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1. 03 06 O7 13 16 20 23 25 32 19 2 5 1 0 2 33F GPRMC 2 GPS data Status Valid GPS quality Indicator Differential GPS fix 26 N 09618 700678 VW 002 0 341 4 240609 5 8 E 0 25 GPGRS 204404 00 1 0 1 0 1 0 4 0 1 0 2 0 1 0 0 0 2 GPS Select mode A 204404 00 7F GPGGA 204405 00 3034 44532033 N 09618 70089651 4 2 10 1 0 96 424 M 23 281 M 5 C GPS working mode 3D fix GPS Satelites Information total satelitea ic 1N Figure 12 Function of Viewing the GPS Raw Data Another toolbar button eS 1s also provided to check the accuracy of the GPS receiver This chart shows the roller running path The screenshot that appears after clicking the Lad button is shown in Figure 13 16 Untitled GPSRoll EIER File Edit View Help File numbe File name Number of GPS reca Test Date Test time Test Comment Cursor GPS position Latitudt 2S 4 O0 EU Y s w udw rp NOM 72800 0cm Latitude 30155306243 Longitude 96729190142 Level Ft 132204 Other Information NMEA type GGA GLL VTG GSV GSV GSV GSA RMC RMC RMC RMC Fixed Satellites total 10 3 6 7 13 16 20 23 25 32 19 PDOP accuracy of position 2 500 HDOP accuracy of Horizontal 1 000 VDOP accuracy of Vertical 2 300 Current time in UTC 202817 00 Current date 240609 Tracking Degree 122 600 Magnetic Tracking 0 000 Read Raw Data Magnetic Variation 5 800 76 GPGGA 202817 00 3033 18374556 N 09617 51408540 W2 10 1 0 92. 11 09 mm glem a 110 852 m E m 1 108525 km 11 085328 km Longitude Accuracy Chart of Roller Moving Distance for Each Digital Change DD DDDDDDDDD Mora 9 649 m 96 486 m 96863 m 9 6486276 km Figure 18 GPS Location Accuracy Chart Figure 19 is an enlarged view of the compaction effectiveness display from Figure 16 This information is displayed in real time for the roller operator to view the coverage on the mat 21 that is being compacted Displays such as this should be useful to ensure that uniform effort 1s being applied to all areas of the mat Figure 19 Color Coded Compaction Effort Map Real Time Displayed j 245 If the user starts the data acquisition by selecting either the ull Or Y l button then the real time number of roller passes or mat temperature of the first pass will be displayed for the operator to view 22 CHAPTER 5 POST PROCESSING AND DISPLAY SOFTWARE This chapter presents the steps required to post process the field data The data are stored in the field computer with a user defined name for example US87 GPS The data file can then be downloaded from the field computer to the office computer The CompactView software 1s activated as described in Figure 7 but this time the button is selected to enter the post processing mode the main toolbar in this mode is shown in Figure 20 CompactView File Edit view Help Od Om ete ex ed eb TE Fil
3. or above 260 F The color display is automatically changed to reflect the color associated with the new level The lower end of the temperature scale can also be changed as can the compaction effectiveness and number of passes charts 33 60 0 300 0 Figure 33 Resetting the Color Scale LOADING AND PROCESSING THE DATA FROM MULTIPLE FILES IN A FOLDER If there are several test sections in one project the user can put all of the corresponding files in one folder These data can be analyzed by processing a single file from this folder as explained earlier or the user can display multiple adjacent segments by simply inputting the folder name By clicking the amp button on the toolbar the user will see the folder selection dialog box as Figure 34 displays Browse for Folder Select Your Source Directory AugSAustinRolerers Sy CorosRollerGPS6 16 201 S Pecos201 1 IT data c DATAZ IG photo Hy sh159 H 1 Wecod 29 2011 HH 1 vweco7 5 11 Tunnel TIL TT E bal Figure 34 Loading the Project Level Data by Selecting the Folder Name 34 After the user selects the folder the roller paths for the whole folder will be displayed as illustrated in Figure 35 De E pee me We mW Aa Se wo s e 24 a oe eas Ei mT wr ae Far y CES nm Tant Cum Tat bru Taur Crean Curr GS poo atada Dureri ee OP puna inp Lge Wale pan ie Ervi eee ETTE mn ETIN Ta Figure 35 Project Level Rolle
4. would be perhaps most useful for the operator to ensure that similar levels of effort have been applied to the entire mat By clicking any of the three display option buttons the user will see the dialog box shown in Figure 14 and can input the file name of the data set and any comments about the project location starting place or weather If the user clicks the Browse button he or she can navigate to a folder where the collected data will be stored or select a file name from that folder 17 as shown in Figure 15 In this system the raw data are stored in a file that is given the GPS extension This extension is automatically added once the user inputs the file name Flle Control Browse Saved file name File Comment Roller GPS Testing in the field x sa Cancel File name SHBfltest Files of type GPS Cancel Figure 15 Use of Browse Button to Select File from Folder After the user clicks the Open button shown in Figure 15 the system begins to collect data and the screen shown in Figure 16 is displayed If the user selects the vom button a current color map shows the compaction effectiveness values As the operator moves backward and forward over the section the color chart will change as more compaction is applied In addition to the compaction effectiveness either the temperature or the number of passes could also be displayed 18 r ET Untitled GPSRall OIX Eh uA yee pep Test Meda cat GPS N
5. 25 31 rn Untitled GP5RaI D pir ye nep uo W am tke G o we od oF al Ea se atico get ah DT dg ST Sa pm Mo Ep AT TT ML SID ey ri ete engem 5 01047201 EHu 15 Figure 31 Details of the Transverse Distribution Data 32 If there is any uncertainty about the number of passes placed over any section of the mat then the user should click the button from the main menu screen to display the path of the roller over that segment An example is shown in Figure 32 The normal rolling pattern is typically two passes on either side of the mat with a final pass down the center of the mat Clearly in this case the center pass was not made and at this location the effectiveness of compaction in the middle of the mat is in question 2219 7 Figure 32 Paths Taken by the Roller in the Compaction of This Segment One last option available to the user is to modify the color display by using the mouse to change the upper limit of the color scale To do this the mouse is placed over the red arrow and this arrow is dragged down to a different level as shown in Figure 33 The two numbers at the top of the screen are the maximum values used in the initial setup menu screen In this case the max temperature 300 F is the surface temperature which is displayed as the color red By moving the red triangle the upper level has been reset to 260 F as shown In this case the red color will be associated with temperatures at
