Best Practices for Smoothness & Density

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1 Best Practices for Smoothness & Density 55 th Annual Paving Conference Presented by Todd Mansell, CAT Paving

2 Outline 1. Paver Setup Smoothness 2. Balanced Paving Paver & Roller Speed Paver operation 3. Density

3 Lines of Communication Foreman Superintendent Truck Boss Project Manager

4 Understanding the Paver Tractor tows screed Accepts mix from trucks, MTV, etc. Feeds mix to screed Screed Floats on the mix Free to rise and fall according to many factors

5 Paver: 15 Steps to Setup &Take Off Ensures consistent takeoff every time Goal: To have a smooth transverse joint & no mat defects from the start

6 Step 1: Heat the Screed Prevents sticking

7 Step 2: Position Tow Point Cylinders Straight line-of-pull

8 Steps 3 through 6 3. Set paving width 4. Set crown 5. Set extender height 6. Set extender slope

9 Angle of Attack Angle of attack is the relationship between the nose of the screed & the trailing edge of the screed Nose up attitude Screed reaches equilibrium

10 Screed Adjustments Tow point fixed Screed pivots around fixed tow point

11 Angle of Attack Normally 1/8 to 1/4 Angle too high, screed compacting with trailing edge Erratic screed behavior Angle too low increases shear factor and wear

12 Increase Angle of Attack More material passes under screed Screed rises to new level As screed climbs, angle of attack decreases Re-establish same angle, but at increased depth

13 Changing Thickness Achieves equilibrium Resumes original angle of attack

14 Change Over 5 Tow Arm Lengths 65% of change occurs in the first tow arm length 35% of change occurs over 4 tow arm lengths Factor improves smoothness

15 Step 7: Lower Screed Place starter boards = to desired mat thickness Lower screed onto starting boards in float position Take out the slack

16 Step 8: Null the Screed Nulling the screed removes all the tension in the screed Use depth screws on each side until no resistance is felt The screed must be free-floating on the mix

17 Steps 9 through Position end gates 10. Set auger height 11. Position feed sensors 12. Set feeder controls (conveyor ratio dial and mix height dial)

18 Step 13: Fill the Auger Chamber Fill auger chamber with asphalt mix to ½ auger height Use conveyors and augers Do not overfill

19 Feed Sensors Mechanical or sonic Control level of material Position Sensor 18" from end of augers

20 Sonic Feed Sensors Sonic Sensor Mounting Distance Mounting position at 18 Working range of sonic sensor 12 32

21 Step 14: Set Automatic Grade Control Joint Match

22 Step 14: Set Automatic Grade Control Smooth

23 Step 14: Averaging Ski for Smoothness Beam Mounted To Paver Averages Surface Variation Over Large Distance Several Types Configuration Varies Depending On Conditions

24 Contact (drag) Averaging Ski 30 or 40 feet long Outside of paving width For highway projects Used with a contact or sonic sensor Reduces deviations by factor of 8

25 Steps 15 Pull off starting boards and quickly get to paving speed Check mix feed Check auger speed Check for lines in mat

26 Controlling Head of ½ auger Adjust gates/ratio Adjust auger speed Adjust auger height Position of sensors

27 Review: Paver Setup & Operation Screed is free-floating Proper head of material is ½ auger height Depth cranks are used to change mat thickness and slope 5 tow arm lengths for full change in thickness to take place Changes in paving speed usually requires a change to mix feed settings (conveyors, mix height dial) Increased head of material causes screed to rise up Decreased head of material results in screed dropping Continuous mix feed and paver speed = smoothness!!

