Intelligent Asphalt Compaction.

JOB
REPORT
 Intelligent Asphalt Compaction
Authors: Hans-Josef Kloubert; Wolfgang Wallrath
Authors’ addresses:
Dipl.-Ing. Hans-Josef Kloubert, BOMAG, Hellerwald, 56154 Boppard, Germany,
Hans-Josef.Kloubert@bomag.com
Dipl.-Ing. Wolfgang Wallrath, BOMAG, Hellerwald, 56154 Boppard, Germany,
Wolfgang.Wallrath@bomag.com
1. Introduction
Efficient compaction equipment plays a key role in
the processing of rolled asphalt. In addition to the
operating weight of a roller, vibration with its
characteristic variables of frequency and amplitude
are also crucial to optimum compaction performance.
Vibration enables asphalt mixes to be compacted
with fewer passes. This is particularly apparent with
those asphalts which have increased in stiffness over
the last few decades and which subsequently require
higher compaction output. Throughout Europe, more
than 70% of asphalt applications are compacted
using vibratory rollers.
The correct operation and handling of vibratory rollers
assumes some knowledge of compaction equipment
and the compactibility of the asphalt mix, as well as
experience in working with compaction per se. Vibra-
tory rollers are often not operated in a targeted
way; vibration is continued for too long or on a mix
that has already cooled down. Too many passes
with vibration and excessive amplitudes can lead to
aggregate crushing or loosening of the base layer.
Supporting the roller driver with specific optimised,
dynamic compaction and increasing the compac-
tion output of equipment were the goals for BOMAG
from the end of the 1990s in designing self-regulating
rollers for soil and asphalt compaction. This intelli-
gent compaction equipment calculates the compac-
2
tion energy required and adjusts this automatically
by regulation of the amplitude. At the same time, the
system determines the EVIB stiffness module of the
material being compacted, which gives an indica-
tion of compaction progress. More than 2000 of these
units have been marketed across the world. This
article reports on experiences with and subsequent
developments to the asphalt roller.
2. Conventional vibratory rollers
Conventional asphalt vibratory rollers are equipped
with circular exciters. The vibration reduces the
internal friction in the mix, so that the simultaneous
effect of basic weight and dynamic load increases
layer density. Besides static linear load, other factors
such as the vibrating mass of the compaction equip-
ment, frequency and amplitude are also influential
in determining the compaction effect. For optimum
compaction of different layer thicknesses, tandem
vibratory rollers with operating weights upwards
of around 6 t are in most cases equipped with two
amplitudes and two frequencies. Low amplitude with
high frequency is recommended for surface layers
and asphalt binders, as well as easily compacted
mixes. Depending on the equipment model, values
lie between 0.2 and 0.4 mm or 50-60 Hz. For base
layers or mixes that are difficult to compact, the
recommended solution is a combination of high am-
plitude (0.5-0.9 mm) and low frequency (40-45 Hz).

