The Asphalt

Compaction
Technology
Guide
Best Practices for Using Technology
to Increase Pavement Durability
& Smoothness
Presented by World of Asphalt
Table of
Contents
i. Introduction
ii. Getting Your Paving Project Off
On the Right Foot
iii. Tips to Achieve Optimal
Asphalt Compaction
vii. Practical Technologies for
Asphalt Compaction
ix. Managing Technology in Your
Paving Business
xi. Compaction Equipment: What to
Consider When Purchasing
xiv. Conclusion
xv. Glossary
xv. Resources
Introduction
Thank you for downloading The Asphalt Compaction Technology Guide.

While the basic elements of asphalt paving have remained the same,
technology in the equipment is changing at an increasingly rapid pace. This
eBook will provide you with tips and expert advice to understand the latest
advances in asphalt compactor control functions and technologies, as well
as what to look for when purchasing new equipment.

On the pages of The Asphalt Compaction Technology Guide, you’ll learn

from experts in all thing “compaction”, many of whom have been past
presenters or exhibitors at World of Asphalt, the industry’s leading asphalt
trade show and conference.

Held every year, except for when CONEXPO-CON/AGG is held, World of

Asphalt features industry manufacturers and service providers in the
aggregate, asphalt, pavement maintenance, and traffic safety sectors. At
the upcoming World of Asphalt, March 29-31, 2022 in Nashville,
Tennessee, an in-depth and well-rounded educational track on paving will
be presented. For more information, visit worldofasphalt.com.

The Asphalt Compaction Technology Guide i

Getting Your Paving Project
Off On the Right Foot
Compaction is the final, but arguably
most important step of constructing
a smooth, durable asphalt roadway.
Compaction by definition is the
process of mechanically increasing
the density of a layer of material.
Density is altered by decreasing the
air voids between the particles of
the mix. Denser material is stronger
and can better support heavier
loads without rutting or cracking.

Effective compaction helps extend the service life of a road and save
on future maintenance costs. Because of this, federal and state highway
administrations have implemented strict standards for
pavement performance.

Unfortunately, many people in the industry are still using dated practices
that lack efficiency or hurt the final product. If the paving world wants to
maintain its reputation for sustainability, then it must return to the heart of
good paving practices: proper compaction.

A lack of knowledge can result in good projects going wrong in the final
steps. Dale Starry, Global Sales Training Manager in Compaction for Volvo
Construction Equipment, shares small but important steps that often get
left out of the equation, beginning with local laws.

Adhering to Local Codes

and Specifications
Every state possesses its own series
of codes and specifications for
paving procedures. Before beginning
a project, simply researching what
the state requires for safety and
longevity can solve the majority
of problems that might arise on
the jobsite.

The Asphalt Compaction Technology Guide ii

Knowing the difference between prescriptive and performance building
specifications can get crews started on the right track.

• Prescriptive codes inform workers on what machines and settings

to use, which lead to a uniform product every time. Most codes
will function on this principle, not requiring any innovation or
outside-the-box thinking from construction crews.
• Performance codes detail only the required result, such as the uniform
density or appearance required by the city. There will be no path or
blueprints on how to achieve these standards. This is why experience
and talent always play a role in the final product.

Understanding the Basics

For pavers looking to maintain a
uniform performance that could
match any code thrown at them,
some of these basics can come
in handy:

• Slow down to optimal speed

(between 2-5 mph depending on
drum diameter).
• Organize paving trains for
optimal speed.
• Adjust amplitude for thickness of layer.
• Read studies like the NCHRP 856.

The needs of roads are changing. With increasing traffic loads around the
country, asphalt needs to handle more weight more often and with greater
resilience. To combat this, new techniques must be implemented and may
require practice. Keep reading to learn expert tips for achieving optimal
asphalt compaction.

