACTICES • 4. LEARN THE ROLES AND INTERACTION REQUIRED BY THE QC TECH, PAVING FOREMAN, AND ROLLER OPERATORS TO ACHIEVE BONUS DENSITY AND SMOOTHNESS. QUALITYCOMMUNICATION • • • • • • • HUDDLE UP EVERY DAY LISTEN AND INFORM TALK SAFETY UTILIZE TOOL BOX TALKS SET DAILY GOALS INCLUDE ALL PERSONNEL; INCLUDING QUALITY CONTROL TECHS TEAMMEETING TRAINING !!! TRAINING!!! 13 2/14/2014 INCORRECTRELATIONSHIPS BETWEENPAVINGFOREMANAND QC NO COMMUNICATION CORRECTRELATIONSHIPBETWEEN PAVINGFOREMANANDQC CONSISTENT, CONSTANT CONSISTENT CONSTANT COMMUNICATION, INCLUDE QC IN CREW HUDDLE UP MEETINGS UNDERSTAND THE JOB GOALS: SAFETY, QUALITY PRODUCTION, BONUS DENSITY AND SMOOTHNESS. CORRECTRELATIONSHIPBETWEEN PAVINGFOREMAN,QCANDROLLER OPERATORS PAVING FOREMAN AND QC UNDERSTAND SETTINGS AND APPLICATION OF EACH TYPE OF ROLLER THE JOB GOALS , ROLLING PATTERNS, AND DENSITY, PATTERNS, AND DENSITY, SMOOTHNESS RESULTS ARE COMMUNICATED TO PAVING FOREMAN AND ROLLER OPERATORS. AND APPROVED BY QC. NO ESTABLISHED GOALS INCORRECTRELATIONSHIP BETWEENPAVINGFOREMAN,QC, ANDROLLEROPERATORS PAVING FOREMAN AND QC DO NOT UNDERSTAND ROLLER CONTROLS, ROLLER SET UP, AND PROPER OPERATION OF ROLLERS IN ROLLING ZONES QC DOES NOT ESTABLISH TEST STRIP TO DETERMINE # OF PASSES AND DENSITY, QC DOES NOT CHECK DENSITY STARTING BEHIND PAVER SCREED, THAN BREAKDOWN ROLLER, INTERMEDATE ROLLER, AND FINISH ROLLER. NO COMMUNICATION BETWEEN PAVING FOREMAN, QC AND ROLLER OPERATORS REGARDING DENSITY. QC NOT TALKING, BUT YELLING AT ROLLER OPERTORS TRAITSOFGOODPAVINGCREWS FAMILY WINNERS COMMUNICATORS 14 2/14/2014 PNEUMATIC TIRED ROLLERS 27TONROLLERWITHSQUAREDPROFILE TIRESANDHEATSHIELDS 15 2/14/2014 16 2/14/2014 PNEUMATICROLLERONPOLYMER MODIFIEDMIXBADPICKUP avingfaults Asphalt sticks to the tires ‐ Rubber tired rollers A separating agent or formwork oil should be used until tires have right temperature. (60 °C (60 C )) PNEUMATICONPOLYMERMODIFIEDNOPICKUP;SPRAYSYSTEM WORKING,CONTROLLEDTEMPERATUREROLLINGZONE185F‐ 212F.GOODRELEASEAGENT 17 2/14/2014 MEASURINGTEMP PNEUMATIC TIRE RULES • INFLATE ALL TIRES TO EQUAL PRESSURE LOOK AT TIRE INFLATION CHART • GET TIRES CLEAN • GET TIRES HOT BEFORE GETTING ON THE MAT • USE GOOD RELEASE AGENT PNEUMATIC TIRE RULES • ON NEAT ASPHALT USE WATER SPRAY ON INTERMITTENT LOW • RUN ROLLER BETWEEN 190F190F225F • ON MODIFIED ASPHALT USE WATER SPRAY ALL THE TIME • RUN THE ROLLER BETWEEN 185F--212F ALL TEMPERATURES 185F ARE SURFACE TEMPS. 18 2/14/2014 COMPACTIONBYVIBRATION • • • • WE REARRANGE THE AGGREGATE WE LOCK UP THE AGGREGATE STRUCTURE WE LEAVE IMPACT MARKS IN THE HMA MAT WE CONTROL THE SPACING OF THESE IMPACT WE CONTROL THE SPACING OF THESE IMPACT MARKS, SO YOU WILL NOT SEE OR FEEL THEM, BY MATCHING‐ TRAVEL SPEED & FREQUENCY SYSTEMSONVIBRATORYROLLERS • AMPLITUDE: THE HEIGHT THE VIBRATING MASS MOVES FROM THE MATERIAL BEING COMPACTED‐ IN ONE ROTATION OF THE VIBRATING MASS. • FREQUENCY: THE NUMBER OF TIMES THE VIBRATING MASS MOVES IN A MINUTE‐ VIBRATIONS PER MINUTE OR V.P.M. • FREQUENCY AND AMPLITUDE CREATE A GIVEN AMOUNT OF CENTRIFUGAL FORCE. 