Fig. 1: Asphalt vibratory rollers with fixed high and low amplitudes and contact forces during compaction.
For the vibration technology to be used correctly,
the roller driver requires some experience and must
ensure that the correct parameters are chosen
to avoid unwanted loosening and disruption to the
structure, and he must also be able to switch off
vibration promptly.
Figure 1 shows contact forces of the roller drum on
the asphalt for fixed, adjustable amplitudes.
The roller works with static load at the beginning
of compaction, i.e. the roller drum is always in
contact with the mix. The contact force FK is never
zero (Figure 1 top diagram). Contact force grows
with increasing compaction due to the consistent
vibration amplitude (Figure 1 bottom diagram). This
I N T E L L I G E N T A S P H A LT C O M P A C T I O N
results in the roller drum lifting, and even
creates periodic drum bounce where the alternat-
ing low and very high impact forces can damage
the asphalt surface. Drivers of vibratory rollers with
fixed amplitudes only have the option of turning off
vibration at the appropriate time based on experi-
ence and instinct.
3. Intelligent vibratory rollers
Since the end of the 1990s, ASPHALT MANAGER
rollers developed by BOMAG have provided the
industry with compaction equipment that deter-
mines and automatically adjusts the compac-
tion energy required. This is intelligent compaction
which provides compaction energy where required
3
 by adjusting the amplitude and reduces the energy
where it is superfluous or even harmful. There is no
need for the roller driver to intervene. The rollers have
a directed vibrator system which can continuously
adjust vibration direction and therefore the deci-
sive, effective amplitude for compaction. The control
is based on the analysis of the interaction between
drum (= roller drum) and the stiffness of the material
being compacted.
By utilising acceleration signals, the effective com-
paction amplitude is automatically optimised which
prevents adverse drum bounce. Aggregate crushing,
structural disruption to the asphalt, unevenness and
loosening are all avoided.
Fig. 2: Intelligent asphalt roller with automatic, progressive amplitude adjustment and contact forces during compaction.
Figure 2 shows contact forces for an intelligent
asphalt roller as compaction increases. These forces
are continuously monitored and their extent limited
by the progressively controlled amplitude before
unwanted drum bounce can occur.
The bounce behaviour of the drum and a power level
control act as control criteria for the first generation
of intelligent asphalt compactors. The drum is kept
predominantly in contact with the asphalt. Three
power levels, symbolised by three hammers, can
4
be selected to limit the contact force between drum
and asphalt even at the beginning of compaction. If
the preselected power level is exceeded, the sys-
tem throttles back the amplitude and therefore the
contact force between drum and asphalt layer. This
means that the depth effect of the system can be
influenced and, for example, adjustments made on
more yielding road structures or on layer subbases
with non-uniform stability.
The acceleration signals are also used in ASPHALT
MANAGER rollers to determine the dynamic stiff-
ness module EVIB (MN/m2) of the layer being worked.
As numerous measurements show, this module
(also called vibration module) for compaction tem-
peratures >100 °C can also be referred to in order
to assess compaction progress and is used as a cor-
relation to the volumetric density of the mix assuming
uniform stiffness in the subbase. ASPHALT MANAGER
rollers are equipped with infrared sensors which
inform the roller driver about compaction tempera-
tures by measuring the asphalt surface temperature
and displaying it on a control screen.
The stiffness module is calculated for each eccentric
rotation from the compression phase of the force-
 I N T E L L I G E N T A S P H A LT C O M P A C T I O N

travel diagram, which is derived from the equilib-

rium of forces and the vibration path of the drum (see
Fig. 3). The contact force and compression deforma-
tion exercised on the asphalt layer by the drum are
calculated at the same time according to a method
developed by BOMAG. Since the machine‘s geometry
and masses are already included in the calculation
method, the dimension-related dynamically calcu-
lated vibration module can be viewed as an absolute
characteristic independent of the machine.

In addition to automatic mode which governs the

self-regulating function, the ASPHALT MANAGER roll-
ers also offer the option of preselecting a required
direction of vibration with a choice of six settings
between vertical and horizontal. The roller driver
makes adjustments on the control screen (BOP,
BOMAG Operation Panel). Horizontally directed vibra-
tion greatly reduces the vibration loads on struc-
tures in contrast to conventional vibratory rollers. This
Asphalt Manager presetting is ideally used on bridges
and in inner-city areas near buildings.
With three articulated and six pivot steered ASPHALT
MANAGER rollers, there are a total of 12 different
models available in weight classes from 7 to 13 t.
The applicational advantages of the ASPHALT
MANAGER rollers are universal use of the equipment
with high compaction output, no risk of aggregate
Fig. 3: Determining the EVIB stiffness module.
destruction, progressive adjustability, even com-
paction, better surface finish, low-vibration surface
compaction and the option of using EVIB measure-
ments for surface covering control.
Wide experience has been gained over the last
10 years. Systematic trials and feedback from wide-
ranging construction projects have led to further
developments in control criteria and improvements
in the algorithm for the automatic stiffness-related
amplitude control. This is based on data records
from EVIB density correlations and the associated
compaction temperatures arranged by mix type, layer
thickness and other placement conditions. Nominal
stiffnesses and EVIB target values can initially be

Fig. 4: Intelligent compaction with a BW 203 AD-AM ASPHALT MANAGER on chip mastic asphalt. The (BOP) control screen displays the EVIB value,
amplitude, speed and surface temperature.

