Compactor

Choosing the right machine
for proper soil compaction

Contributed | December 11, 2014
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A system that allows detection of thermal segregation in the asphalt mat, in

real time, and records a thermal profile is now being used by some state
Departments of Transportation. The reason is to eliminate inconsistent
densities because freshly paved asphalt pavement doesnt compact properly
after becoming too cool, and the low temperatures contributed to these low
densities.
There
are many factors that influence the choice of compaction equipment
selected for a project. Sometimes it is based on the contractors previous
experience and other times by the type of soil, method specification or
available equipment.
How well a machine will conform to the hauling and spreading operation are
also considerations, and climatic and traction conditions are also important.
There is no single compactor that will do all things in all applications. Each
type has a definite material and operating range on which it is most
economical. In many cases, there are applications where machines of
different sizes and types can achieve the compaction target; but choosing
the machine that is most suitable will complete the work most economically
and efficiently due to reduced passes, reduced fuel use and less working
time.
Vibratory Compactors
Vibratory compactors work on the principle of particle rearrangement to
decrease voids and increase density and load bearing strength. They come in
two types: smooth drum and padfoot drum. For increased versatility, smooth
drum compactors can be equipped with optional padfoot shell kits, which
allows the use of smooth drum rollers in padfoot applications, albeit with
limited performance.
Smooth drum vibratory compactors generate three compactive forces: static
pressure, impact and vibration. Padfoot drum machines generate the same
forces, plus they also generate manipulative force. Vibratory compactors
provide uniform compaction throughout the lift.
Density is achieved from the forces generated by the vibrating drum hitting
the ground. Compaction results are a function of the frequency and
amplitude of the blows, as well as the force of the blows and the time period
during which the blows are applied.
The frequency/time relationship accounts for slower working speeds on
vibratory compactors. Working speed is important because it dictates how
long a particular part of the fill will be compacted. For vibratory compactors,
a speed of 1 to 2.5 km/h (0.6-1.6 mph) for rock and clay, and 2 to 5 km/h
(1.2 to 3 mph) for gravel and sand will provide the best results.
Based on the principle of particle rearrangement to decrease voids and increase density, vibratory compactors come
in either smooth or padfoot drums. (Read a companion piece that ran in the May 2014 issue, Size Matters in Mix
Grades and Aggregate Shapes, at betterroads.com/size-matters-in-mix-grades.)
Smooth drum vibratory compactors were the first vibratory machines