Tips to Achieve Optimal

Asphalt Compaction
Smooth pavement is the goal,
but there are many factors that
play a role in the end result of your
blacktop. It can be difficult to
achieve optimal density of your
asphalt mix, but by changing one

The Asphalt Compaction Technology Guide iii

or multiple facets of your daily operations, you’ll be on your way to
smoother, denser asphalt.

To assist contactors in attaining high quality compaction, Todd Mansell, a

product application specialist for Caterpillar, shares his best practices for
asphalt compaction.

What is Compaction?
Compaction in its most basic form is the act of getting the air out of your
asphalt mix in order to reach peak performance of your mix. Compaction
starts behind the paver screed – both tamping and vibratory. Operators only
have a limited amount of time to get the best density from the asphalt mix.
Smoothness of the road is directly impacted by the compaction efforts.
Understanding the compaction process helps roller operators be more
efficient and effective.

Crews should try to keep compacted air voids between three and seven
percent. Air voids higher than eight percent can allow moisture to permeate
the pavement. Air voids below three percent can also be problematic as
it won’t allow sufficient room for expansion of the asphalt binder in
hot weather.

Here are five practical tips to help your paving crew achieve both density
and production:

1. Keep an Eye on Your Mix Temperature

To reach optimal compaction, you need to hit the optimal temperature for
your mix. This is achieved when the mix is still hot, regardless of the type
of mix you use. Creating density is easiest when you’re at the highest
temperature for the type of roller you’re using. An excessively wetted drum
can overly cool asphalt, resulting in less flexibility after additional passage
and potential segregation of the pavement.

The chart to the right

reflects the temperature
to hit for each specific
roller. If you’re working with
a heat that’s too intense for
your roller, you run the risk
of bulging.

The Asphalt Compaction Technology Guide iv

Climate and weather conditions are additional factors that must be
considered. Cold weather and high wind velocity will cool the hot mix down
faster and it will be more difficult to compact. Since there is less time to
compact the mix, contractors may want to consider using a larger roller or
more rollers to speed up the compaction process.

2. Establish an Effective Rolling Pattern with the Correct Roller

The number of rollers required for your project should be based on the
square yardage being placed. While six or more rollers may be necessary
for large jobs, small jobs may require just one.

The rolling pattern of your machine or machines used directly affects

compaction. Not only is uniformity among the pavers key, but the vibration
capabilities of the machines may vary by make and model. This requires
specific consolidation and planning by the drivers beforehand.

Many projects are compacted with three rollers: a breakdown roller, an

intermediate roller and a finish roller. Each roller makes multiple passes.

The breakdown roller develops the majority of the density in an asphalt

layer. It works immediately behind the paver where the asphalt is the hottest
and it must match the production and speed of the paver. Breakdown rollers
can be of any type but are most often vibratory steel wheel or pneumatic
tire. This initial roll should be completed before the surface temperature of
the mix falls below 240° F.

Next, you have the intermediate roller, which comes into play immediately
after the breakdown roller. The goal here is to develop final target density of
100 percent. Pneumatic tire rollers are occasionally used as intermediate
rollers because they provide a different type of compaction than a
breakdown steel wheel vibratory roller. If using a pneumatic tire roller, make
sure the tires stay at the same temperature as the mat being compacted.
Sitting and waiting will cause the tires to cool and may result in them
picking up chunks of the mix during the next pass.

Lastly, there are finish rollers whose goal is to clean up marks left by
previous rollers. This state may achieve additional density gain. Static
steel wheel rollers are primarily used as finishing rollers because they can
produce the smoothest surface of any roller type. This final pass should be
completed at a mix surface temperature above 175° F.

The Asphalt Compaction Technology Guide v

3. Roll at the Right Speed
Speed is another factor that can have a significant impact on the quality of
the mat. Speed should be kept constant and it’s very important that the
paver and roller are in sync to maintain consistent density.

Speed also helps maintain the correct impact spacing for vibratory rollers.
Maintaining 10 impacts per foot can help prevent ripples in the mat.
Operators should also avoid stopping or starting quickly and sharp turns,
which can cause rips, tears and indentations.

4. Use Test Strips to Ensure Compaction Quality

If you’ve done everything right up to this point, your next step is to check
your work. Start by confirming your equipment and patterns developed the
required density for the project. Check screed laid density and monitor the
temperature of the asphalt layer. Document the start and stop of your
tender zone, if any, directly on the road. Check the density across the width
of the asphalt layer and after each breakdown pass so you can outline the
gauge placement and pull the core out as soon as possible. Verify the
accuracy of onsite testing gauge and determine the number of roller
passes. Trial and error will lead you to the ideal roller pattern to achieve
optimal density and compaction.

5. Communicate with Your Team

Preparation, planning and training are key
components of achieving optimal asphalt
compaction, but they mean very little if
nothing is being communicated. Smooth
asphalt roads are paved when the paving
operator is in tune with the roller operator
who is in sync with the quality control team
who is working closely with the hot plant.

With these tips, site managers and their

teams can achieve the optimal asphalt
compaction keeping customers and drivers
safe and happy. Holding regular meetings, planning and communicating
before a job, and reducing distractions can be the strongest tactics in
raising the quality of paving. Because at the end of the day, no amount of
equipment or measurements can change the skill of the operators; they
have the final say in the quality of the product, so they should be where the
industry starts to improve.

The Asphalt Compaction Technology Guide vi

Practical Technologies
for Asphalt Compaction
Compaction is a very technical and
important process in roadway
construction. Achieving required
density specifications is critical,
and technology can help optimize
this process.

Tim Kowalski, applications support

manager for Hamm, shares some
of the asphalt compactor control
functions and technologies that can
help you attain high-quality and
uniform pavements.

1. Vibrating Drum Amplitude and Frequency

The vibratory force of rollers used in asphalt paving use the weight and
impact of the rollers vibrations to create a rapid succession of pressure
waves that spread in all directions. These pressure waves help break the
bond between the aggregates and set them in motion. The aggregates
reorient themselves under the weight of the drum and impact forces.
Centrifugal force is used to lift and drop the steel drum of the roller as it
moves. Amplitude is the height at which the drum lifts.

The other aspect of vibratory force is frequency. Frequency is the number

of times that the drum hits the mat and is rated in vibrations per minute.
Vibratory frequency is relative to the machine’s working speed. The drum
moves up and down rapidly to create the force of vibration.

There are many factors to consider in rolling when it comes to vibration,

including pavement thickness. Many rollers are now equipped with
automatic adjustments of vibrating drum amplitude or frequency based on
the feedback the machine is receiving from the material it is compacting.

Operators can change either the amplitude or the frequency. But take
caution when changing the frequency, as it effects impact spacing. Impact
spacing is critical to ensuring consistent density from pass to pass. In
addition, vibration should not be used for any pavements under 175 degrees
Fahrenheit as it will build bumps or destroy the aggregate.

The Asphalt Compaction Technology Guide vii

2. Dynamic Force of Compaction
Optimal asphalt compaction is achieved by drum energy vectoring. The
automatic adjustment of drum dynamic force is possible and already
available from several manufacturers. For example, BOMAG’s Asphalt
Manager II system automatically measures, regulates and documents
changes in compaction. As conditions change, the machine will correct
the compaction direction from vertical (deep-acting high-performance
compaction) to horizontal (sensitive, low-vibration surface compaction).
Systems like this can help reduce the number of roller passes required
while maximizing density and smoothness.

3. Oscillation Drum(s)
Oscillation is another important factor for good compaction. When you
can’t vibrate because of temperature, you can always oscillate. Oscillation
does not move off of the ground, but rather scuffs the surface. It will not
destroy or damage the mat. An oscillatory drum motion alternative to
vertical drum movement (amplitude) is now available from most vibratory
compactor manufacturers.

4. Pass Mapping
Intelligent Compaction (IC) systems typically incorporate pass mapping
technology using high-resolution GPS technology. This results in a more
consistent pass count, more consistent density and increased productivity
by using the most efficient rolling pattern.

5. Temperature Mapping
Temperature is critical for better compaction. Operators of every roller in
the train benefit from knowing the surface temperature beneath their
compactors. Monitoring temperature ranges through IC helps improve
consistency with density. Operators should monitor the pass counts and
temperature warnings to compact the newly laid asphalt at the right
temperature in the shortest amount of time.

6. Mobile Apps
There are now apps available from many manufacturers that enable
contractors to work smarter and be more efficient. For example, the
PaveCool app allows you to input the temperature of the base, the
temperature of your mix, thickness and type of mix to calculate the
automatic cool down rate and how much time you have until your
pavement hits 175 degrees Fahrenheit.

The Asphalt Compaction Technology Guide viii

Managing Technology in Your Paving Business
It is not always easy to produce a consistently high-quality pavement. Two
new technologies that may help in this area are thermal imaging, which
measures the temperature of the mat behind the paver, and intelligent
compaction. These can provide paving crews and engineers with
information that may be used to improve consistency of paving and
compaction operations.

Tim Kowalski, applications support manager for Hamm, says both

technologies have merit on their own but both can also give us a broader
understanding of how to manage technology in our businesses.

What is Thermal Imaging?

Thermal imaging uses an infrared (IR) bar that hangs off the back of
the paver, just behind the screed, and uses infrared sensors to monitor
pavement temperature. The number of sensors varies to match the paving
width. Those sensors provide real-time information on temperature and
while the system saves the data for later analysis.

What is Intelligent Compaction?

Intelligent compaction debuted in 2007, saw wider use starting in 2011,
and now is used on about 1,000 projects each year. The tool provides the
information needed to compact the mat optimally while minimizing
over-compaction. This reduces cost and improves the long-term
performance of the pavement. The system can be factory-ordered or
upfitted later to Hamm rollers. Hamm also provides a gateway portal so
that systems from Topcon and Trimble can use Hamm OE sensors.

The Asphalt Compaction Technology Guide ix

Technology Lessons Learned
Here are the top five things learned from these paving technologies that we
can apply to our use of technology in general.

1. Know the requirements of your market. “States vary in their require-

ments for thermal imaging,” says Kowalski. “Some are merely interested,
some are in trial and testing, some require it but only on specific projects.”
He says it will likely be three to five years before the majority of agencies
start requiring the type of data thermal imaging provides.

2. Understand the limitations. “I prefer the term ‘GPS mapping’ to

‘intelligent compaction,'" says Kowalski. “The latter implies the technology
controls machine function, as it does on a dozer, which it does not on a
roller. It provides good information but it’s up to the operator and the
contractor to make adjustments based on that information.”

3. Understand the data. Intelligent compaction provides information on

pass count, stiffness and temperature. Know what the numbers mean.
“Thermal imaging can indicate two types of problems,” says Kowalski,
“sporadic or consistent.” Sporadic issues can result from the number of
stops the paver makes, the number of trucks in use, the unloading
procedures and more. An example of a consistent problem would be a
streak in the mat, which suggests possible paver setup issues.

4. Look to the future. Infrared bars were a first step in thermal imaging
and were a real boon to the industry when introduced, but their mapping
accuracy and data-gathering capabilities are now being eclipsed by
emerging technologies that use infra-red cameras and more sophisticated
sensors. If you have an IR bar, consider upgrading. If you don’t, consider
skipping that device and starting out with a more sophisticated system. As
for intelligent compaction, many contractors are adopting it now even if it’s
not being required in their market at this time. “They know it will eventually
become a requirement and they want to have the equipment and expertise
in place when that day comes,” says Kowalski.