19 2/14/2014 Smoothness Frequency & Travel Speed VIBRATORYIMPACTSPER FOOT IPF FOOTIPF MAINTAIN BETWEEN 10‐14 IPF IPF GIVES US DENSITY, SMOOTHNESS, AND BALANCED PRODUCTION VIBRATORYROLLERCONTROLS • ABILITY TO SET TRAVEL SPEED AND LIMIT OVERSPEEDING • SET TRAVEL SPEED IN RELATIONSHIP WITH FREQUENCY • THIS GIVES US A READOUT IN REAL TIME OF IMPACTS PER FOOT HowToMeasureRoughness? Equipment 1.Straightedge 2. Inertial Profiler 20 2/14/2014 Impact Spacing Frequency 2 MPH 3 MPH 4 MPH 5 MPH 2000 vpm 2200 vpm 2400 vpm 2600 vpm 2800 vpm 3000 vpm 3200 vpm 3400 vpm 3600 vpm 3800 vpm 1.06 0.96 0.88 0.81 0.75 0.70 0.66 0.62 0.59 0.56 1.58 1.44 1.32 1.22 1.13 1.06 0.99 0.93 0.88 0.83 2.14 1.92 1.76 1.63 1.51 1.41 1.33 1.24 1.17 1.11 2.64 2.40 2.20 2.03 1.89 1.76 1.65 1.55 1.47 1.39 DrumImpactsperfoot Frequency 2000 vpm 2200 vpm 2400 vpm 2600 vpm p 2800 vpm 3000 vpm 3200 vpm 3400 vpm 3600 vpm 3800 vpm 2 MPH 11.36 12.50 13.64 14.77 15.91 17.05 18.18 19.32 20.45 21.59 3 MPH 7.58 8.33 9.09 9.84 10.61 11.36 12.12 12.88 13.64 14.39 (10/ft minimum) 4 MPH 5.68 6.25 6.82 7.39 7.95 8.52 9.09 9.66 10.22 10.80 5 MPH 4.55 5.00 5.45 5.91 6.36 6.82 7.27 7.72 8.18 8.63 21 2/14/2014 TRAVELSPEEDOFROLLERS DOUBLE DRUM VIBRATORY 2‐4 MPH PNEUMATIC ROLLER 2‐3 MPH STATIC STEEL WHEEL ROLLER 3‐5 MPH SPEED CAN KILL 22 2/14/2014 BESTPRACTICEFORVIBRATORY ROLLERS • 1. CONTROL FRQUENCY AND AMPLITUDE‐ BEST: LOW AMPLITUDE AND HIGH FREQUENCY • 2. CONTROL TRAVEL SPEED AND # OF 2 CONTROL TRAVEL SPEED AND # OF VIBRATORY PASSES TO ACHIEVE DENSITY AND SMOOTHNESS AND BALANCE PRODUCTION BY CONTROLLING IMPACT SPACING IPF • 3. MINIMUM: IPF 10 IN 12” MAX: 14 IPF LiftThickness • Recommended 3:1 to 6:1 Thickness:NMAS • Thin lifts cool faster – less time available for compaction 23 2/14/2014 “3 IN 1” PAVING FOREMAN RESPONSIBILITIES SAFETY OF CREW QCTECH PAVING FOREMAN ROLLER OPERATORS QUALITY PPRODUCTION COMMUNICATE WITH CREW MMEMBERS & QUALITY CONTROL SET GOALS FOR CREW TRAIN CREW QUALITYCOMMUNICATION • • • • • • • HUDDLE UP EVERY DAY LISTEN AND INFORM TALK SAFETY UTILIZE TOOL BOX TALKS SET DAILY GOALS INCLUDE ALL PERSONNEL; INCLUDING QUALITY CONTROL TECHS GOALS??? DAILY 24 2/14/2014 SAFETY‐QUALITY‐ PRODUCTION GOALS • DAILY PRODUCTION • DENSITY AND SMOOTHNESS SPECS & BONUS GOALS INDIVIDUAL JOB RESPONSIBILITIES • INDIVIDUAL JOB RESPONSIBILITIES • JOB LAYOUT PAVING & TRUCKING SETUP • EVERY PROJECT • EVERY DAY • EVERY TON QUALITY CONTROL TECH RESPONSIBILITIES OVERALL JOB QUALITY UNDERSTAND JOB SPECS:MIX DESIGN, LIFT THICKNESS, DENSITY AND SMOOTHNESS SPECS WORK WITH PAVING FOREMAN AND ROLLER OPERATORS TO SET ROLLING PATTERNS TO ACHIIEVE QUALITY PRODUCTION, BONUS DENSITY AND BONUS SMOOTHNESS SET UP INITIAL TEST STRIP BEFOR EACH DAY’S PRODUCTION COMMUNICATE WITH ROLLER OPERATORS AND PAVING FOREMAN 25 2/14/2014 PAVINGSPEED50FPM;3ROLLERSINECHELON;2‐84”&1‐ 66” SMOOTHNESSIRI“20” ROLLEROPERATOR RESPONSIBILITIES UNDERSTAND THE CONTROLS AND SETTINGS ON ROLLER MAINTAIN THE ROLLER WITH DAILY MAINTENANCE ESTABLISH CONSISTENT ROLLING PATTERN WITH QC & COMMUNICATE WITH PAVING FOREMAN KNOW THE DENSITY AND SMOOTHNESS SPECS; LIFT THICKNESS, PAVING WIDTH, AND PRODUCTION RATE MAINTAIN ROLLER TYPE IN BREAKDOWN, INTERMEDATE, OR FINISH ROLLING ZONE TO OBTAIN QUALITY PRODUCTION, BONUS DENSITY AND SMOOTHNESS NAPATOOLBOXTALKS • • • • • • LONGITUDINAL JOINT CONSTRUCTION OPERATION OF MTV PROPER ROLLING PROCEDURES 4 FORCES OF COMPACTION 4 FORCES OF COMPACTION TRUCKING OPERATION OF PAVER NEW DEVELOPMENTS • TRAINING • NEW MIX DESIGN: WARM MIX WITH RAP & RAS • NEW DEVELOPMENTS IN COMPACTION : INTELLIGENT COMPACTION • VIBRATORY PNEUMATIC • OSCILLATORY VIBRATORY ROLLERS StepsinMakingGood LongitudinalJoints 1- Control Segregation at the Outside Edges of the Mat 2- Steer a Straight Line 3 Compact Unconfined Edge 34- Maintain Correct Overlap 5- Place the Proper Depth for Roll Down 6- Do Not Lute the Joint 7- Compact the Joint for Density 26 2/14/2014 90% of the reason for joint failures or not achieving density at th jjoint; the i t is i ROBBING THE JOINT OF MATERIAL PAVEDPARKINGLOTWITH2LIFTS11/2” BINDER&11/2”SURFACE Crack along longitudinal joint 27 2/14/2014 WARM MIX 28 2/14/2014 WhatisWMA? • Process or additive that allows for the production and compaction of asphalt pavements at temperatures lower than traditional HMA – Reduction can range between 275 ‐‐ 185 275 185°°F – Different mixes and technologies dictate temperature change HOT OR WARM CONSIDERATIONS • MIX DESIGN • RAP OR RAS YES OR NO • AGGREGATE MOISTURE CONTENT • LIFT THICKNESS • DENSITY REQUIREMENTS • ROLLERS USED WARMMIXASPHALT COMPACTION MIX DESIGN: PG 82‐22, POLYMER MODIFIED WARM MIX PROCESS: SASOBIT ADDED AT THE PLANT JOB LAYOUT: PAVING WIDTH 12’, PAVING SPEED 25 FEET/MIN., LIFT THICKNESS 21/2 INCH LOOSE TEMPERATURES: MIXING TEMP. 315 F LAYDOWN TEMP OFF THE SCREED 287‐305F IS IT HOT ??? IS IT WARM?? SimilaritiesWithHMA • Same plants, just modified in many cases • Same paving equipment • Same rolling equipment WARMMIXJOBROLLINGPROCEDURES,TEMPERATURE ZONES,#OFPASSES,LENGTHOFROLLINGZONES, DENSITYACHIEVEDINEACHZONE. • BREAKDOWN ZONE 66” DOUBLE DRUM VIBRATORY 3000vpm DISTANCE OF ZONE 150’ TEMPERATURE IN ZONE 287‐305 F ROLLING PATTERN 5 PASS PATTERN DENSITY ACHIEVED 90% 92% 90%‐92% • INTERMEDIATE ZONE 66” DOUBLE DRUM VIBRATORY 3000vpm DISTANCE OF ZONE 150’ TEMPERATURE IN ZONE 200‐250 F. ROLLING PATTERN 5 PASS PATTERN DENSITY ACHIEVED 92.4%‐94.3% 29 2/14/2014 WARMMIXROLLING PROCEDURES • FINISH ROLLING 66” DOUBLE DRUM OSCILLATING DRUM ROLLER VIBRATE IN STATIC OUT 5 PASS PATTERN 200’ TEMPERATURE IN THE ZONE: 100 F AND DOWN ROLLING ZONE DENSITY ACHIEVED 94.7%‐95.6% • DENSITY INCREASED FROM 92.4%‐94.3% IN INTERMEDIATE ZONE TO 94.7%‐95.6% IN FINISH ROLLING ZONE AT 100 DEGREES F. MAT SURFACE TEMPERATURE. NoDistressApparentafterOneYearofService GoodLongitudinalJoint BESTPRACTICEFORCOMPACTING WARMANDHOTMIXASPHALT YES WE CAN Anotheryearlater…NoDistress November9,2010 BradfordCounty,PA 19mm .3<3 25% RAP… WMA with MAXXAM Foaming Process Air temp = 42°F 30 2/14/2014 2ND JOB STUDY Extended2010Season CompactionResults Spread of results of 233 cores Spread of results of 65 cores 25mm Base 25% Rap 80 9.5mm Wearing 15% RAP 25 70 F r e q u e n c y F 20 r e 15 q u e 10 n c y 5 60 50 40 30 20 10 0 0 90.5 - 91.5 - 92.5 - 93.5 - 94.5 - 95.5 - 96.5 91.4 92.4 93.4 94.4 95.4 96.4 97.4 Percent of Theoretical (Spec is >88 - <97) • • • • • • MAINTAINENCE JOB LIFT THICKNESS 21/2” LOOSE PG GRADE 64-22 15% RAP 5% RAS 12’ PAVING WIDTH LAYDOWN: ROADTEC PAVER WITH MOBAY TEMPERATURE SENSING SYSTEM MTV: ROADTEC SHUTTLE BUGGY MODEL 2500 89.5 - 90.5 - 91.5 - 92.5 - 93.5 - 94.5 - 95.5 - 96.5 90.4 91.4 92.4 93.4 94.4 95.4 96.4 97.4 Percent of Theoretical (Spec is >90 - <97) 31 2/14/2014 INTELLIGENT COMPACTION IS: IntelligentCompaction? WHAT IS INTELLIGENT COMPACTION INTELLIGENT COMPACTION IS NOT: • A SYSTEM THAT MEASURES DENSITY • ALWAYS AN ACCURATE MEASUREMENT OF STIFFNESS AS RELATED TO DENSITY; IT DEPENDS ON QUALITY OF BASE • NOT NEEDED ON ALL ROLLERS • A SYSTEM FOR MEASURING THE STIFFNESS OF HMA ON THE ROLLER • A RECORDING OF THAT STIFFNESS MEASUREMENT; IS A GOOD PROOF ROLLER • PROOF OF THE STIFFNESS OF THE HMA AS RELATED TO DENSITY • PROVIDES INFORMATION FOR THE ROLLER TO MAKE DECISIONS – NOT THE ROLLER OPERATOR • A QUALITY CONTROL SYSTEM THAT PROVIDES FEEDBACK ON MATERIAL STIFFNESS AS RELATED TO THE NUMBER OF PASSES MADE AND LOCATION OF PASSES COMPONENTS OF INTELLIGENT COMPACTION • OPERATIONAL SYSTEMS • MAPPING SYSTEMS • GPS 32 2/14/2014 EVIB [M MN/m²], [°C] EVIB and Density as function of passes; BW 174 AD Asphalt Manager, Automatic mode; Asphalt Base 0/32 CS B65, Nürnberg A3 102 100 98 96 94 4 cm SMA 0/11 S 8 cm Binder 0/22 92 > 10 cm ATS 0/32 90 88 86 84 [%] 280 260 240 220 200 180 160 140 120 100 Evib Surface temp. Core temp. Troxler density 0 1 2 3 4 5 6 Passes ULTIMATESMOOTHNESS 2PASSESVERSUS3INTESTSTRIP • ONE DRUM VIBRATING IN HORIZONTAL VIBRATION DIRECTION‐‐‐FRONT DRUM • REAR DRUM SHUT OFF 13/4INCH LOOSE LIFT 2PASSES‐DENSITY DENSITY • 13/4INCH LOOSE LIFT 2PASSES 93.7% MTD • SMOOTHNESS 38.5‐42.0 IRI MEASURED WITH A LAZER MOUNTED VEHICLE 33 2/14/2014 $VALUE • I/C MEASURES THE STIFFNESS OF A LIFT OF HMA • DENSOMETERS MEASURE DENSITY OF HMA • THIS GIVES US TWO MEASUREMENTS OF THE SG S S O S SO STABILITY OF THE HMA • WHY CUT SO MANY CORES THAT COST $800.00‐$1000.00 A CORE IC Vario Benefits –– Why IC ??? IC Vario Benefits • • • • • • • • • • • • • • • Enhances Quality Control Consistent Rolling Patterns Exceptional Compaction Performance Real Time Data Display Wide Range of Adaptability Reduced Shock Loads to Surroundings Increased Depth Effect Proof Rolling to identify soft spots Under Compaction is avoided Over Compaction is avoided Unnecessary Passes are avoided Yields Fuel and Labor Savings Reduces In-Situ Measurements / Cost Reduces Highway Maintenance / Repair Provides Clear Documentation BEST PRACTICE ASPHALT COMPACTION BEST PRACTICE • KNOW THE SPECIFICATIONS • KNOW THE OPERATION OF THE ROLLERS • BALANCE PRODUCTION 34 2/14/2014 VIBRATION IS A RAPID SERIES OF IMPACT BLOWS ROLLER MAINTENANCE VIBRATORY ROLLERS • 1. CHECK ENGINE OIL, HYDRAULIC SIGHT GAUGE, ALL DAILY LIBE POINTS2 • 2. FILL WATER TANK RUN WATER SPRAY SYSTEM; ALWAYS CARRY EXTRA NOZZLES AND WELDING WIRE TO CLEAN NOZZLES WIRE TO CLEAN NOZZLES • 3. CHECK DRUM SCRAPERS; MAKE SURE THEY ARE CONTACTING DRUM; CLEAN DRUM • 4 CHECK RUBBER ISOLATORS ON VIBE ROLLERS • 5.CHECK AIR PRESSURE ON RUBBER TIRED ROLLERS 35 2/14/2014 C766C & C778B MSPI ‐ MULTI SYSTEM PERFORMANCE INDICATOR ELECTRONIC CONTROL SYSTEM 36 2/14/2014 BEST PRACTICE • BONUS DENSITY • BONUS SMOOTHNESS TEST STRIP DENSITY TESTING SMOOTHNESS TESTING CONSISTENCY • QUALITY PRODUCTION 37 2/14/2014 279”VIBRATORYROLLERSROLLINGIN ECHELON5PASSPATTERNON12’WIDTH 38 2/14/2014 39 2/14/2014 40 2/14/2014 41 2/14/2014 Pavingfaults Shoving effect Mat shoves under roller drums - Roller too heavy on a tender mix (too high linear load) - Drum diameter too small - Asphalt mix not stable - Compaction start at too high T°C avingfaults Asphalt sticks to the drum ‐ Mix being compacted at too high T°C ‐ Roller drums not wet enough ‐ Bitumen of tack coating or of joints sticks to the drums Hint: Start compaction with permanent spray (short term) for quickly wetting the drums. Pavingfaults Longitudinal joints Possible causes - Pre-compaction too low - Imperfections of underlay (also layer compound) - Shearing of the mat under heavy roller - Mix design (e.g. % of Sand, Bitumen content) avingfaults Campers - Rubber tired rollers 42 2/14/2014 43 2/14/2014 THE PAVING CYCLE PLANT OPERATIONS MIX DESIGN COMPACTION TRUCKING LAYDOWN BASICPRINCIPLESOFGOOD COMPACTION KNOW THE VARIABLES KNOW THE SPECS KNOW THE LAYOUT ESTABLISH A PATTERN TO ACHIEVE: COVERAGE, DENSITY, SMOOTHNESS, AND BALANCED DENSITY, SMOOTHNESS, AND BALANCED PRODUCTION KNOW THE BASIC OPERATION OF EACH TYPE OF ROLLER November9,2010 BradfordCounty,PA 19mm .3<3 25% RAP… WMA with MAXXAM Foaming Process Air temp = 42°F TEMPERATURE, DENSITY, LENGTH OF ZONES • MIXING TEMPERATURE: 290* • TEMPERATURE BEHIND SCREED: 250* DENSITY: 90.8 MTD • TEMPERATURE BEHIND BREAKDOWN ROLLER: 235* DENSITY: 93 93.2% 2% LENGTH OF ZONE: 150’ 150 • TEMPERATURE BEHIND INTERMEDIATE ROLLER: 180* DENSITY: 93.5 LENGTH OF ZONE: 70’ • FINISH ROLLER: TEMPERATURE START OF ZONE:160* TEMPERATURE AFTER 3RD PASS: 150* TEMPERATURE AFTER LAST PASS: 130* LENGTH OF ZONE: 300’ DENSITY: 94.6%MTD. BUILDINGQUALITY HOTMIXASPHALT JOINTS CW CHUCK DEAHL FAT BOY ROLLER L.L.C. [email protected] 44 2/14/2014 StepsinMakingGood LongitudinalJoints 1‐ Control Segregation at the Outside Edges of the Mat 2‐ Steer a Straight Line 3 Compact Unconfined Edge 3‐ Compact Unconfined Edge 4‐ Maintain Correct Overlap 5‐ Place the Proper Depth for Roll Down 6‐ Do Not Lute the Joint 7‐ Compact the Joint for Density 1 ControlSegregationattheOutsideEdges oftheMat 2 SteeraStraightLine Minimize Segregation at the O t id Ed Outside Edges of the Mat Properly Adjust the Material Sensors Use Correct Length of Auger Tunnels Maintain Proper Overlap A Must for Proper Joint Construction 45 2/14/2014 Maryland Reference to assist in getting the 1st pass straight Maryland Great Results String line 46 2/14/2014 47 2/14/2014 CompactingUnsupportedEdgeusingSteel Wheel Roller 3 Option 1 Hang over 6” Option 2 1st Pass 3”-6” inside 3”-6” Roller Roller 2nd Pass hang over 3”-6” 6” Roller 3”-6” 48 2/14/2014 3 CompactionofUnsupportedEdgeusing PneumaticTireRoller 6” Recommended Pushes out Not Recommended 49 2/14/2014 Maryland 4&5 MaintainProperOverlapand MatchingDepth Proper Roll Down – Start With 25% of the Depth 1st Pass (Cold) 1/2 ‐ 1 1/2” (13‐35mm) Overlap Ideal overlap 1” 2nd Pass (Hot) Practical overlap 2”” Minimum Overlap for Compaction is 1/2 Inch (13mm) Always Check Joint Roll Down Behind the First Roller 50 2/14/2014 Maryland 4&5 MaintainProperOverlapand MatchingDepth If Your Joint is Set Up Correctly, Set Up Correctly Little or No Handwork Should be Required No lute person 51 2/14/2014 6 DoNotLuteJoint • Moves material away from joint • Results in low‐ density zone at density zone at joint Bump the joint Cold Hot Cold Hot Hot to Cold Cold to Hot 7 Compacting Longitudinal Joints Hot Cold 6” – 8” Offset 52 2/14/2014 7 MaterialFlowatJoint Roller Drum (Static) COLD Material Flows Toward Confined Edge & Builds Greater Density COLD Compacting Your Longitudinal Joints 7 Pinching the Joint Material Flows Away From the Confined Edge & Less Density is Achieved HOT Second Pass First Pass Roller First Pass Cold Hot Roller First Pass Cold Hot 6 to 8 Inches Roller Drum (Vibratory) Creates a Confined Edge & Raised Area Second Pass Use, Vibratory to Build Density HOT ULTIMATESMOOTHNESS • ONE DRUM VIBRATING IN HORIZONTAL VIBRATION DIRECTION‐‐‐FRONT DRUM • REAR DRUM SHUT OFF 13/4INCH LOOSE LIFT 2PASSES‐DENSITY DENSITY • 13/4INCH LOOSE LIFT 2PASSES 93.7% MTD • SMOOTHNESS 38.5‐42.0 IRI MEASURED WITH A LAZER MOUNTED VEHICLE 53 2/14/2014 THANK YOU 54
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