5
 deduced from this; these are then included as control
criteria and enable optimised control with improved
amplitude adjustment when compared to the first
generation. There have also been further improve-
ments to the validity of the EVIB value and its repro-
ducibility. Figure 5 shows the increase of EVIB and
density, as well as the correlation for a CMA cover
layer mix on two different sites.
4. Target value control
Further developments in the control system had the
following aims: On one hand, inexperienced users
should be able to rely on an efficient, non-destructive
compaction process by simply selecting the layer
thickness to be compacted, without further need for
adjustments and settings when used in automatic
mode. The nominal stiffnesses saved and allocated to
layer thicknesses help in this process. On the other
hand, users are also given the opportunity of setting
individual target values for any mix type based on
their own EVIB density correlations.
Fig. 5: EVIB, density, asphalt temperature and correlation with increasing passes.
Bomag creates “active amplitude management”
adjusted to the increasing density of the asphalt
layer using the new target value control in ASPHALT
MANAGER. The greatest possible compaction output
with maximum amplitude is made available in the
initial passes and at optimum compaction tempera-
6
ture. The asphalt exhibits increasing resistance to
the drum as compaction progresses; the contact
force and stiffness module EVIB increase with den-
sity. During ongoing compaction, the movement of
the drum and the increase in stiffness is monitored;
the amplitude is throttled back if there is a risk of
drum bounce, or of the maximum contact force
being exceeded or of reaching a nominal stiffness
(Fig. 6).
The interplay of control parameters in automatic
mode is shown in a simplified form in Fig. 6. The
roller driver selects the desired layer thickness on
the control screen. This is all he needs to do to acti-
vate all the benefits of this intelligent compaction
system. The input values for the target value control
create the individual power level and EVIB target
value for the selected layer. The control continually
receives current data, such as amplitude, contact
force, compression and actual stiffness, from the
vibrating drum. The optimum nominal amplitude is
calculated and progressively adjusted
just-in-time based on these reference variables.
With no further action by the driver, compaction
energy is optimised and automatically adjusted
to the compaction status. The number of passes
is reduced because full power is provided during
the hot initial phase and the amplitude is greatly
 I N T E L L I G E N T A S P H A LT C O M P A C T I O N

If a nuclear gauge is available, the asphalt stiffness

module EVIB can be individually correlated to
the density for the existing asphalt layer by rolling
over the measuring point.

By using this particular EVIB target module, the target

value control of the ASPHALT MANAGER is capable
for the first time of individual, layer-related compac-
tion to a specific nominal density. This is an important
step in avoiding over-compaction and in meeting per-
meability specifications

The target value control not only provides benefits,

such as

■ Optimum use of compaction energy

■ Automatic adjustment of the effective depth and
measuring depth
■ Prevention of drum bounce, aggregate crushing
and uneven layers
■ Correlation to asphalt density within a compactible
temperature range
■ Controlled compaction to a target value,

but is also an essential precondition for surface

covering quality assurance on asphalt.

Fig. 6: Operating and control concept of the new ASPHALT MANAGER

generation.

reduced only towards the end of compaction or

when the material is too cold. The effective ampli-
tude is limited from the start for thinner layers. The
measuring depth and the layer being installed are
also limited by adjusting the effective depth. This
minimises disruption to the subsurface. The driver
can track the current status or compaction pro-
gress on the control screen using EVIB, temperature
and effective amplitude.

7

250 MN/m2
corresponding
to 98% density
Fig. 7: Example of individual correlation of the EVIB module to asphalt density.
5. Measuring results on asphalt
A61 motorway with 15 cm base layer
In the course of renovating the Koblenz carriage-
way on the A 61 near Erftstadt, a 7.5 t pivot steered
BW 154 AP-AM ASPAHLT MANAGER roller with target
value control was used in automatic mode on the
bottom 15 cm thick layer of the asphalt base layer
Fig. 8: Compaction of ABL with BW 154 AP-AM.
(AC 32 TS, B50/70). Trial compaction gave a target
value of 250 MN/m2. Subsequent measurements
showed a continuous increase in volumetric density
and in the EVIB value. The surface temperatures,
which were measured directly by infrared sensors on
the roller, were between 160 °C and 140 °C.
8
Isotope gauge
reading
e.g. 98%
Additional measurements using an inserted
thermometer gave a temperature difference
between asphalt core and asphalt surface of
approx. 15 °C. Density increased from 82% behind
the paver to 97% after 6 passes with the
BW 154 AP-AM (3x forwards and 3x backwards);
the EVIB value rose from 140 MN/m2 (1st pass)
to 230 MN/m2 (6th pass) (Fig. 9).
Analysing the change in amplitude shows that the
first two passes were compacted at maximum
amplitude (0.9 mm) and that compaction was
continuously throttled back from the third pass to
0.5 mm (Fig. 9). A further reduction in amplitude
was unnecessary in relation to the density of the
laid material (15 cm). The amplitude is regulated
automatically with no input from the roller driver.
A48 motorway CMA, cover layer 3 cm
During renovations to the Trier carriageway on the
A 48, trials were carried out on the Polch Mayen
section with a 10 t ASPHALT MANAGER roller, type
BW 174 AP-AM, on a 3 cm chip mastic asphalt
layer. The compaction requirement was 98%.
Sample compaction on the CMA 8 S PmB 25 / 55-55
gave a target value setting of 300 MN/m2.
 I N T E L L I G E N T A S P H A LT C O M P A C T I O N

