BMG Varoo

BOMAG
Compaction Technologies
Lutz Stallgies – November 2017
The complete process – Need of compaction
Compaction matters …
Objectives of compaction
Soil compaction results in
 higher density
 higher strength
 reduced settlement
 reduced permeability
© BOMAG GmbH Slide 5

Each soil is different

Degree of compaction / compaction specifications
maximum dry laboratory density

according to Proctor test ( MDD ) field density
Degree of compaction = dry field density / maximum dry Proctor density ( % )
Typical compaction specification for subbase : 98 %

Compaction control by using plate tests
© BOMAG GmbH - Slide 8

Typical soil compaction problems
• Unexperienced operators
• Too many compaction passes with vibration
• Overcompaction
• Soft sublayer
• Surface loosenning specially with sandy
gravelly soils or crushed aggregate base
• ………
Compaction methods
Static compaction
Vibratory compaction
Intelligent compaction (Bomag VARIOCONTROL)
Measuring and documentation of compaction results

Static compaction with pneumatic tired roller
Compaction of 40 cm gravel sand layer ( subbase )

with BW 213 DH-4 BVC, surface compaction with
pneumatic tired roller BW 27 RH
Important weight of roller > 16 t

Very helpful for surface compaction of sandy and granular soils
BW 211 and Pneumatic tyred roller on subbase
25 cm subbase
Compaction requirement ≥ 98%

BW 211D-4 10 passes
BW 25 RH (20 t) 6 passes
Soil Compactors
Efficient large-scale spreading and distribution of soil
High pushing power

Perfect compaction of cohesive soil
and large area output
Surface compacted
with
35 t soil compactor
Soil Compactor Jobsites
France: construction of yacht harbor platform
USA: highway construction
Argentina: Road construction project N11
Soil : light plastic clay ( CL )

IP ~ 12 - 14
W opt ~ 22,8 % , PRD ~ 1,529
W n 25 - 27 %
Contarctor : Vialco
compaction achieved : 98 %

Brasil: Hydro power dam project Simplicio
upstream dam
silty soil
clay core
Contractor : Odebrecht
Layer thickness: 40 cm
leight plastic silty soil , wn ~ wopt = 21 -23 %
Compaction achieved after 10 passes:
99 % middle of layer

Static compaction with vibratory roller
Compaction depth of 12 t roller < 10 cm
Good for compaction finish on sandy and sensitive

granular and crushed material with low fines
Compaction methods
Static compaction

Traditional vibratory single drum rollers
Two amplitudes / two frequencies
small amplitude and high frequency or high amplitude and low frequency
Switch for amplitude / frequency selection on dash board

Basics in Compaction:
Which amplitude should be selected?
density
First with large – then small amplitude

depth
Large Amplitude
Small Amplitude
Basics in Compaction:
What is the right speed to select?
Speed selection
Materials Working speed
Rock
1 – 2,5 km/h
Loam
Gravel
Gravel-sand 2 – 4 km/h
Sand
"If you are driving to fast less compaction energy is transferred.”

Wide range of rollers from 3 up to 26 t
BOMAG SDR
4–8t 9 – 16 t 19 – 26 t
■ Inner city works  Road works /  Deep compaction

■ Bicycle lanes highway  Large
■ Parking areas construction construction sites
 Medium size to (e.g. airports)
■ Small to medium large
constructions  Embankment
compaction task construction
 Land reclamation
Lift thickness (m)
Machine Operating weight Rock Gravel, sand Mixed soil Silt, clay
type t
4-8 - • 0,20 - 0,40 • 0,20 - 0,30 0,10 - 0,20
10 - 15 0,30 - 0,60 • 0,20 - 0,50 • 0,20 - 0,40 0,10 - 0,20

19 - 26 • 0,50 - 1,50 • 0,30 - 1,00 • 0,30 - 0,80 0,20 - 0,40
10 - 15 0,30 - 0,60 0,20 - 0,50 • 0,20 - 0,40 • 0,10 - 0,20
19 - 26 0,50 - 1,00 0,30 - 0,80 • 0,30 - 0,60 • 0,20 - 0,40
26 - • 0,50 - 2,50 • 0,50 - 1,50 • 0,50 - 1,00
21
*
0,20 - 0,30 0,20 - 0,30 • 0,20 - 0,30 • 0,20 - 0,30
29 - 35
*
0,20 - 0,40 0,30 - 0,50 • 0,30 - 0,40 • 0,30 - 0,40
10 - 16 - 0,10 - 0,20 0,10 - 0,20 -

20 - 30 - 0,20 - 0,30 0,20 - 0,30 0,10 - 0,20
10 - 12 - 0,20 - 0,30 0,20 - 0,30 -
* only soft rock

• particularly suited to this type of soil
The heavier the roller the higher the compaction performance
12 t roller BW 212 19 t roller BW 219
BW 212 D-40 on 30 cm laterite base BW 219D-4 on 30 cm stabilized

Senegal 12 passes ≥ 95% MOD subbase, Kenia 6 passes ≥ 95 % MOD

Standard drums
Smooth drum (D/DH) Pad Foot Drum (PD/PDH)

■ Compaction of sand, gravel and ■ Use on cohesive soils
crushed rock ■ Surface enlargement for faster
■ Optimum surface quality drying
■ Tapered drum edges ■ Flexing and kneading effect
Compaction of wadi material ( 0 - 250 mm )
on water dam project Salalah, Oman
BW 219 DH - 4
compaction requirement : 98% MDD and kf 10 E6

compaction with 19 t BW 219 DH-4 on 40 cm , 6 passes

Earth dam for sedimentation basin,
gold mine, Peru
BW 219 PD
Shell kit
■ 3 segments
■ Easy installation/removal
■ No modifications necessary to the
front frame
https://youtu.be/TJnXb1CmUMk
Strong engines – true traction
Excellent Gradeability:
Reliable Engines Ready for the future:
Double pump
Deutz/Kubota Emission
& No-Spin differential
Chile cupper mine
Compaction of 30cm silty sand layers on slope
BW 213 DH-4 25 - 30 % slope
25 % gradient

The right drum for every application.
Smooth Pad foot
Bomag DI = Deep RC = Rock

Variocontrol Impact crusher
© BOMAG GmbH 38
Compaction methods
Static compaction

Intelligent Compaction
Variocontrol (BVC) singledrum roller with
automated controled variable amplitude
and integrated compaction measurement
system
> higher compaction performance - less passes, higher

layer thickness
> much more uniform compaction
> less over compaction problems
> less loosening problems in case of granular materials
> integrated compaction measuring system for
proof rolling and weak spot analysis
Directed Exciter- VARIOCONTROL
Oszillation Amplitude
From gentle to powerful!
© BOMAG GmbH 41
BOMAG VARIOCONTROL (BVC)
Oscillation – Vibration and more!
Amplitude Amplitude
= Max = Min
Advantages
■ Gentle compaction
■ Oscillation Mode
■ Intelligent control
■ Manual control
■ TERRAMTER (Evib)
Compaction tests with VARIOCONTROL at
CER Rouen , France
Degree of compaction
Taux de compactage (%)
85 90 95 100
0
50
100
150
200
250
15 t standard roller
profondeur (mm)
300
15 t VARIOCONTROL
350
depth 400
450
500
550
600
650
700
750
modèle compact 3 - BW213D3 - B2s - remblai modèle compact 3 - BW213D3 - B2m - remblai
© BOMAG GmbH - Slide 43 CER - Centre Experimentation Routiers

Railway construction in Germany
BW 219 DH
Embankments up to 8 m ;
embankment material is coming from
tunnel excavation.
type of soil: mixed soil,
% of hydlaulic binder: 1-2%
layer thickness : 400 mm
BW 226 DH-3 BVC on Shuibuya rockfill dam, China,
BW 225 DH-3 BVC

> 25 t roller with BVC system
> max amplitude : 2,6 mm
> compaction measuring system
80 cm layers

BOMAG VARIOCONTROL (BVC)
Advantages close to structures
Production building
(Steel construction)
Gravel
Clay
2m
5m
10 m
■ Step-by-step increas the amplitued (6 Steps)

■ Avoid damages to neighbouring buildings through vibrations!
■ Limit manual work with tampers and plates
Compacting over pipelines
The Challenges
■ Ethylene pipeline that provides a large chemical company with
an important resource: failure = very dangerous and costly
■ Requirements for compaction high
■ Pipeline and soil equipped with acceleration sensors
Achievements
■ Step-by-step increasing the BVC exciter
■ Documentation of compaction with EVIB
BW 226 DI-4 BVC Polygon Roller
First polygon roller 1998
today many units worldwide:

Europe , Middle East, Africa,
South America, Singapore
26 t vibratory compactor main applications :

drum load : 18 t > post compaction
1- 3 m
static linear load : 80,7kg / cm of existing ground
max. amplitude : 2,85 mm > thicklift compaction
frequency : 26 Hz
max. centrifugal force : 530 KN

Polygon-drum with BVC
High-tech for the construction site
■ For special depth effect

■ Installation of thick layers
■ Post-compaction of existing layers
Surface
pressure
Wedge Plate
= = N/cm2
horizontal Vertical
forces forces
Polygon-drum with BVC
High-tech for the construction site
Dichte Dichte
nach 2 Übergängen nach 8 Übergängen
Verdichtungsgrad [%] Verdichtungsgrad [%]

80 85 90 95 100 105 80 85 90 95 100 105
0,0 0,0
-0,2 -0,2
-0,4 -0,4
-0,6 -0,6
-0,8 -0,8
Tiefe [m] unter OK

Tiefe [m] unter OK
-1,0 -1,0
-1,2 -1,2
-1,4 -1,4
-1,6 -1,6
-1,8 -1,8
-2,0 -2,0
-2,2 -2,2
-2,4 -2,4
-2,6 -2,6
-2,8 -2,8
2 Ü. Rundbandage 8 Ü. Rundbandage
-3,0 -3,0
2 Ü. Polygon 8 Ü. Polygon
Layers of double thickness.

High productivity.
Compaction trials with 26 t BOMAG polygon roller
BW 226 BVC DI on North Al Wathba Development Zone1
density test at 1,25 m depth
All density results show compaction values > 95 % modified Proctor
> for wet ( moisture close to optimum) material 99% modified Proctor
has beenreached in 1,25 m depth after 10 passes with BW 226 BVC-DI.
> for dry material ( moisture < 0,5 % ) 96 % modified Proctor has been
reached in 0,75 m depth after 8 passes with BW 226 BVC-DI.
© BOMAG GmbH 54
Copper mine, El Sauce, Chile
heavy 26 t polygon and smooth drum rollers for mining
layer thickness 60 cm

Nigeria–Togo road, Benin section Ndali–Djougou (125 km)
Compaction of laterite Lift thickness: 60 cm

BW 226 DI-4 polygon Compaction specs : 95% MDD

BW 226 DI polygon roller
Post compaction and compaction tests ( CPT )
of dock area , seaport , Belguim
Compaction depth achieved ( CPT > 10 Mpa ) : 2m

Rock crusher – single drum roller with 26 t and BVC
 Rocks can be directly placed

 No transportation, no breaker
 Rock that can be crushed with
a sledgehammer is also
suitable for the RC
Crushing and compacting of sand rock fill
Compaction methods
Static compaction

Soil compaction Inspection Methods, Germany
100
Random spot test
90
80
Density tests on formation area
70
60
e. g. 8 tests for 2500 - 3000m²
50
12 tests for 4500 - 5000m²
40
30
20
10
0 5 10 15 20 25

Continuous Compaction Control (CCC)
full test / 100 % of area
Measuring principle video clip
Display and
Processor unit documentation unit
CCC measuring value

63
BOMAG measurement system with acceleration
sensors, electronic unit , display and printer
CCC print out for a 50 m track
measurement of soil stiffness

>> Evib (MN/m²)
BCM05 - documentation system
Evib and number of passes
CCC measuring and documentation system
CCC = Continuous Compaction Control
EVIB values Passes

Airfield extension Kristiansund / Norway
Compaction of rockfill 2 x BW 226 DH-4 BVC VARIOCONTROL

Lift thickness: 1,50 m with BCM05 and GPS

New Istanbul Airport Project
6 runways
9 km ² airport area
> 400 mio m³ of fill up to 40 m
650.000 m³ fill and compaction / day
requirement: ≥ 95 % mod. Proctor
60 BW 226 PDH
40 BW 226 DH
15 BW 226 DI
Quality Control Testing Concept video clip

600.000 – 800.000 m³/day of soil to be compacted; layer thickness 0,40 m
≥ 1.500.000 – 2.000.000 m² / day to be checked
Conventional test procedure 1 test / 2000 m²

≥ 750 – 1000 tests / day
Quality Control with BOMAG CCC
40 BW 226 DH with BCM05 / GPS

 full area control
 Much less conventional inspection test: 50 – 70 / day
 Much faster
 Full documentation
Compaction quality control with BCM / GPS

Compaction measurement and documentation systems
for soil and asphalt compaction
ECONOMIZER ECONOMIZER BTM and printer

for plates and light
tandem rollers
for heavy tandem rollers for single drum rollers
BCM05 BOMAG StarFire ®

BCM net
BOMAG Compaction BOMAG DGPS for pass communication between asphalt
Management for quality counting and easy quality rollers for more efficient and
documentation documentation better compaction process
Benefits of roller integrated
measurement and documentation systems
■ Less compaction passes

■ Better compaction efficiency
■ More uniform compaction
■ Less conventional density tests required
■ Much better compaction quality control
Asphalt road design solutions depending on
road classification , German road classes
Thickness in cm, modulus of deformation EV2 in MN/m²

VB = number of vehicles on one lane with a total weight of > 2.8 t (according to German specifications)
Asphalt structure after compaction
The authorities require good compaction, even surface and

nice uniform surface quality with good skid resistance
the authorities and / or consultants don`t like to see

damaged mix ; break or even pulverization of aggregates
they don` t like too smooth surface without skid resistance
Wide range of various types of asphalt mixes
 Hot Mix Asphalt with x % of recycling mat. (RAP)

 Stone mastic asphalt / SMA (German design)
 Porous asphalt (European design )
 Warm mix asphalt (European and US design)
 Superpave asphalt (US design)
Dense-graded Gap-graded
Open-graded
Easy to compact Difficult to compact Difficult to compact

Structure of conventional hot mix asphalt
continuous graded mix
Continuous graded mix with crushed

and or round shaped aggregates
standard or polymer modified bitumen
Stone mastic asphalt ( SMA 0/11)
SMA increases safety by reducing vehicle spray

SMA is a strong pavement for high traffic and heavy truck routes
Less chance a vehicle will hyrdo-plane on a SMA surface
gap graded mix
Gap graded with high crushed

aggregate content
aggregate skeleton,
filled with a mastix of filler , sand
and polymer modified bitumen :
> difficult to compact

Paving and compaction
the higher the precompaction the better the eveness

low : < 80 %
medium: 80 - 90 %
high: > 90%

Asphalt rollers
Walk behind rollers, 5 models Light tandem rollers, 10 models Combination rollers, 10
0.65 - 0,75m; 650 -1000kg 0,80m - 1,30m; 1,5 t - 4,5 t models; 0,80 - 1.68m ; 1,5 t - 9 t
Heavy articulated tandem Heavy pivot steered tandem PTR rollers;

rollers, 8 modeles ; rollers, 5 models; 10 - 27 t 4 modeles
1,50m - 2,13m, 8 - 14 t 1,50m - 1,68m; 7 - 10 t

Compaction methods
Static compaction
Oscillation /
Intelligent compaction
Compaction measuring and documentation

Static compaction
Pneumatic tired roller
Smooth compaction
kneading the asphalt by
vertical and horizontal forces
tire pressure,no asphalt cracks
Operating weight classes

+ light: 5–10 t
+ medium: 12–16 t
+ heavy: 20–30 t
Applications of PTR
Breakdown rolling Chip and seal
Intermediate and
finish rolling
Static compaction with tandem roller
Applications:
breakdown rolling
compaction of tender mixes
finish rolling
thin layers ( ≤ 2,5 cm )
Static compaction often not efficient for new asphalt mixtures

Compaction with combination roller
Compaction methods
Static compaction
Oscillation /

Traditional vibratory tandem roller
Asphalt rollers / tandem rollers with two amplitudes and two frequency
Amplitude´setting by operator
> high compaction performance, less passes

> necessary for difficult to compact mixes and thick layers
> trained and experienced operatores required
Typical and asphalt compaction problems
 Unexperienced operators
 Too many compaction passes with vibration
 Overcompaction
 Crushing and pulverization of aggregates
 Surface loosenning effects specially
 crushed aggregates
Asphalt base compaction , highway Turkey
2 BF 800 C
2 BW 27 RH
2 BW 206 AD
Compaction of asphalt surface course
Highway Beijing – Tibet, China
paving: 2x BF 800 C
compaction:
4x BW 203 AD-4 (13t)
2x BW 27 RH (20t)
Worldwide jobsites
Asphalt compaction
BF 700-2, BW 202 AD-50 and BW 24 RH; Bolivia

Compaction methods
Static compaction
Oscillation /

Compaction methods
…. the efficient Oscillation

for asphalt rollers
BOMAG Oscillation
Characteristics of TanGO:
 Drum always in contact
 For high speeds, no “Impact spacing”
 The frequency has double effect
 No waves
 No jumping
 No crushing
BOMAG Oscillation
BOMAG oscillation for

BW 161 / 190 / 202 ADO-5
BW 161 / 202 ADO-50
Vibration
Oscillation :
> for asphalt layers
> less critical in case of too many passes
> suitable for thin layers and on bridges
> very easy to operate – only on/ off switch
> wear resistant steel
BW 161 Tango roller on asphalt job in Mexico
Excellent compaction and surface finish result

Compaction methods
Static compaction
Oscillation /

Asphalt Manager (AM)
Tandem roller and with automated controled variable

amplitude and integrated asphalt temperature and
compaction measurement system
- highcompaction performance
- Very good asphalt surface quality (texture)
- Good for thick and for thin layers
- Recommended to be used on bridges
 The optimum power for any material, layer thickness and application
 Amplitude adjustment by switching the oscillation direction
 Fastest compaction increase using linear amplitude
Advantage: Versatile, flexible roller

One roller for all applications
 The driver only chooses the layer thickness

 The machine regulates the rest
 Simple to operate
 Always an eye on the temperature
 The end of compaction can be recognized
EVIB target reached
Amplitude is reduced
Optimal quality with just a minimum number of passes

No system is as flexible as ASPHALT MANAGER

ASPHALT MANAGER includes also oscillation.
But ASPHALT MANAGER is able to do much more:

- The right power for each application
- Quickest compaction increase by vertical amplitude
Oscillation mode Maximum depth effect

Automatic adaptation of vibration to the travel direction

No bow waves, no scuffing
Standstill control:
Vibration runs with zero-amplitude, no digging in, quick reaction
Compaction methods
Static compaction
Oscillation /

Compaction control for asphalt roller
ECONOMIZER:
easy
efficient
robuste
Transparency with the Economizer –

a permanent display of compaction progress
 Avoids under/overcompaction
 Saves time
 Reduces remedial work
 Improves quality
 Saves money
ECONOMIZER for tandem roller, series – 5 and - 50
Easy to operate and efficient

110 °C Indication of
- Increase of compaction
- temperature in °C
Documentation of Evib values , number of passes and asphalt temperature
BW 154 AP AM BCM05 documentation :

- Evib values
- number of passes
- asphalt temperature
BCM – Compaction quality and compaction pass

BOMAG Compaction Management
 The entire compaction process
is continuously documented:
> number of passes,
> compaction progress
> asphalt surface temperature
 Operator has the information
in real time on the BCM display
in front of him
 All information is stored and
can be printed out
BCM05 documentation :
- Evib values
- number of passes
- asphalt temperature
BCM net
 Networking of rollers in a network
 Each participant in a network can follow the complete compaction
progress of the entire construction site in real time
BCM net
 Networking of rollers
 Each operator can see the complete compaction progress
of the entire construction site in real time.
BCM net - compaction process presentation

for all roller operators

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BOMAG

© BOMAG GmbH Slide 5

© BOMAG GmbH Slide 6

maximum dry laboratory density

Degree of compaction = dry field density / maximum dry Proctor density ( % )

Typical compaction specification for subbase : 98 %

© BOMAG GmbH Slide 7

© BOMAG GmbH - Slide 8

Intelligent compaction (Bomag VARIOCONTROL)

Measuring and documentation of compaction results

Compaction of 40 cm gravel sand layer ( subbase )

Important weight of roller > 16 t

Compaction requirement ≥ 98%

Efficient large-scale spreading and distribution of soil

High pushing power

Soil : light plastic clay ( CL )

© BOMAG GmbH Slide 19

© BOMAG GmbH Slide 20

Compaction depth of 12 t roller < 10 cm

Good for compaction finish on sandy and sensitive

Intelligent compaction (Bomag VARIOCONTROL)

Measuring and documentation of compaction results

Switch for amplitude / frequency selection on dash board

First with large – then small amplitude

"If you are driving to fast less compaction energy is transferred.”

■ Inner city works  Road works /  Deep compaction

4-8 - • 0,20 - 0,40 • 0,20 - 0,30 0,10 - 0,20

10 - 15 0,30 - 0,60 • 0,20 - 0,50 • 0,20 - 0,40 0,10 - 0,20

26 - • 0,50 - 2,50 • 0,50 - 1,50 • 0,50 - 1,00

10 - 16 - 0,10 - 0,20 0,10 - 0,20 -

10 - 12 - 0,20 - 0,30 0,20 - 0,30 -

* only soft rock

12 t roller BW 212 19 t roller BW 219

BW 212 D-40 on 30 cm laterite base BW 219D-4 on 30 cm stabilized

© BOMAG GmbH Slide 29

Smooth drum (D/DH) Pad Foot Drum (PD/PDH)

compaction requirement : 98% MDD and kf 10 E6

© BOMAG GmbH Slide 32

© BOMAG GmbH Slide 37

Smooth Pad foot

Bomag DI = Deep RC = Rock

Intelligent compaction (Bomag VARIOCONTROL)

Measuring and documentation of compaction results

> higher compaction performance - less passes, higher

From gentle to powerful!

© BOMAG GmbH - Slide 43 CER - Centre Experimentation Routiers

BW 225 DH-3 BVC

© BOMAG GmbH Slide 46

■ Step-by-step increas the amplitued (6 Steps)

First polygon roller 1998

today many units worldwide:

26 t vibratory compactor main applications :

© BOMAG GmbH Slide 49

■ For special depth effect

Verdichtungsgrad [%] Verdichtungsgrad [%]

Tiefe [m] unter OK

Layers of double thickness.

density test at 1,25 m depth

All density results show compaction values > 95 % modified Proctor

heavy 26 t polygon and smooth drum rollers for mining

© BOMAG GmbH Slide 55

Compaction of laterite Lift thickness: 60 cm

© BOMAG GmbH Slide 56