5. Understand your agencies. They’re not contractors and they don’t have a
contractor’s mindset. “They may require the information provide by thermal
imaging or an intelligent compaction system,” says Kowalski, “but they’re
not analyzing it at the end of each day. It’s more likely they won’t look at it
until the end of the week or even the end of the project.” And the data aren’t
there to provide a basis for finger pointing by the agency. “Both thermal
imaging and intelligent compaction are data-gathering tools allowing
agencies and contractors the ability to acquire, access, and analyze
project-related information together to build future projects better.”

The Asphalt Compaction Technology Guide x

Compaction Equipment:
What to Consider When Purchasing
Compaction equipment has been
undergoing rapid change in recent
years. Just about everyone working
in road construction has at some
point operated a compactor. It is
the machine that many people first
operate before taking on more
challenging jobs. However,
technological changes to the
machine category has made
compaction equipment operation
more sophisticated, and contractors would be wise to change who they put
in the operator’s seat so they can gain the greatest benefits from the most
recent technological innovations.

Chief among the changes to modern compactors include:

• Intelligent compaction
• New drum technologies
• Technologies that ease operation and maintenance

Intelligent Compaction
Intelligent compaction (IC) is comprised of a series of features that include
providing real-time information to the operator and automation.

Case DV Series rollers can be equipped with Case ACE Force IC system,
which improves compaction quality by giving the operator needed visibility
in order to avoid under- and over-compaction. “It is now very common to
see compaction meters made available from compaction equipment
manufacturers,” says Jeremy Dulak, product manager, compaction, Case
Construction Equipment. “These meters measure the amount of rebound at
each drum as they go over an area.

Volvo’s proprietary IC system—Compact Assist with Density Direct—

provides real-time density data so operators can eliminate guesswork, as
well as temperature mapping and pass mapping. Available on all C-Series
compactors, these features allow operators to react while the mat is still
workable versus waiting for a core sample or nuclear test. And it measures
the entire mat, whereas core samples and nuclear tests reveal density data
for only a single location.

The Asphalt Compaction Technology Guide xi

“Intelligent compaction solutions enable operators to monitor critical
factors such as pass count and mat temperatures in real time. This allows
them to optimize the efficiency and uniformity of their work, leading to
lower costs, greater smoothness and longer pavement life to enable
consistent, uniform compaction,” says Bryan Downing, Global Sales
Consultant, Caterpillar.
New Drum Technologies
The single most important
component on the compactor is
the drum, so it is no wonder that it
gets a lot of attention when
manufacturers redesign these
machines.

The drum off-set design on

Hyundai and Case compactors
offers tighter turning radiuses for
added maneuverability when
compacting in confined areas and when maneuvering around obstacles, as
well as improves mat quality.

“The ability to offset drums is important for a couple of reasons,” says

Dulak. “When compacting asphalt on a roadway or another large-scale
project, it’s important to bind each pass together. By having a compaction
machine that allows you to have the rollers either in-line or offset, you’re
able to have an overlap of up to six inches to bind the two passes together.”

Cat rollers can be equipped with one of three different vibratory systems,
allowing contractors to choose the system most suitable for the types of
asphalt mix they work with. Additionally, some models can be configured
with an oscillatory drum to provide alternate compaction energies.

On some Volvo compactors, an optional eight-amplitude drum provides

lower amplitude to prevent over-compaction on thin lift applications.
“To improve productivity for thicker lifts, the drum’s higher settings ensure
thorough compaction in as few passes as possible. The large diameter
drum provides a high-quality mat finish and can be set to rotate
continuously in its travel direction to prevent shoving of the material,” says
Mark Eckert, Global Product Manager, Volvo.

The Asphalt Compaction Technology Guide xii

Technology That Simplifies
To aid contractors in their practice
of putting lesser experienced
operators in their rollers, OEMs are
simplifying machine operation.

“Cat rollers are advanced

machines, but very simple to
operate,” says Downing. “Controls
are ergonomically designed and
easy to understand. The operator’s
station ensures comfort and
maximizes visibility and safety. These factors help operators maintain
confidence and control, allowing them to focus on the work and
optimize production.”