The stable CMA layer, which was only 3 cm thick,
required rapid automatic reduction of the vibration
amplitude. A relatively high amplitude (0.5 mm)
was still used for compaction in the first pass, but
during the second and third passes the amplitude
was throttled to 0.2 and finally to 0.1 mm. Although
the asphalt temperature had in the meantime
The position accuracy of the BOMAG Starfire iTC
GPS system is between 20 and 30 cm. USB memory
sticks are used to transfer data to the construction
site office. This is where data is evaluated and
managed with the BCM 05 Office program module.

Fig. 9: Compaction of ABL, d =15 cm Density, EVIB and amplitude Fig. 10: BW 174 ASPHALT MANAGER.
regulation.

dropped from 160 °C to 110 °C, the system still

measured a growth in stiffness due to increasing
compaction. After three vibration passes, an EVIB
value of approx. 300 MN/m2 was achieved with a
density of 98%, as measured with a Troxler probe.

For work on the A48, the ASPHALT MANAGER roller

was equipped with the BCM 05 documentation
system (BOMAG Compaction Management) and a
DGPS system (BOMAG Starfire iTC) to monitor the
EVIB values, compaction temperatures and machine
parameters over a larger area and to compare
them with the previously determined target value.
The systems can be relatively easily and quickly
attached to ASPHALT MANAGER machines. All
decisive variables for compaction are recorded and
shown in different colours to the roller driver indi-
Fig. 11: Compaction of CMA, d=3 cm Density, EVIB and amplitude
vidually or in combination on the BCM 05 display. regulation.

9
 Fig. 12: GPS supported surface covering documentation of Fig. 13: GPS supported display of compaction of the SMA surface,
compaction with BCM05. A48, for a 370 m section.

The measured EVIB values and operating parameters

of the ASPHALT MANAGER roller are documented in
Fig. 13 for a section 370 m long and a placing width
of 7.10 m, and in Fig. 14 for a smaller section. 88%
of the EVIB values for the measured area of 2625 m2
achieved a target value of at least 300 MN/m2.
The average value is 312 MN/m2. 90% of the surface
temperatures were above 120 °C. The temperature
Fig. 14: GPS supported display of EVIB values for a section of the
distribution for the smaller section is shown in CMA.
Fig. 15. When combined with the EVIB/density
correlation which was made, this gives surface cov-
ering evidence of compaction and also ensures that
the entire area has been evenly compacted with vir-
tually the same temperature conditions.

The two representative examples show that

preselection of nominal stiffness and subsequent
target value control can very precisely monitor and
continuously adjust the amplitude. The stiffness
measurement is related more closely than before Fig. 15: Measured surface temperature (blue T > 140 °C).

to the layer being compacted. Re-producibility and

validity in terms of compaction quality are improved.
The new target value control will be part of the
latest ASPHALT MANAGER generation for series
BW154AP-4 AM, BW174AP-4 AM from spring 2010.
6. Outlook
Further developments to intelligent compaction tech-
nology by implementing target value control based on
stiffness calculations will optimise vibratory roller
compaction and improve quality.
Target value control makes it possible to co-
ordinate compaction control to the compactibility of
the mix and to produce better correlations between
the EVIB vibration module and asphalt density for
compaction temperature ranges from 160-100 °C.
The data base, which has already been developed