28 Smooth Transverse Joint Straight edge tells the story Too high more rolling may help Too low hand work needed to fill in

29 Poor Starting Point Rounded face at the joint Plunge cut too deep

30 Good Starting Point Cut straight starting joint Butt joint flat Tack butt joint Clean area where screed will rest

31 Measure Height of Starting Joint Calculate thickness of starter boards General rule vibratory screed: ¼ compaction per 1 loose depth Example: Place 2-½ loose to end up with 2 after rolling In this picture, need ½ boards

32 Transverse Joint Rolling Patterns Breakdown roller starts normal pattern Paver should not have to stop and wait

33 Transverse Joint Rolling Pattern One Lane Pinches joint at angle rather than pushing hot mix away All stop marks can be cleaned up during first normal rolling pattern

34 Transverse Joint Rolling Pattern Space Allows Pinch joint from the side Utility size compactor makes job easier Leaves drum edge cut mark perpendicular to direction of rolling pattern

35 Transverse Joint Rolling Pattern First pass most of drums on cold side Check flatness Second pass, if needed, move farther onto hot side All passes static Should not have to vibrate to pinch a transverse joint

36 Balancing Paver & Roller Speed = Profile & Density Based on hot plant output and rate of mix delivery to job site Goal = continuous paving

37 Balancing Plant, Trucking, Paver, Roller Expected 2,500 tons/day 8-hr paving window End dumping (18-ton) 12-ft wide, unconfined edge 2-inch overlay 12.5mm polymer-modified mix Autumn < 70 F Given 3 rollers 84 steel vibratory (Cat CB64) 79 steel vibratory (Cat CB54XW) 82 pneumatic (Cat CW34)

38 Planning 20 minutes Pre- paving planning Tons per day Number of trucks needed Paver speed Roller speed Rolling Pattern Density Smoothness Tools available NAPA IS-120 Paving Production Calculator App Amplitude Selection App PaveCool or MultiCool Apps

39 Need 7 pieces of information Use Paving Production Calculator or use NAPA IS- 120 Worksheets 1. Plant tph & silo capacity 2. Paving window 3. Average truck capacity 4. Truck cycle time 5. Mat thickness (loose) 6. Mat width 7. Loose mix density

40 Input 7 pieces of information

41 Number of Trucks = 20

42 Paver speed using end dumps Use 75% efficiency for end-dumping Use 100% for MTV 36 fpm

43 Paver Speed, trucking & plant is balanced

44 Now, let s look at the rolling pattern 1 x Cat CB64 (84 wide drum) 1 x Cat CB54-XW (79 wide drum) 1 x Cat CW34 (82 compaction width)

45 Breakdown Intermediate Finish %TMD 90-92% 92-94% 94+ % Temp Coverage F F F (1 vibe, 1 static) Settings High A, Low F 90 psi Low A, static 120 feet 200 feet 200 feet

46 Vibratory Steel Drum Breakdown, intermediate and finish rolling Settings for amplitude and frequency Static mode for finish rolling

47 Amplitude = compactive effort High Amplitude Low Amplitude

48 Frequency = speed x impacts per foot Low Frequency High Frequency Roller speed is constant

49 Impacts per foot, Frequency & Roller Speed 10 to 14 Impacts per foot

50 Balancing Plant, Trucking, Paver, Roller Expected 2,500 tons/day 8-hr paving window End dumping (18-ton) 12-ft wide, unconfined edge 2-inch overlay 12.5mm polymer-modified mix Autumn < 70 F Given 3 rollers 84 steel vibratory (Cat CB64) 79 steel vibratory (Cat CB54XW) 82 pneumatic (Cat CW34)

51 What is a good target density for breakdown? Job spec is 92-97% Our job target for final density is 94% A good goal for breakdown compaction is 95% of our overall target density 0.95 x 94% 90%

52 Amplitude App

53 Test Strips Verify equipment and patterns develop required density Plan each phase of compaction Can be done first day of job Sometimes required in advance Don t fake it Communicate plan to all crew members

54 Number of roller passes Breakdown Intermediate Finish 12-ton DDV 14-ton tire 8-ton DDV Settings High A, Low F 1 vibe, low A, high F, 1 static 1 st Pass Temp Density 88% 92% 94% (vibe) 2 nd Pass Temp Density 90% 93% 94% (static) 3 rd Pass Temp Density 91% 93.5% 4 th Pass Temp Density

55 12-Foot Wide Lane: 84 x 2 passes Roller A Roller B 6 Overhang 12 Overlap 6 Overhang 12 Wide Mat

56 Amplitude for CB64

57 Roller speed using 84 drum Wider drum Lower frequency Higher amplitude 5-Pass pattern 40 fpm 40 fpm > 36 fpm

58 Establish an effective rolling pattern 1. Based production and density 2. Equipment Selection 3. Balance paver & roller speed 4. Test Strip Decision Point Decision Point 5. Verify during production

59 How far back?? Breakdown

60 Length of the Roller Pass Speed = Distance Time Roller speed based on frequency (ipf) Time available for compaction (MultiCool) Solve the equation for distance

61 Length of the Roller Pass Distance = Speed x Time

62 Roller Ground Speed Distance = Speed x Time Speed Calculation Frequency = 2,520 vpm We want 10 impacts per foot 2, = 252 fpm

63 Time Depends on Temperature Breakdown rolling Intermediate rolling possible tender zone Finish rolling 160 Stop rolling Keep steel drums off the mix!!!

64 MultiCool Website and Android App Google Play App store

65 MultiCool from 275 F to 252 F (breakdown roller only) Time 3 minutes

66 Length of the Roller Pass Roller speed = 252 fpm Time = 3 minutes Distance = Speed x Time = 252 x 3 = 756 ft (in 3 minutes)

67 Length of the Roller Pass 756 feet traveled in 3 minutes We have a 5-pass pattern (from test strip) to cover the mat twice = 151 feet Assume 80% roller efficiency 151 x 0.80 = 120 Length of roller pass = 120 feet Pass 1 Pass 2 **If conditions change re-calculate the length of roller pass

68 Sequence & Timing Breakdown Intermediate Finish %TMD 90-92% 92-94% 94+ % Temp Coverage F F F (static) Settings High A, Low F 90 psi Low A, static 120 feet 200 feet 200 feet

69 Top 5: Checklist for Smoothness 1. Set a target paving speed for continuous paving. 2. Make quick stops & starts with paver when end dumping. 3. Consider an MTV for non-stop paving. 4. Maintain constant head of ½ auger height. 5. Position feed sensors for continuous auger movement.

70 Top 5: Checklist for Density 1. Breakdown roller should cover mat in 3 drum widths or less. 2. Balance breakdown roller speed with paver 10 ipf. 3. Goal: Breakdown roller achieves 95% of target density. e.g x 94 90% 4. Determine the maximum roller distance behind the paver. Based on cooling rate of the mat from MultiCool or PaveCool 5. Stop the roller at an angle to the mat.

71 Locking in the joint

72 Locking in the joint

73 Paving Multiple Lifts for Density t:nmas NCAT Report 9-27 (2004) Fine mixes (12.5mm) 3:1 or greater Coarse mixes (19mm) SMA 4:1 or greater 4:1 or greater

74 Paving Multiple Lifts for Smoothness Generally best results with maximum 2 3 lifts Do NOT use automatic slope control if it can be avoided DO use automatic grade control Joint-match using averaging ski Pave mainline first, then tie-ins (driveways, shoulders, ramps, etc.) Wait until bottom layers have cooled mid-depth

75 Joint matching with ski for smoothness

76 Who s responsibility is it? Paver Speed? Paver operator? Roller Speed? Roller operator? Quality Control? Meeting Density & Smoothness targets? Quality Control? Foreman Superintendent Truck Boss Project Manager Quality Control

77

78 Thank-you for your attention! Questions? 2017 Caterpillar All Rights Reserved Materials and specifications are subject to change without notice. Featured machines in photography may include additional equipment for special applications. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, Caterpillar Yellow, and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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