introduced. They are most effective on granular materials with particle sizes
ranging from large rocks to fine sand. They are also used on semi-cohesive
soils with up to 50 percent cohesive soil content. Lift thicknesses vary
according to the size of the compactor. Whenever large rock is used in the
fill, the lifts may be very thickup to 1.2-m (4-ft.) lifts are not unusual. One
thing to remember when large rocks are in the fill is that the thickness
should be about 300 mm (12 in.) more than the maximum rock size. This
permits lift consolidation without having large rocks protrude above the
surface.
Padfoot drum machines expand the material range to include soils with more
than 50 percent cohesive material and a greater percentage of fines. When
the pad penetrates the top of the lift, it breaks the natural bonds between
the particles of cohesive soil and achieves better compaction results. The
pads are involuted to walk out of the lift without fluffing the soil and tapered
to help them stay clean. The typical lift thickness for padded drum units on
cohesive soil is in the 150- to 460-mm (6- to 18-in.) range.
Caterpillar has two pad shapes available: square faced pads and oval-faced
pads. Square pads perform well on semi-cohesive soils and thinner lifts of
less than 150 mm (6 in.). Square pads do a good job of sealing the surface.
Oval pads have less surface area than square pads, so they apply greater
ground pressure than square pads. This allows the pad to penetrate deeper
into the lift. Oval pads perform better on cohesive soils and thicker lifts of
150 to 460 mm (6 to 18 in.). Oval pads do not seal the surface as well as
square pads.
Tamping Foot Compactors
Tamping foot compactors are high-speed, self-propelled, non-vibratory
compactors. They usually have four padded steel wheels and are equipped
with a dozer blade. Their pads are tapered with a rectangular face.
Tamping foot compactors compact from the bottom of the lift to the top.
Because the pads are tapered, they can walk out of the lift without fluffing
the soil. Therefore, the top of the lift is also being compacted and the surface
is relatively smooth and sealed. Tamping foot compactors are capable of
speeds in the 16-32 km/h (10-20 mph) range, but they typically operate in
the 10-15 km/h (6 to 10 mph) range.
Generally, two to four cycles (4 to 6 machine passes) will achieve desired
densities in 200- to 300-mm (8- to 12-in.) lifts although four cycles may be
needed in poorly graded plastic silt or very fine clay. Tamping foot
compactors are effective on all soils except clean sand.
Tamping foot compactors leave a fairly smooth, sealed surface so hauling
units are able to maintain a high speed when traveling over the fill. Also,
since dozer-equipped tamping compactors do both spreading and
compacting, the contractor may be able to reduce the number of track-type
spreaders.
Tamping foot compactors are best suited for large projects. They need long,
uninterrupted passes to build up speed that generates high production. On
lifts greater than 300-mm (12-in.) thick, tamping foot compactors are about
two to three times more productive than single-drum vibratory compactors.
Sheepsfoot Compactors
Sheepsfoot compactors derived their name from the fact that early Roman
road builders would herd sheep back and forth over base material until the
road was compacted. The word sheepsfoot became a generic term to
describe all types of padded drums. In reality, a sheepsfoot compactor is
very different from a padded drum or tamping foot compactor.
A sheepsfoot pad is cylindrical, usually 200-mm (8 inches) long. The pad is
circular and will range in diameter from 76 to 127 millimeters (3 to 5 inches).
The pads on tamping foot or padded drums are tapered with an oval or
rectangular shape. And the pad face is smaller than the base of the pad
thats an important difference.
The pads on sheepsfoot drums penetrate through the top lift and actually
compact the lift below. When a pad comes out of the soil, it kicks up or fluffs
the material. The result is a loose layer of material on top. When more fill is
spread, the top lift will be fluffed and the previous layer will be compacted. A
sheepsfoot compactor truly compacts from the bottom up.
Using a sheepsfoot compactor has one definite benefit. Because the top lift
of soil is always being fluffed, the process helps aerate and dry out wet clays
and silts.
But the disadvantages of sheepsfoot compactors are numerous. The loose
top-lift material can act as a sponge when it rains and slow the compaction
process. The loose material also slows hauling units that deposit fill material,
so haul cycle times are increased.
Plus, sheepsfoot compactors can work only at speeds from 6 to 10 km/h (4 to
6 mph), which cancels any benefit from impact and vibration. Pressure and
manipulation are the only compactive forces exerted on the soil. Usually, 610 cycles (12-20 machine passes) are needed to reach target density on 200mm (8-in.) lifts. Sheepsfoot compactors are no longer widely used.
Pneumatic Compactors
Pneumatic compactors are used on small-to-medium size soil compaction
jobs, primarily on bladed, granular base materials. Often, they are used as a
finishing compactor after a vibratory drum compactor completes compaction
of the lift.
Pneumatic compactors are best suited for sealing the surface, special
applications such as compaction of thin lifts, or special requirements dictated
by the job.
The compactive forces (pressure and manipulation) generated by the rubber
tires work from the top of the lift down to produce density. The amount of
compactive force can be varied by altering the tire pressure (the normal
method) or by changing the weight of the ballast (done less frequently).
The kneading action caused by the staggered tire pattern helps seal and
smooth the surface. Pneumatic compactors can be used on soil and asphalt,
an advantage that allows a roadbuilding contractor to use one compactor for
multiple stages of construction.
This article and photos are courtesy of Cat Paving.

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Choosing the right machine

for proper soil compaction

A system that allows detection of thermal segregation in the asphalt mat, in

Smooth drum vibratory compactors were the first vibratory machines

This article and photos are courtesy of Cat Paving.

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