6. 4 Figure 34 Loading the Project Level Data by Selecting the Folder Name 34 Froure 35 ProJect Level Roller Path Chart ui a a a 35 Figure 36 Variations m Roller Paths aa a RE UE ebd a a 38 Figure 37 Variations in Compaction Effectiveness cccccccccseeeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 39 Figure 38 Variations in Temperature on First Roller Pass rrrrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnne 40 1X LIST OF TABLES Page Tablet LoolBar Punctions NG 12 Table 2 Meaning or DOP Values essen ee ee 15 Table 3 Meaning of Post Processing Toolbar Buttons r rrrrrrnnrrnrrrnnnrrrrrnnnnnvvrrrnnnnnnnnnnnnnnnnnnnnr 24 CHAPTER 1 INTRODUCTION In TxDOT Project 0 6992 Development of Practical Field Guidelines for the Compaction of HMA or WMA an asphalt compaction monitoring system CMS was built and field tested to measure the uniformity of hot mix asphalt HMA overlays under the steel wheel breakdown roller This system uses the latest global positioning system GPS technologies to provide 100 percent coverage of the new mat The system produces color coded maps showing e The number of roller passes e The compaction effectiveness number of passes x effectiveness factor e The mat temperature on the first pass of the roller The complete system was demonstrated on a number of new overlay projects 1n Texas and typical results are shown in Chapter 5 In this r
7. 8 263 M 23 288 M 3 8 0033 42 GPC Geoidal separation 76 404 5v 202817 00 A D 78 GPVTG 122 5 T 043 557 N 080 668 K D 42 GPGSV 3 1 10 03 38 136 45 06 37 114 Age of differential 3 80 Diff station ID 46 78 GPGSV 32 10 15 48 040 46 20 36 215 43 25 73 343 49 25 36 302 45 7C GPGSV 3 3 10 32 25 187 GPS data Status Valid D GPGSA A4 3 03 06 07 13 15 20 23 25 32 19 2 5 1 0 2 3 3F GPRMC 202817 00 A 3033 183746 N 09617 GPS quality Indicator Differential GPS fix GPS Select mode c 9 5 6 E 0 26 GPGRS202817 00 1 0 0 0 0 0 1 0 0 0 1 0 1 0 2 0 1 0 4 0 3 8 GPGST 202617 00 77 GPS working mode 3D fix 3033 17738951 N 09617 50210247 W 2 10 1 0 97 658 M 2 223 288 M 8 2 0 GPS Satelites Infarmatinn total satelitea is 1N Figure 13 GPS Raw Data and Running Path Function The following three buttons are important and are used to select the type of data to be displayed during data collection or data processing Y sin N L ull and p respectively show the compaction effectiveness index the number of roller passes and the mat temperature at the time of the first roller pass The compaction index as described earlier is a computed value obtained by multiplying the number of passes by a factor based on the drum location The temperature and number of passes is continuously stored and the compaction effectiveness value is computed These buttons permit the operator to view any of these items The compaction index
8. Figure 37 Figure 37a shows that the minimum compaction effectiveness number of passes x compaction effectiveness index is 3 9 This means that all areas of this mat had a minimum of four full passes under the center of the roller This 1s to be compared with Figure 37b where the compaction index ranged from 0 9 to 4 Clearly higher air voids would be anticipated in the locations that received only one roller pass e Temperature uniformity Examples of varying temperatures are shown in Figure 38 One of the simplest indications of compaction uniformity is related to the temperature where the breakdown roller first hits the mat This is the surface temperature of the mat and is the temperature that an inspector would measure with a handheld temperature gun However the temperature at mid depth in the mat will be higher Throughout the monitoring completed in this study these temperatures were consistently lower than anticipated given that the suggested mix placement temperatures ranged from 260 F to 280 F Figure 38a shows a typical pattern where in the right side of the figure the roller is catching up with the paver where the temperatures were measured at 236 F The roller 37 operator then waited for the paver to place more HMA Once he had placed between 100 and 150 ft the roller operator started his rolling sequence again In this case the temperatures were between 190 F and 216 F for the first pass There were no major variations fr
9. SETEEN PPP ka tii LL aai aud ctii SET Te PREPARAN PTTUTTRETE BYTE PT TET ERP PETTY TOT La iia La PREPARA Serta uci dL a La e aL a a i o van 3 ux i BOG ag H sr I 18 35 T BOs iu i is Figure 25 First Display Screen Showing the Entire Section Length 28 The user can then click any one of the buttons to display compaction effectiveness wim number of passes and first pass temperature i Figure 26 shows an example of what is displayed when user selects the alm button Clicking the 6 button will return the display to Figure 25 U ww oH a a Om Ohm 0 1 e ed ob aL moe NO tar ph 1 ed Vand g ins x TAM GA Vu 51299 art tation ES pees pbi eee mere mn n or ian ansarsrdararrr n dc aa rac ridarara i ndaani ia srrniarralari arasp nansanaialcc arabinrsnd sasarsaralicra ri N ETETE POTTEN PETE IT PTET la ranicarcidacia4rcaia dur ararssidararcninpodacarapca nicancnccca 7 Figure 26 Compaction Effort Color Map View of the Entire Loaded Data File The width of the paved lane is typically 12 ft which is relatively small compared with the length of the section Therefore reviewing the display of the complete section to find problem areas is very difficult For this reason an option was included to permit the user to zoom into any part of the project To zoom in the user puts the cursor in the required location and while holding down the left mouse button drags the mouse As show
10. ST OF FIGURES Page Figure 1 GPS Roller Data Acquisition System Hardware Setup ccccccccccnnncncnnnnoonoccnnnnnnnnnnnnnnnnnnnos 5 Figure 2 Roller Hardware with Data Acquisition Computer and Control Box 6 Figure 3 TTI s Complete Compaction Monitoring System rrrrnrnnnnnnnnnnnnnnnvrvnnnnnnnnnnnnnnnnrsrnnnnnnnne 6 Figure 4 Diagram of Sensor Location in the TTI Asphalt Compaction System 7 Figure 5 Infrared Sensor Installation ooi A E ee 8 Figure 6 Accelerometer Mounting Example rrrrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnne 9 Figure 7 The CompactView Main Menu Screen for Field Data Collection 11 Figure 8 Fi1eld Tesung Toolbar Bibi ar ee 12 Figure OPS Serial Port Parameters Setup Cr an 13 Figure 10 Finding the COM Port on the Computer sese 13 Figure 11 GPS Satellites Available to the System aaa na aaa l4 Figure 12 Function of Viewing the GPS Raw Da aaa u doe dracrit aio uot depu eu rade 16 Figure 13 GPS Raw Data and Running Path Function esee 17 Figure 14 Dialog Box for User Input of the File Name and Comments for the Field o a OO PEOR E S 18 Figure 15 Use of Browse Button to Select File from Folder nennen 18 Figure 16 Real Time Display of Compaction Effectiveness rrrrrnnnnnornnnnnnnnvrrrnnnnnnnnnnnnnnnnnnnnrr 19 Figure 17 Sensor Display from Data Acquisition Screen 19 Figu
11. Sv vulvl NUM O No 1043 Latitude 30 57408867 PDOP 2 30 Longitude 9634168161 SPD 2 3 Level Ft 316 4 Other Information NMEA type GLL YTG GSV GSV GSV GSA RMC RMC RMC GGA GGA Fixed Satellites total 10 3 6 7 13 16 20 23 25 32 19 PDOP accuracy of position 2 500 HDOP accuracy of Horizontal 1 000 VDOP accuracy of Vertical 2 300 Current time in UTC 204405 00 Current date 240609 Tracking Degree 341 400 Magnetic Tracking 0 000 Magnetic Variation 5 800 Geoidal separation 76 381 Age of differential 5 00 Diff station ID NMEA Read List SGPGLL 3034 444926 N 09618 700678 W 204404 00 4 D GPYTG 341 4 T 002 017 N 003 735 K D GPGSY 3 1 10 03 43 129 45 06 40 105 45 07 24 290 41 13 43 324 47 SGPGSV 3 2 10 16 41 039 47 20 30 209 43 23 81 353 49 25 40 309 47 SGPGSV 3 3 10 32 19 185 40 19 25 153 41 SGPGSA A 3 03 06 07 13 16 20 23 25 32 19 2 5 1 0 2 3 SGPRMC 204404 00 4 3034 444926 N 09618 700678 W 002 0 341 4 240609 5 8 E D SGPGRS 204404 00 1 0 1 0 1 0 4 0 1 0 2 0 1 0 0 0 2 0 6 0 4 SGPGST 204404 00 GPGGA 204405 00 3034 44532033 N 09618 70089651 W 2 10 1 0 96 424 M 23 281 M 5 0 0033 Read Raw Data An S amp 3P II 30534 444926 N09618 700678 WW 204404 00 A D 7D GPYTG 341 4 T 002 017 N 003 735 K D 41 49 SGPGLL 3034 445 5 06 40 105 45 07 24 290 41 13 43 324 477E GPGSV 3 2 10 16 41 039 47 20 30 209 43 23 31 353 49 25 40 3 0 32 19 185 40 19 25 153 41 74 GPGSAA3
12. Technical Report Documentation Page 1 Report No 2 Government Accession No 3 Recipient s Catalog No FHWA TX 12 0 6992 1 4 Title and Subtitle 5 Report Date DEVELOPMENT OF TTI S ASPHALT COMPACTION Published July 2012 MONITORING SYSTEM 6 Performing Organization Code 7 Author s 8 Performing Organization Report No Wenting Liu Tom Scullion and Emad Kassem Report 0 6992 1 9 Performing Organization Name and Address 10 Work Unit No TRAIS Texas Transportation Institute AR The Texas A amp M University System 11 Contract or Grant No College Station Texas 77843 3135 Project 0 6992 12 Sponsoring Agency Name and Address 13 Type of Report and Period Covered Texas Department of Transportation Technical Report Research and Technology Implementation Office September 2010 August 2011 P O Box 5080 14 Sponsoring Agency Code Austin Texas 78763 5080 15 Supplementary Notes Project performed in cooperation with the Texas Department of Transportation and the Federal Highway Administration Project Title Development of Practical Field Guidelines for the Compaction of HMA or WMA URL http tti tamu edu documents 0 6992 1 pdf 16 Abstract In recent years the Texas Department of Transportation has made significant progress with the development and implementation of new technologies to measure the uniformity of new hot mix asphalt layer construction Early studies focused on the development of the Pave IR s
13. ber of GPS reco Test Date Test time Test Comment C 42 960 Er Y ds wall NOM Figure 7 The CompactView Main Menu Screen for Field Data Collection There is a toolbar at the top of this screen All of the functions related to the field test are triggered by this toolbar Figure 8 shows the detailed images of the toolbar items Table 1 lists all the functions related to each toolbar button 11 26 ER AN GSE e Sul el MEM O Figure 8 Field Testing Toolbar Button Table 1 Toolbar Functions List SM Explanation of Each Button Image Switch to post processing toolbar menus for analysis of field data Fu as GPS setup function shows a dialog box for setting the serial port parameters Once setup is complete this screen will show the GPS receiver s status and satellite information el View the GPS raw data Before collecting data the user can click this button to check if the GPS receiver is working View the GPS raw data and draw the chart to show the roller path For system checking only Create demo data for testing the software Before collecting data 1f the user creates the demo data the demo data will be replayed on the screen compaction effectiveness status LU i 1 Same as the above button except the number of roller passes is shown on the screen N Ee Same as the above button except the temperature at the first pass of the roller in a color map 1s shown on the screen This 1s the data collecti
14. cation is displayed In the middle part of the screen the location of each satellite is displayed with individual signal strengths displayed as a bar chart If a satellite has good signal strength this value should be higher than 40 Since 1978 the United States has launched 72 satellites however currently the number of operational satellites is only 31 Typically in rural areas of Texas we can see more than 10 satellites If the number of active satellites is less than five the GPS location data will not have sufficient accuracy for this application Another key requirement is to install the antenna as high as possible on the roller at least on the roof of the cab to get the best access to satellite signals Dilution of precision DOP is a special term used by the GPS industry This value is used to estimate the accuracy of the reported GPS location On the bottom left corner of the 14 screen the user can find three values that have the same DOP term in them The important ones are the vertical DOP VDOP and the horizontal DOP HDOP and positional DOP PDOP which indicate the longitudinal and latitudinal positions x y z directions The meanings of the DOP values are given in Table 2 Table 2 Meaning of DOP Values DOP This 1s the highest possible confidence level to be used for applications demanding the highest possible precision at all times At this confidence level positional measurements are considered acc
15. e Setup Figure 2 Roller Hardware with Data Acquisition Computer and Control Box T 7 _GPS ENS T3 Mir J T er T Accelerometer Figure 3 TTI s Complete Compaction Monitoring System CHAPTER 3 INSTALLING THE SYSTEM ON A TYPICAL ROLLER In this chapter the installation of the system on any steel wheel asphalt roller is described The design is based on the need for rapid field installation with no permanent mounts on the roller The goal is to have a system that can be installed and operational in less than 10 minutes Figure 4 illustrates the sensor locations The infrared sensors are installed on each side of the roller body typically in a recessed area The installation height 1s around 2 to 3 ft As the infrared sensor has an optical angle of 10 1 to the target area the target diameter is around 3 inches This area is large enough for measuring the surface temperature These IR sensors have strong magnets for easy installation Figure 5 shows how to install the infrared sensors onto the roller sides Accelerometer in the center of the axis Infrared Intelligent Roller drum compaction Roller drum Roller operator Figure 4 Diagram of Sensor Location in the TTI Asphalt Compaction System Infrared sensor location Figure 5 Infrared Sensor Installation The accelerometer is used to determine if the drum is vibrating or not during compaction Figure 6 provides an example of
16. e local contractor 4 Modify the mounting of the CMS system so the roller operator can view the temperature and coverage color coded maps in real time as he or she 1s compacting the mat Train the roller operator to read the map and get his or her input of the usefulness of the output 5 Get TxAPA involved with the proposed system It is important be open with the contracting industry and to get their evaluation of the system as soon as possible 6 Contact a commercial manufacturer to make and sell ruggedized versions of the CMS system similar to the MOBA arrangement to make Pave IR 4
17. e numbe File name Number af GPS reco Test Date Figure 20 Post Processing Toolbar and Main Interface Due to the fact that a single paving project could last several days or could have data collected on several adjacent lots or sub lots two methods were incorporated into the CompactView system to process files The first method allows the user to process a single data file at a time The second method allows the user to open a folder that may contain several data 23 files the system then opens all of the files and displays them in a single display Table 3 lists the options available for post processing the field data Table 3 Meaning of Post Processing Toolbar Buttons Button Image Load a single file to perform single file processing i Load one project folder and perform group file processing Explanation of Each Button am Show the compaction effort color map chart on the display screen amp E Show the number of roller passes color map chart on the display screen Show the first rolling temperature color map chart on the display screen Show a line diagram with the roller paths o 4 Show the previous file in the project Show the rolling path chart for all files in the project folder p Show the next file in the project Zoom into the data to fit the screen Change the roller compaction effectiveness chart These relate the compaction effectiveness for different lateral locatio
18. ed on Project 0 6992 This dialog box also permits the user to control the graphical display of the color map by changing the max and min limits on each of the color maps For example for the temperature map the lower limit blue color is 80 F and the upper limit red color 1s 300 F These values can be changed in this dialog box SINGLE FILE POST PROCESSING To process a single file the user must click the button then the dialog box shown in Figure 24 opens allowing the user to select the file to process The GPS extension is used by the data collection system and the user provides the file name 24 Open the GPS data to file LI or sec4 GPS File name B7sec4 GPS Files of type GPS Cancel Figure 24 Selection of the Test File to Be Processed After the user selects the file to be processed a screen similar to Figure 25 is displayed showing the length in feet of the complete section tested over 2300 ft for this example section The user has the option to zoom into any location in the data set Untitled GPSRoll Elm pi yew Feb qe e a GR S 6 amp 4 oF ada rd one aper prodere aL been aa rg TTE FICAN GR aan TPM tee OO modas a EN ox uns sin ath un Sun wun xun ug 3 0 LE xt ith EER fh xul Set Shh Huu ui Ei EI LY 01 ns ini d AM xui ani xd Ll a amp PUI Aspira rar li cit PARAR PERRERA PETSTTSETEPETSETTSPIRTTSETTGETREPTEPTSETERTT
19. eport e Chapter 2 describes the system components e Chapter 3 provides detailed information on how to install the system on a typical steel wheel vibratory roller e Chapter 4 presents a user s manual for the operator on how to collect data in the field the roller operator can view in real time the mat coverage and temperature e Chapter 5 describes the post processing software that can be used to review the data in the field or 1n the office CHAPTER 2 SYSTEM COMPONENTS The following items were integrated into the Texas Transportation Institute s TTP s asphalt compaction monitoring system for this project e A high accuracy GPS e Two infrared IR sensors for measuring the asphalt surface temperature e One accelerometer for detecting if the roller is in vibratory mode e A Toughbook computer for collecting and viewing the data e A battery for the power supply e A data acquisition DA system for converting the analog signals to digital data One important component of the system is the high accuracy GPS system In the first year of Project 0 6992 multiple tests were conducted on different commercially available systems at TTI s Riverside Campus to check the repeatability and accuracy of the latest generation of GPS transponders Based on this work the Trimble SPS 852 model was selected and the accuracy determined by the research team for this unit 1s 4 inches This system also has a serial port for connecting to the da
20. fied Unclassified 52 Form DOT F 1700 7 8 72 Reproduction of completed page authorized DEVELOPMENT OF TTVS ASPHALT COMPACTION MONITORING SYSTEM by Wenting Liu P E Associate Research Engineer Texas Transportation Institute Tom Scullion P E Senior Research Engineer Texas Transportation Institute and Emad Kassem Associate Research Scientist Texas Transportation Institute Report 0 6992 1 Project 0 6992 Project Title Development of Practical Field Guidelines for the Compaction of HMA or WMA Performed in cooperation with the Texas Department of Transportation and the Federal Highway Administration Published July 2012 TEXAS TRANSPORTATION INSTITUTE The Texas A amp M University System College Station Texas 77843 3135 DISCLAIMER The contents of this report reflect the views of the authors who are responsible for the facts and the accuracy of the data presented herein The contents do not necessarily reflect the official view or policies of the Federal Highway Administration FHWA or the Texas Department of Transportation TxDOT This report does not constitute a standard specification or regulation nor 1s it intended for construction bidding or permit purposes The United States Government and the State of Texas do not endorse products or manufacturers Trade or manufacturers names appear herein solely because they are considered essential to the object of this report The researcher in charge was Tom Scu
21. how to install the accelerometer Under ideal conditions the sensor 1s mounted inside the rubber vibration isolators The accelerometer is installed onto the inside frame with the use of a magnet The GPS transmitter is installed on the roof of the roller directly in the center of the roller as shown earlier in Figure 3 Inside rubber isolator this part vibrates with the roller drum gr Drum rotating Outside rubber isolator Figure 6 Accelerometer Mounting Example CHAPTER 4 COLLECTING DATA WITH THE ASPHALT COMPACTION MONITORING SYSTEM After the hardware installation is complete the system is ready to collect data The intention is that the compaction system will eventually be operated by the roller operator The operator can view in real time a color coded map showing the total mat coverage for the area being compacted the same data can be saved and post processed to document the effectiveness and uniformity of the compaction process The first step is to power up the entire system by switching on the control box the GPS control unit located under the computer and the computer The data acquisition computer uses the Windows XP operating system Once the system boots up the CompactView icon A appears on the desktop The operator should double click this icon to start the program and the main menu screen shown below in Figure 7 will be displayed CompactView E BIK File Edit View Help File numbe File name Num
22. information on the uniformity of the mat being placed The contractor can use this information to judge 1f changes are needed to the rolling pattern or the number of rollers being applied to any placement operation The proposed system is the logical follow up to the Pave IR system that is operational in Texas The Pave IR system is mounted behind the lay down machine and allowable temperature variations are defined If the 40 temperature differentials are more than 25 F a warning is issued and 1f they are more than 50 F paving can be suspended Similar criteria need to be developed for the compaction monitoring system described in this report The following steps are recommended for TxDOT to continue the implementation of the CMS 1 Establish pilot acceptable criteria for any project for example a Minimum temperature on first roller pass 1s 240 F b Maximum variation within a mat is SO F c Minimum compaction effectiveness index is 3 0 2 Develop post processing software to determine how much of the project 1s outside of these operational tolerances Provide GPS coordinates of major defect areas so that validation cores can be taken in these areas Provide standard reports on a fixed length interval perhaps 150 ft as done by Pave IR 3 Coordinate closely with the construction division and district to conduct a series of demonstration projects with the CMS and the performance criteria described above Share all data with th
23. llion P E Texas 62683 ACKNOWLEDGMENTS This project was made possible by the Texas Department of Transportation in cooperation with the Federal Highway Administration In particular the guidance and technical assistance provided by the project director Jeremy Dearing P E of TxDOT s Lubbock District and the program coordinator Dr German Claros P E proved invaluable Many thanks to the technical staff of the Bryan Yoakum Austin and Waco Districts who provided excellent field support when conducting the field testing in this project vi TABLE OF CONTENTS Page ET TN vili List of Table E w X Chapter Larousse l Chapter 2e Sy SEN COMPONIST A A di 3 Chapter 3 Installing the System on a Typical Roller oooooonnnnnnncccnnnnnononcnnnonononnnnnccnnnnnnnos 7 Chapter 4 Collecting Data with the Asphalt Compaction Monitoring System 11 Chapter 5 Post Processing and Display Software rrrrrrrnnnrrrrrnnnnnnnnnrnnnrrrrrrnnnnnrvrrnnnnnnnnnnnnnnnnnnner 23 SMET IE PO PSN A ES 27 Loading and Processing the Data from Multiple Files in a Folder 34 Chapter 6 Using the Data Generated by the Compaction Monitoring System 37 Examples of Different Outputs Obtained rrrrrrrrnnnnrrorrrrrnrrnnnnnnrrrrrrrnnnnnnnnnnenrsrrnnnnnnnnnneeeee 37 Next Steps m System Implementation ana I E N E 40 vll LI
24. n in Figure 27 a black rectangle is Superimposed on top of the project When the user releases the mouse button the information from this section only is displayed as shown in Figure 28 29 Untitled GPSRoll SE s Ele Git Yew nep a de Om Om ef Od e4 oF nta Ory ore e crie py olen gs a des no 5143 X 030047264 96101117945 v rt staten SO 32 01 100068 49 16917006 0 000 o sn nu SHA sn SD Xu SUR KUN XY SEU sus SHS SHu KO SEO SUN EV SV EVA Su smi SVI SVI SU 4 EOI X BOM vw xx 5 22 29 9 peas were PVEN UT ews iii vere FUVEUT Te SHUNT ee TS PUVOV UNTER dar ri dsd de Perey we PTS PVETTTTS ERES nan sarral rs I mew j sot 1 TE 1 i a 2 Bee re Bees m less tunm tu 3 1 ui E Hr woe ba nes im p t wm vin E im Di are 47 Benj c je n ire m Mee yo n 1 1 rm 1 2 4 1 1 1 im 1 nex 3 1 1 5m 4 TTE 1 lama TE 4 i nor 1 m mem 1 t 4 y TIA Bel 08 pe I T7 E La as B om en E ET ar m M um zum zur m MUR PIO Figure 27 Highlighting the Area to Zoom Into TF Untitled GPSRoll OA Em G Vae Help ee e a GR OA 0 md b E Crh ore opereres Ma aroem giorag ACIS urban m A gt d 5 20 5 0 KUE SIA kun EH EEH nun ETU ESE i ME men Eure i HE HEN 7 VER UR MERA E E xm A 0 0 a 6 0 Eu Fig
25. ng button Clicking this will result in the user being asked to input the file name and then the compaction map will show the current is still under development and not ready for use L xl Stop button Stop data acquisition and close file MON This button is used to select the location of cores for validation testing The GPS coordinates of the proposed cores are listed and shown graphically This function 12 Details of the screens activated on the main menu screen are described below The AM oe TU du toolbar button the user will see the GPS setup dialog box for setting the serial port parameters following sequence describes the setup functions for the GPS system By clicking the as shown in Figure 9 GPS Setup COM Port Baud Hate Farity Data Bits COM 9600 v none fe v Stop Bits Flow Control Figure 9 GPS Serial Port Parameters Setup Screen Most of the commercially available GPS systems use the serial port or COM port as the main interface when communicating with the computer If the user does not know which port should be selected he or she should click Control Panel then System Properties and then Device Manager under the Ports COM amp LPT it is possible to find a list of all the available ports as shown in Figure 10 E Device Manager File Action View Help as x HE BB Network adapters B 1394 Net Adapter B Bluetooth LAN Access Server Driver B Broadcom Netxtreme 57xx Gigabi
26. ns on the roller drum where the edge is less effective than the center of the drum The field studies conducted in Project 0 6992 demonstrated that the center of the roller has better compaction effectiveness than the edge This is believed to be based on the lack of confining the mat at the edges of the roller This non uniformity of roller compaction effort will affect the final density of the mat Based on this and earlier studies the model shown in Figure 21 has been proposed to explain the variations in air voids found in the field after mat compaction As seen in the figure chart for a 7 ft wide roller drum there 1s 3 ft in the middle section of the drum that achieves the full compaction strength value is defined as 1 0 At the edge of the roller drum the effectiveness factor is only 0 1 or 10 percent of that in the middle of the drum This is the key calculation made by the CompactView system The GPS tracks the 24 position of the roller and calculates the compaction effectiveness for each pass by multiplying the number of passes by the effectiveness factor index from Figure 21 Effectiveness Factor 0 05 1 15 2 25 3 35 4 45 5 55 6 65 Roller Width ft Figure 21 Standard Effectiveness Factor Chart for 7 ft Wide Roller The CompactView software provides the user with several options for selecting the shape FE button of the compaction effectiveness chart These options are ac
27. om one side of the mat to the other Figure 38b shows interesting first temperature data from a thin overlay 1 inch thick being placed under very hot summer temperatures in Texas air temp gt 100 F Even under these ideal temperatures there was substantial cooling of the mat as observed by the measured temperatures under a single breakdown roller placing two passes on each side of the mat with one side being above 240 F and the other side being at 190 F This is disturbing as the binder used in the mat was a PG 76 22 with a target placement temperature of 280 F Only 1 pass in this zone b Less than ideal sequence with only one pass in the indicated area Figure 36 Variations in Roller Paths 38 a Good compaction effectiveness color display Number of Passes Compaction Index correct b Poor uniformity of compaction index Figure 37 Variations in Compaction Effectiveness 39 236 212 216 a Uniform temperature over mat 98 54 49 98 54 48 98 54 47 98 54 45 98 54 45 98 54 44 98 54 43 98 54 42 98 54 41 300 0 First pass temperatures Rapid Cooling of 1 inch Overlays under ideal conditions b Significant variations in temperature from both sides of the mat Figure 38 Variations in Temperature on First Roller Pass NEXT STEPS IN SYSTEM IMPLEMENTATION The compaction monitoring system described in this report provides TxDOT and the contractor with very useful
28. r Path Chart By clicking any of the following buttons alm Be 0 4 or the user can view the selected compaction color map screen for the first file If the user clicks the e button the screen will go back to the display seen in Figure 35 and if the user clicks 4 or e b the system will go to the previous or next file in this project folder 35 CHAPTER 6 USING THE DATA GENERATED BY THE COMPACTION MONITORING SYSTEM EXAMPLES OF DIFFERENT OUTPUTS OBTAINED During the course of this study several different TxDOT projects were tested and details of the results of these monitoring efforts are presented in the final report of this study The adequacy of compaction can be judged in terms of e The consistency of the rolling sequence Most jobs determine a rolling pattern for the breakdown roller for example two passes on the left side two on the right side and then one down the middle Figure 36 shows the paths taken by the roller during compaction and illustrates both good and bad sections of projects The pattern in Figure 36a is judged as ideal where in the middle it is clear that the roller 1s placing two passes on either side of the mat and then one down the middle This is to be compared with the pattern in Figure 36b where there is an area where only one pass was made e Consistency in the compaction effectiveness The rolling pattern shown in Figure 36 can be converted to compaction effectiveness color maps as shown in
29. re 18 GPS Location Accuracy Chart esseserrerserssrrsssnnnnnnnnnnnnnnnnnnsssesssnsnssssssnnnnnnnnnnnnnnnnnnssseeee 21 Figure 19 Color Coded Compaction Effort Map Real Time Displayed 22 Figure 20 Post Processing Toolbar and Main Interface rrrrrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 23 Figure 21 Standard Effectiveness Factor Chart for 7 ft Wide Roller nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 25 Figure 22 Roller Effectiveness Factor Model Selection Dialog Box sss 26 Figure 23 Recommended Roller Effectiveness Distribution Based on Project 0 6992 27 Figure 24 Selection of the Test File to Be Processed u 28 Figure 25 First Display Screen Showing the Entire Section Length esses 28 Figure 26 Compaction Effort Color Map View of the entire Loaded Data File 29 Figure 27 Highlighting the Area to Zoom Into qois ramse a a ACE Ges ana 30 Figure 28 Zoomed View of Color Coded Compaction Effort sess 30 Figure 29 Pomt 5pecihic Compaction Dala en eU n ELE EE Red EPA deste 3l Figure 30 Transverse Distribution of Compaction Data at User Selected Location 32 Figure 31 Details of the Transverse Distribution Data eene 32 Figure 32 Paths Taken by the Roller in the Compaction of This Segment 33 Figure 33 Reseltine The Color Seal aor oso ved vet e eee 3
30. t Controller B Intel R WiFi Link 5100 AGN Mi PCMCIA adapters g Ports COM amp LPT E Bluetooth Communications Port COMI 1 y 4 ECP Printer Port LPT1 SB Processors SCSI and RAID controllers RA Secure Digital host controllers X Smart card readers Sound video and game controllers 3 System devices g B imi ims mal f 2522l Meco om om om for ov Pl am ov ov Figure 10 Finding the COM Port on the Computer 13 If the settings such as the Baud Rate or Data Bits are not changed then the default values in Figure 9 are used By clicking the OK button the user will see the GPS status and the active satellite information as Figure 11 illustrates Untitled GPSRoll EAR Pia dui Vive hay Fe rum Filo name dumber of GPS reco Test Dain Tesi Test Comment Cursor GPS pos Latte ne AED Ve Compachon Vale Compaction times First compati 2 4X 40 AZ valde PRE 0 GPS INFORMATION Humber of satelites gt 10 Selelefes Information Table Ho Code Elevation Azim SNR Chan Fixed 3D status 6 35 00 108 00 45 00 PTR Tracking Angle 311 30 Labolude 3055313445 LangHlude 36 29673653 Level feat 339 92 6 20 32 00 211 00 43 00 __ 2 aaa LEA Speed miles 46 25 T 23 78 00 348 00 48 00 VDOP 2 400 HDOP 1 000 PDOP 2 600 Figure 11 GPS Satellites Available to the System As an example in Figure 11 there are 10 satellites in the current view In the left column summary information about the current lo
31. ta acquisition computer The power requirement for the system is low 3 W with the unit requiring 12 VDC For measuring the temperature two infrared sensors were installed on either side of the roller The sensors are made by Raytek and are MI Series infrared temperature sensors Although small in size they have a 1 percent accuracy and a fast response time The sensor response time is 150 milliseconds so if the roller is running at 3 mph the distance between readings will be about 8 inches The measured temperature range is between 40 F to 1112 F In this project we selected a new type of accelerometer that uses the latest sensor technology of micro electro mechanical systems MEMS These sensors are known for their exceptionally high measurement accuracy and outstanding overload and shock durability The most attractive feature of this accelerometer is the fact that it only requires 5 VDC for the power supply it directly outputs analog data and therefore no additional signal conditioning 1s required For the data acquisition device the National Instrument NI USB 6009 data acquisition card was selected This card has four different channels and a maximum data collection rate of 48 000 samples per second The USB interface with the computer is another advantage of this card Another component in this roller system 1s the rugged computer used for collecting the data in the hostile environment on top of the breakdown roller The compu
32. ter must withstand strong vibrations hot temperatures and water spray Based on these operation conditions the Panasonic Toughbook H1 field model was selected Another useful feature of this tough computer is that it has two battery packs and the user can swap the batteries without interrupting the computer A fully charged battery lasts seven hours which is adequate for most paving projects Figure 1 shows the complete system schematically Figure 2 shows the control box and the data acquisition computer All of the connectors and controllers were installed inside the control box as shown in the photo at the right of Figure 2 The two green boxes are the infrared sensor control boxes The black box is the power adapter to convert 12 VDC to 110 VDC for the computer The white box 1s the data acquisition card and a USB cable will connect this box to the computer The GPS receiver box and computer are located outside the control box for easy access and operation Special high damping rubber feet were installed under the box to absorb some of the roller vibrations The whole package weight 1s around 50 Ib and most of the weight is from the battery There 1s a switch on the top of the box to power up the system The computer is locked to the docking station Figure 3 shows the final assembled system GPS Antenna Trimble Control Computer Adapter Roller Drum ES V Battery Figure 1 GPS Roller Data Acquisition System Hardwar
33. the computed distance from the start of the run and infrared temperature readings are displayed in real time This distance is a calculated distance based on the GPS position readings The left and right side of the temperature readings are shown in degrees Fahrenheit This is typical of a first pass of the system where the left side reading is 86 F and the right side 1s 217 F As with most roller operations the first pass runs down one edge of the mat which results in one of the sensors not being on hot asphalt The display system takes this into consideration if there 1s more than a 30 F temperature difference from the two sensors then the system assumes that one sensor is off the mat The high value is used and displayed on the color plot However if reasonable readings are found on both sensors then the system averages these values and saves the averaged value for the entire width of the roller typically 7 ft at that location On the right side of Figure 17 there 1s a sine wave showing the current vibration amplitude of the roller If the operator turned off the vibration this chart would show a flat line Currently we collect accelerometer data and save it to a file but with this prototype system these data are currently not processed or displayed Figure 18 shows the GPS accuracy scale for both the longitudinal and latitudinal displays 20 Latitude Accuracy Chart of Roller Moving Distance for Each Digital Change TR ve sa
34. tivated by clicking the on the toolbar the roller effectiveness factor model selection dialog box 1s shown in Figure 22 25 Roller Compaction Patern Control Color Map Limit Control Minimum Maximum Compaction effort E Ff Haller Rolling Times TTI Distribution Flat model f Sine model First Rolling Temp F so Roller Drum width ft LE Figure 22 Roller Effectiveness Factor Model Selection Dialog Box From the dialog box shown in Figure 22 the user can select the roller effectiveness model using the radio buttons The standard distribution from Figure 21 is the one displayed in Figure 22 However in year one of Project 0 6992 a similar but slightly modified pattern was recommended based on testing of control sections built at TTI s Riverside Campus Figure 23 shows this new TTI Distribution In the new distribution the effectiveness of the roller edge was found to be closer to 30 percent than the 10 percent found in the initial work For the time being the TTI Distribution 1s recommended for all current data processing 26 Roller Compaction Patern Control Roller compaction Index Pater f Standard Distribution le TTI Distribution t Flat model Sine model Roller Drum width ft B Color Map Limit Control Minimum Maximum Compaction effort f nn Roller Falling Times First Rolling Temp F 80 E Cancel Figure 23 Recommended Roller Effectiveness Distribution Bas
35. umber ef GPS raca Test Dam Tat tere Roller GPS Testing in he eld Cursor OPS pousen satus Current curser GPS position Legkude Compaction Vale Comparten times Fire cempata 245 2 ER SA AGE va wu O 3012374 WRT ip by Moa Wn EFEN ET Wig urn Wurm uil MA Bel A T3 I i I I i 1 i I I 1 AT ih HIFI 1 11 11 m nat z AMAA LULA PU UU UNIV Mile Feel Right IA Left IA EEQ 1481 86 0 217 0 0 0 Figure 16 Real Time Display of Compaction Effectiveness The right side of the screen is the color scale for this map The numbers at the top and bottom of the scale 5 and 0 are the range displayed in the figure With an effectiveness index number of passes X effectiveness factor a final value of 5 in the effectiveness scale would be red and close to 0 would be blue On the bottom left of the screen the user can see all the information from the system sensors and GPS receiver This display is shown below in Figure 17 No 606 Lat 31 28680569SPD 0 0 DOP Lot 103 22202489Lel 2080 0 Mile Feet LeftiR Right IR Figure 17 Sensor Display from Data Acquisition Screen 19 In Figure 17 the top box shows the GPS information The most important information is the latitude and longitude of the current position of the roller The installed GPS system is very accurate as demonstrated below in Figure 18 which shows the accuracy for each displayed digit The last digit represents mm 0 04 inches Under the GPS box
36. urate Excellent enough to meet all but the most sensitive applications suggestions to the user This level marks the minimum appropriate for making business decisions 5 Good Positional measurements could be used to make reliable en route navigation Positional measurements could be used for calculations but the fix quality 10 Moderate could still be improved A more open view of the sky is recommended This is a low confidence level Positional measurements should be discarded Fair or used only to indicate a very rough estimate of the current location At this level measurements are inaccurate by as much as 300 m with a 6 m 20 Poor accurate device 50 DOP x 6 m and should be discarded The DOP values shown in Figure 11 1 0 2 4 and 2 6 indicate that the GPS accuracy at this location is on average excellent The user can click the o button on the toolbar area to exit this screen and go back to the main screen see Figure 7 Next the user can click the e Q button to view the GPS raw data as shown in Figure 12 This function was designed for testing the accuracy of the GPS unit Normally the operator does not use this function It is a tool for the system developer to debug the software in case there is a problem with the GPS system 15 Untitled GPSRoll File Edit View Help File numbe File name Seles Number of GPS reco Test Date Test time Test Comment Cursor GPS position Latitude 7 DIG 4X 29 EP s
37. ure 28 Zoomed View of Color Coded Compaction Effort 30 Some very useful information can be generated and displayed by the user simply placing the cursor on any location in the color display For example when the user places the cursor at the location of the X shown in Figure 29 the following data appear in the boxes at the top of the screen e Longitudinal position from GPS 30 01208 e Latitudinal position from GPS 96 167853 e Compaction effectiveness 6 32 e Number of passes of roller over this location 8 e Temperature at the first roller pass 239 F 30 01208437 96 16785376 6 322 8 PATA 239 300 0 300 0 1506 140 We Figure 29 Point Specific Compaction Data By clicking the mouse at a location of interest the user is able to see the transverse distribution of compaction number of passes across the mat and temperature data across the mat as shown in the box in the upper left corner of Figure 30 and in detail in Figure 31 The upper chart is the compaction effectiveness index the middle chart is the number of passes placed across the mat and the lower chart is the temperature profile during the first pass over the mat The width shown in Figure 31 is 15 ft but the paving width is only 12 ft This means that there was at least a 1 5 ft overlap of the roller off each side of the mat Clicking the F button at any time will redraw the screen and zoom back to the full section display shown in Figure
38. ystem for checking temperature uniformity during mat placement In Project 0 6992 researchers took this check one step further by developing an accurate global positioning system tracking system for compaction rolling so that the compaction effort applied can be monitored for 100 percent of the new surface Additional sensors were also included in the system including two temperature sensors and an accelerometer to monitor whether the roller is vibrating The new system can be mounted on any roller in a matter of minutes and it provides the roller operator with real time color displays of The number of passes of the entire mat The compaction effectiveness this study found that better compaction was found directly under the center portion of the roller than at the roller edges The temperature at the first pass of the roller This report presents details of the hardware and software developed in this study The system was field tested on a number of new overlay projects in Texas Those results will be reported in later reports from this study 17 Key Words 18 Distribution Statement HMA Compaction Mat Temperatures No restrictions This document is available to the public Compaction Effectiveness Air Voids QC QA through NTIS Testing National Technical Information Service Alexandria Virginia 22312 http www ntis gov 19 Security Classif of this report 20 Security Classif of this page 21 No of Pages 22 Price Unclassi
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