10

from different compaction applications and con-
tains correlation data records, will be continuously
expanded over the next few years.
The aim is for a series of asphalt applications (laid
and compacted under acceptable measuring con-
ditions) to produce nominal values which can then
be used as practical orientation values for the roller
driver to choose from.
In combination with the BCM 05 documentation
system and a GPS system (e.g. BOMAG Starfire
iTC), there is now the option of extensively record-
ing and documenting the compaction status of the
laid mix and the compaction process. Passes are
automatically counted and can be accessed on the
screen. This type of application, which is already
in use today, can be viewed as a work-integrated
method for technical and economical optimisation
of compaction work. To provide evidence of com-
paction with construction contracts, it is necessary
to carry out calibration to the EVIB stiffness module
(MN/m2) based on a correlation. The relationship
between EVIB and density has been improved by
implementing target value control, which means
we can anticipate dynamic compaction control on
asphalt in a few years.
Fig. 16: BCM net, information exchange between the laying and
compacting equipment.
I N T E L L I G E N T A S P H A LT C O M P A C T I O N
Another step towards practical implementation of
comprehensive surface covering documentation of
compaction and surface covering compaction control
for asphalt applications through the networking of
all machines involved in the placing and compacting
process. Fig. 16 shows BOMAG’s concept of BCM net
data management. Information about the compaction
status, number of compaction passes and the com-
paction temperature are exchanged between rollers
and finishers.
The cooling behaviour of the mix is determined, and
a working window is communicated to the whole
workforce which helps to improve the overall con-
struction process by making operations more con-
sistent. The first practical deployment is planned for
the summer of 2010.
Bibliography
FGSV* (2005) MV A
Merkblatt für das Verdichten von Asphalt
(Leaflet on compaction on asphalt)
* Forschungsgesellschaft für Strassen und
Verkehrswesen
Floss, R., Kröber, W., Wallrath, W. (2001)
Dynamische Bodensteifigkeit als Qualitätskriterium
für die Bodenverdichtung, Berichte, Internationales
Symposium Technik Technologie des Verkehrswege-
baus, München
(Dynamic soil stiffness as quality criterion for soil
compaction)
Kloubert, H.-J. (2003)
Optimierte Asphaltanwendung, Möglichkeiten des
Asphalt Manager Systems von BOMAG, Asphalt Heft
3, Giesel Verlag, Bonn
(Optimized asphalt application, potentials of BOMAG’s
Asphalt Manager system)
11
www.bomag.com

Head Office / Hauptsitz: BOMAG France S.A.S.

BOMAG 2, avenue du Général de Gaulle
Hellerwald 91170 Viry-Châtillon
56154 Boppard FRANCE
GERMANY Tel. +33 1 69578600
Tel. +49 6742 100-0 Fax +33 1 69962660
Fax +49 6742 3090 france@bomag.com
info@bomag.com
BOMAG (GREAT BRITAIN), LTD.
BOMAG Maschinen- Sheldon Way
handelsgesellschaft m.b.H. Larkfield, Aylesford
Porschestraße 9 Kent ME20 6SE
1230 Wien GREAT BRITAIN
AUSTRIA Tel. +44 1622 716611
Tel. +43 1 69040-0 Fax +44 1622 718385
Fax +43 1 69040-20 gb@bomag.com
austria@bomag.com
BOMAG Italia Srl.
BOMAG MARINI EQUIPAMENTOS LTDA. Via Roma 50
Rua Comendador Clemente Cifali, 530 48011 Alfonsine
Distrito Industrial Ritter ITALY
Cachoeirinha – RS Tel. +39 0544 864235
BRAZIL Fax +39 0544-864367
ZIP code 94935-225 italy@bomag.com
Tel. +55 51 2125-6677
Fax +55 51 3470-6220 FAYAT BOMAG Polska Sp. z o.o.
brasil@bomag.com Ul. Szyszkowa 52
02-285 Warszawa
BOMAG (CANADA), INC. POLAND
3455 Semenyk Court Tel. +48 22 482 04 00
Mississauga, Ontario L5C 4P9 Fax +48 22 482 04 01
CANADA poland@bomag.com
Tel. +1 905 361 9961
Fax +1 905 361 9962 FAYAT BOMAG RUS OOO
canada@bomag.com 141400, RF, Moscow region
Khimki, Klayazma block, h. 1-g
BOMAG (CHINA) RUSSIA
Compaction Machinery Co. Ltd. Tel. +7 (495) 287 92 90
No. 2808 West Huancheng Road Fax +7 (495) 287 92 91
Shanghai Comprehensive russia@bomag.com
Industrial Zone (Fengxian)
Shanghai 201401 BOMAG GmbH
CHINA 300 Beach Road
Tel. +86 21 33655566 The Concourse, #18-06
Fax +86 21 33655508 Singapore 199555
china@bomag.com SINGAPORE
Tel. +65 6 294 1277
BOMA Equipment Fax +65 6 294 1377
Hong Kong LTD singapore@bomag.com
Room 1003, 10/F Cham Centre
700, Castle Peak Road BOMAG Americas, Inc.
Kowloon 2000 Kentville Road
HONG KONG Kewanee, Illinois 61443
Tel. +852 2721 6363 U.S.A.
Fax +852 2721 3212 Tel. +1 309 8533571
bomahk@bomag.com Fax +1 309 8520350
usa@bomag.com
07/14 PRE 108 072