Compactor IOE 2010

CONSTRUCTION EQUIPMENT
COMPACTORS
1800
August 22, 2010 Er. Satya Narayan Shah 1
COMPACTION
CO C O
1. The process of inducing a closer packing
of the solid particles in freshly mixed
concrete or mortar during placement by
gp y
reducing the volume of voids, usually by
, g , p g,
vibration, centrifugation, tamping, or
some combination of these actions.
2 A similar manipulation of other
2.
cementitious mixtures, soils, aggregate, or
the like
the like.
PURPOSE OF COMPACTION
3
y To develop the potential strength of a

material as required by the intended
use
y To create state of volumetric stability
for the ultimate state to which the
material will be subjected.
j
y To produce a minimum permeability of
the material in its final in-place
in place state.
state
Er. Satya Narayan Shah August 22, 2010
The amount of compaction is influenced by the
following4 factors.
factors
y The moisture content of the soil
y The nature of the soil (Grain size
distribution and physical properties)
y Depth of lift
y Climatic conditions
y The type and amount of compacting effort
y Type of equipment
Among above factors, the last two factors
are related to the compacting equipment.
Er. Satya Narayan Shah August 22, 2010

Compacting effort refers to the method employed
by equipment to impart energy into the soil to
by equipment to impart energy into the soil to
achieve required compactions. The equipment are
designed to use one or a combination the
designed to use one or a combination the
following types of compactive efforts to the soil to
achieve ultimate result of compaction
achieve ultimate result of compaction.
Actions required for compaction
• Static Weight (or Pressure)
• Crushing
• Kneading Action
• Impact (or Sharp Blow)
• Vibration (or Shaking)
RECOGNIZE THE EARTH
yBoulders > 254mm)
yGravel ((2 to 75 mm))
ySand (0.05- 2 mm)
ySilt (0.005mm to 0.074mm)
yClay
Cl ( <0.005mm)
0 005 )

SOIL PROPERTIES AND
CHARACTERISTICS
Compressibility, Elasticity,
Shearing Resistance,
Resistance Capillarity,
Capillarity
Permeability,
y, Shrinkage,
g ,
Consolidation, Settlement,
S b d
Subsidence

Types of Compaction Equipment
Types of Compaction Equipment
Compactors can be grouped in the following types: ‐
• Smooth Steel Drum Rollers
Smooth Steel Drum Rollers
• Sheep Foot Rollers
• Grid or Mesh Rollers
• Tamping Rollers
– Towed tamping
– Vibratory tamping
• Vibrating Rollers
• M lti T d P
Multi Tyred Pneumatic Rollers
ti R ll
• Plate Compactors
• Vibrating Compactors
Vibrating Compactors
SMOOTH STEEL DRUM
9 Er. Satya Narayan Shah August 22, 2010

Smooth Steel Drum
y Oldest form of mechanical compaction.

y Concrete Drums are also used for small works.
y Single drum or multi drums.
y Available
A il bl upto 14 to 20 ton
y Towed type to Self propelled.
y Generally
G ll used
d where
h crushing
hi effect
ff t iis required.
i d
y Good for surface finishing.
y Lift up to 12”
12 can be compacted efficiently.
efficiently
y Compacting Weight can be increased or decreased
byy varying
y g the ballast.
Smooth Steel Drum
y Front wheel is split steering roll on dead axle used for
steering. Split roll is used for easy steering prevent
surface scuffing g and dragging.
gg g
y Rear wheels are powered.
y Power is transferred from engine through clutch/torque
converter shaft and gears.
g
y Most commonly used is 3-axle tandem roller.
y Differential locking arrangement.
y It is best used for base courses of crushed stone.
stone
y Not suitable for surface dressing.
y Bridging characteristic.
y Not possible to prevent bow-waving. (tendency to create wave of
asphalt in the front roll)
y A steell roller
ll isi basically
b i ll slow.
l
SHEEP FOOT ROLLERS
SHEEP FOOT ROLLERS
• 40
40 to 72 inches dia
to 72 inches dia drum ranging in weight 3 to 30 Tons.
drum ranging in weight 3 to 30 Tons
• 7 to 17 inches long cylindrical pads are welded over the
circumference of the drum.
• Generally they are towed type.
• They are intended to shear and knead the soil.
• Suitable for compacting all fine‐grain materials.
Suitable for compacting all fine‐grain materials
• Not suitable for use on non‐cohesive granular materials.
• Low speed from 6.4 to 9.6 km/hr.
• Efficient for silt‐to‐clay soils and
• Nos. of passes depend on the lift; usually 6 to 10 passes
will be needed to compact a 20 cm clay lift
will be needed to compact a 20 cm. clay lift.
• The roller becomes lighter as the density of the soil
increases. .
TAMPING ROLLERS
TAMPING ROLLERS
TAMPING ROLLERS
• Similar to Sheep foot rollers.
• Shape and size of the foot is different they are
p y
tapered so that the entry and exit are clean.
• Fluffing of soil is avoided.
• Working speed is higher than sheep foot roller (8‐
12 mph) .
• Handle nearly all soils.
Handle nearly all soils
• Not suitable for clean sand.
• Suitable to compact 12” to 18
Suitable to compact 12 to 18” lift.
lift
• There are towed and self propelled.
• Static and vibratory.
Static and vibratory.
GRID OR MESH ROLLERS
The roll surface is made of cast steel with grid or
The roll surface is made of cast steel with grid or
mesh. They are particularly effective on granular
soils to compact 6 to 8 inches to up to 18 inches
soils to compact 6 to 8 inches to up to 18 inches
on rock fills. It is an excellent compaction
machine for rock fills as it crushes the rocks with
machine for rock fills as it crushes the rocks with
the help of mesh and crushed particles fill the
voids as it moves forward
voids as it moves forward.
Vibratory Rollers
Vibratory Rollers
Vibratory Rollers
• Eccentric Shaft creates Vibration due to centrifugal force.
• Vibration has two measurements– amplitude, which is the
q y
measurement of the movement, or throw, and frequency, which is
the rate of movement, or number of Vibrations (oscillations).
• The amplitude controls the effective area, or depth to which the
vibration is transmitted into the soil, while the frequency
determines the number of blows or oscillations that are
transmitted in a period of time.
• Vibration creates impact forces, and these forces result in greater
compacting power than an equivalent static load.
i h i l i l d
• Vibrating drum rollers are actuated by an eccentric shaft that
produces the vibratory action.
• The Vibrating mass (drum) is always isolated from the main frame
of the roller.
• Vibrations normally vary from 1,000 to 5,000 per min.
Vibratory Rollers
Dynamic force created by a vibrator’s mechanism can be calculated from the following
calculation;
0.00034WRN2
FF=0.00034WRN
Where, F = Dynamic force in pounds
W = Weight of eccentric mass in pounds
R = Radius from center of eccentric mass to center of rotation in feet
N R
N = Rotation speed in revolutions per minute
i di l i i
From the above formula, it is seen that the dynamic force increases with the square of
the frequency. