TECHNOLOGY. BOMAG ASPHALT MANAGER 2. Intelligent compaction.

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1 TECHNOLOGY BOMAG ASPHALT MANAGER 2. Intelligent compaction.

2 Innovation Around the world cost pressures are obliging contractors to reassess the effectiveness of their compaction equipment. In addition to compaction efficiency, the issue is also about increased flexibility on site. This varies greatly with mix properties, layer thicknesses and the specified quality requirements. The objective is clear: operators demand versatile compaction equipment and then require it to be used to full capacity. BOMAG rollers with ASPHALT MANAGER 2 have been developed specifically for this purpose. 2

3 BOMAG ASPHALT MANAGER 2 The concept: ASPHALT MANAGER 2. The exciter system itself is based on the directed vibration principle. This means that the compaction forces from the eccentric weights are combined and directed in a specific direction. The advantages: the exciter s maximum compaction output is always available, because the intelligent control system ensures that available potential is adjusted instantly to requirements. This is achieved by simply realigning the exciter system, including the eccentric mass, to the roller s direction of travel. Depending on how well the material compacts, the compaction force is automatically adjusted towards either vertical or horizontal. Other influencing factors are the layer thickness and stability of the substructure. In addition the automatic system always prevents the drum from bouncing and over-compacting the mix. The measuring technology integrated into ASPHALT MANAGER indicates compaction progress using a reference value. This means a physical reference value E VIB (MN/m 2 ) is continuously calculated and the operator is able to follow the changes on the display after each pass. Another highly useful feature is the continuous display of the asphalt surface temperature during compaction. Contents: 4... Innovation. The exciter systems in detail Technology. The AM 2 display: simple and safe Cost-effectiveness. ASPHALT MANAGER 2 on site Conclusion. Analysis of soft spots (proof-rolling). 3

4 Innovation The exciter systems in detail. At the heart of rollers featuring ASPHALT MANAGER 2 (AM 2) is the efficient and powerful directed vibrator which basically comprises two counter-rotating eccentric weights. The centrifugal forces generated by these weights accumulate when focused in the same direction (directed vibrator) and are counterbalanced when pointed in the opposite direction. The exciter system mounted in the drum can be infinitely turned allowing for constant control of the compaction force direction. A special feature is that the resulting compaction force is also adjusted to the direction of travel, so that the direction of rotation of the drum and the force correspond with each other. Intelligent measuring and control technology for the AM 2 system drum makes this possible. Drum cross-section with exciter system on pivot-steered rollers in the BW 154 AP/ACP and BW 174 AP series and articulated rollers in the BW 151 AD-5 series. Drum cross-section with exciter system for articulated rollers in the BW 190 AD-4/203 AD-4 series. 4

5 BOMAG ASPHALT MANAGER 2 The advantages: the compaction intensity (effective amplitude) is controlled in such a way that the drum is prevented from bouncing (as with conventional vibration). On scuff prone types of asphalt the mix automatically flows under the drum and is not pushed away. The advantages at a glance: n efficient and smooth compaction n no aggregate crushing or fatting up of the surface n less risk of crack formation Directed vibration principle: automatic adjustment of the compaction force Directed horizontally: transfer of thrust forces and less depth effect. Any direction from horizontal to vertical: automatic adjustment or fixed manual setting; depth effect depends on the vertical direction. Directed vertically: extended depth effect; high intensity. 5

6 Technology The AM 2 display: simple and safe. ASPHALT MANAGER is a patented system for automatic compaction control that has been in use for years around the world. The technology is now well established and the system has been constantly optimised. BOMAG is now launching the second generation ASPHALT MANAGER (AM 2). Initially there are three items of important information the operator needs to know: n Current effective amplitude n Asphalt surface temperature n Compaction characteristic E VIB (MN/m²) Simple menu with AM 2. All at the touch of a button! This is where BOMAG s experience becomes evident: the simple menu gives the operator a choice of several automatic functions. These are programmed applications which apply to typical mixes and the respective layer thicknesses. Amplitude [mm] The special feature: a specific E VIB value is programmed as the limit value for each application. Once achieved, the compaction intensity is reduced immediately. Advantage: this prevents over-compaction with potential aggregate crushing, or the asphalt layer becoming loosened again. Evib target value Efficient amplitude control reduces the risk of over-compaction. Manual operation: if necessary, ASPHALT MANAGER can also compact in manual mode. There are six different compaction settings available from horizontal to vertically directed. From experience, the operator can constantly adjust a particular force direction as well as the compaction intensity (depth effect). 6

7 BOMAG ASPHALT MANAGER 2 Simple menu: Experienced operators use AUTOMATIC prof Experience shows many sites are similar, but none are the same. Unfavourable weather conditions (rain and wind) often cause the asphalt layer to cool down too quickly or the mix itself proves difficult to compact despite favourable temperatures. In prof mode, the operator can individually adjust the exciter system. The push of a button is all that is needed here too, to increase or lower the target values for E VIB. Highly practical: ASPHALT MANAGER stores these values until a new selection is made. Simple to operate: a push of a button and compaction can begin. Measuring the surface temperature Rollers with AM 2 have an infra-red device to measure the asphalt surface temperature. The optimum compaction temperature range can be set in prof mode ; a colour change (red or blue) indicates an extremely hot or cold zone. Advantage: The operator has a clear idea of the condition of the mix. On large scale sites, frequent checks are carried out in the course of monitoring (using nuclear gauges) by a testing laboratory. In this case, the operator can compare or calibrate the E VIB value (MN/m 2 ) calculated by the roller. Colour red: the upper limit for the asphalt temperature set by the driver has been reached Calibration: E VIB -value (MN/m²) and Marshall density. 7

8 Cost-effectiveness ASPHALT MANAGER 2 in practice: Investing in ASPHALT MANAGER 2 can pay off after just one construction season e.g. if consistent and reproducible results have been achieved on large area compaction sites saving expensive remedial work or contractual penalties. The reference value: E VIB (MN/m²) The E VIB value (MN/m2) continuously calculated by ASPHALT MANAGER can be used to evaluate the increase in compaction. This is reproducible as long as the mix temperatures during paving stay within the practical working range of 100 C and 150 C and there is a stable substructure. Recommendations for use: BOMAG rollers with ASPHALT MANAGER are suitable for typical applications in the compaction of all asphalt materials, as well as anti-frost layers and unbound base courses. Work is mainly carried out in automatic mode. Provided these criteria are met, the E VIB value can be calibrated on site with the aid of an isotopic probe (to determine the Marshall density). BOMAG s years of experience with ASPHALT MANAGER shows theory and practice are in correlation. [NM/m 2 ], [ C] Evib Surface temperature Core temperature Troxler density These are good criteria with which to check large area compaction work. As soon as a max. E VIB value has been recorded as a reference, the operator also has a target for the max. number of passes. Passes E VIB and density are part of the passes; BW 174 AD ASPHALT MANAGER; analysis of the results for asphalt base course AC 32 T. Amplitude [mm] 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0, Effective amplitude is already clearly reduced after 2 passes. 8

9 BOMAG ASPHALT MANAGER 2 Thin layers A reduced compaction force is set when placing thin top layers or the mix is sensitive to scuffing. Static compaction is available for open texture layers to reduce noise. Chip mastic asphalt (SMA) The hot mix is compacted immediately with vibration. The middle hammer symbol is selected in the menu. Fewer passes save time an important factor when the mix cools rapidly in bad weather conditions. ASPHALT MANAGER s efficient control system also allows the fast reduction of effective amplitude; this prevents the subsequent unwanted crushing of aggregate, or the asphalt layer losing binding with the substructure. Low vibration compaction: Near buildings or on bridges it is important to optimise the efficiency of compaction and at the same time minimise the effects of vibration on the environment. To achieve this horizontal vibration is set in ASPHALT MANAGER. This is carried out in manual mode ( bridge setting).... before compaction. After vibration compaction of a top layer SMA (0/11) with a BW 203 AD the surface demonstrates an open texture with good grip. 9

10 Conclusion Analysis of soft spots (proof-rolling). Efficient compaction management with AM 2 is essential for all operators who wish to increase the efficiency and quality of compaction work. However, the system is also suitable for checking the load bearing capacity of surfaces in the road sub-base that have already been compacted. We recommend equipping the roller with a printer to document areas with limited space. The printer can be operated via the display. To check the compacted layer we recommend selecting manual mode (uncontrolled compaction) and setting the system to a stage with little depth effect. Effect of vibration on structures It is usually necessary to minimise the intensity of vibrations during dynamic compaction when used on bridge structures or compacting near dwellings. This is where the full flexibility of ASPHALT MANAGER 2 is demonstrated: in this case, the system s manual, horizontal setting are selected, identified by a bridge symbol. The result is sensitive compaction concentrating on the area of layer near the surface. Manual mode: using a printer. Print-out on site: assessment of load bearing capacity. 10

11 BOMAG ASPHALT MANAGER 2 The future of modern compaction technology. BOMAG rollers with ASPHALT MANAGER (AM 2) are already well prepared for the technology of tomorrow. For example, a motorway several kilometres long can be compacted and at the same time used to document the compaction results. Satellite navigation All measuring data, e.g. the number of roller passes, the asphalt surface temperature and the compaction characteristic E VIB (MN/m 2 ) of a large site (e.g. an airport) are recorded down to the centimetre. To achieve this the rollers need a receiver for satellite communication and the BCM 05 (BOMAG Compaction Management System) with relevant software. The compaction characteristics measured by the roller can be followed on a large screen and allocated an exact position. The modern asphalt site is networked On large-scale sites, several rollers need to be used at the same time. Depending on the size of the sites, rollers can be arranged side by side or behind each other in sections. In either case, an even number of passes always needs to be applied. However, this is not always possible in practice. A reliable option for uniform compaction of asphalt is the BCM net from BOMAG; up to ten rollers can be connected in a networked WLAN system and exchange their measuring data in real time. This means every roller operator is kept informed online about the compaction progress, number of passes, surface temperature, etc., of his own roller and those of his colleagues. Data exchange: The same information for all operators Construction management and quality control 11

12 Head Office / Hauptsitz: BOMAG Hellerwald Boppard GERMANY Tel Fax info@bomag.com BOMAG (GREAT BRITAIN), LTD. Sheldon Way Larkfield, Aylesford Kent ME20 6SE GREAT BRITAIN Tel Fax gb@bomag.com BOMAG Maschinenhandelsgesellschaft m.b.h. Porschestraße Wien AUSTRIA Tel Fax austria@bomag.com BOMAG (CANADA), INC Semenyk Court Mississauga, Ontario L5C 4P9 CANADA Tel Fax canada@bomag.com BOMAG (CHINA) Compaction Machinery Co. Ltd. No West Huancheng Road Shanghai Comprehensive Industrial Zone (Fengxian) Shanghai CHINA Tel Fax china@bomag.com BOMA Equipment Hong Kong LTD Room 1003, 10/F Cham Centre 700, Castle Peak Road Kowloon HONG KONG Tel Fax bomahk@bomag.com BOMAG France S.A.S. 2, avenue du Général de Gaulle Viry-Châtillon FRANCE Tel Fax france@bomag.com BOMAG Italia Srl. Via Roma Alfonsine ITALY Tel Fax italy@bomag.com FAYAT BOMAG Polska Sp. z o.o. Ul. Szyszkowa Warszawa POLAND Tel Fax poland@bomag.com FAYAT BOMAG RUS OOO , RF, Moscow region Khimki, Klayazma block, h. 1-g RUSSIA Tel. +7 (495) Fax +7 (495) russia@bomag.com BOMAG GmbH 300 Beach Road The Concourse, #18-06 Singapore SINGAPORE Tel Fax singapore@bomag.com BOMAG Americas, Inc Kentville Road Kewanee, Illinois U.S.A. Tel Fax usa@bomag.com 01/13 PRE