The automatic vibration control found on Case DV series compactors

makes it easier to avoid surface damage when starting or stopping the
machine. The ability to set a maximum speed means the compactor will
not move forward too quickly relative to the frequency of the drum.

Along with simpler operation comes simpler maintenance. Hyundai uses a

sealed, maintenance-free, Teflon-coated bearing in the articulation joint of
their single-drum roller models. “This reduces maintenance costs and
eliminates the need for daily greasing,” says Plotkin. Also, sealed bearings
and drums simplifies daily maintenance routines and helps limit
maintenance expenses.

Key Insights for Buyers

For those who are considering purchasing a new compactor, these experts
urge you to consider uptime, ease of use and total cost of ownership when
making a purchase.

“There are many variables that determine the right roller for each
compaction job,” says Dulak. “Factors include the width of the area to
be compacted, the final density required, the grade of the area to be
compacted, the type of asphalt mix, as well the type of materials that lay
below the lift being compacted. There are also considerations related to
weight, frequency, amplitude and centrifugal force that will have an effect
on final density.”

The Asphalt Compaction Technology Guide xiii

“No matter the brand or model, buyers should look for a compactor capable
of maximizing uptime with high-quality output and consistent results, as
well as one that is backed by reputable dealer and equipment OEM support
and service,” says Eckert.

“Simplicity is the key,” says Plotkin. “Most compaction rollers don’t have a
dedicated operator – anyone operating another piece of equipment on the
jobsite can and does operate a compaction roller. Hyundai has taken that
fact into consideration in designing our compaction roller models to be very
easy and intuitive to operate.”

“Buyers should consider the total cost of ownership—not just the initial
purchase price, but also other factors over the lifetime of the machine,” says
Downing. “This will include the owning and operating costs. What is the
annual cost for maintenance? Does the machine offer Eco-mode for lower
fuel consumption? What are the costs for training? What is the resale value?
Over the course of ownership, these factors can have a big effect on the
actual cost of the machine.”

To see the latest compaction equipment and technology on display, attend

World of Asphalt 2022. For more information visit worldofasphalt.com.

Conclusion
We hope you’ve found the insights presented in this eBook to be of value.
Whether you’re an entry-level equipment operator or a company owner,
understanding the importance of compaction is key to producing smooth,
durable pavements while preventing unnecessary wear and tear
on equipment.

Many of the experts who’ve shared insights for this eBook have been
past presenters at World of Asphalt. Held every year, except for when
CONEXPO-CON/AGG is held, World of Asphalt features industry
manufacturers and service providers in the aggregate, asphalt, pavement
maintenance, and traffic safety sectors.

World of Asphalt’s comprehensive education program is the leading source

for contractors, business owners, construction material producers and end
users to obtain cutting-edge information for today’s challenging economy
and business model. For more information, visit worldofasphalt.com. The
next show will be held March 29-31, 2022 in Nashville, Tennessee.

The Asphalt Compaction Technology Guide xiv

Glossary
Amplitude is the size of the hammer used to compact material with.
Frequency is speed at which the hammer can swing.
Centrifugal Force is the force generated in pounds by the eccentric weights
rotating within the drum.
Nominal Amplitude is the vertical movement of the drum in inches created
by the centrifugal force.
Operating Weight is the maximum weight of all machine components
and operator.
Density is the unit weight of a mixture. It measures specific gravity on
in-place compacted density divided by the theoretical maximum
gravity (Gmm).
Air void content measures the amount of air pockets in the asphalt, with too
much or too little leading to a host of different complications.
VPM is vibrations per minute.
IPF is impacts per foot.

Additional Resources
For more insights on proper asphalt compaction, our sources recommend
the following additional resources:

• Transportation Research Board

• National Asphalt Pavement Association
• Federal Highway Administration

The Asphalt Compaction Technology Guide xv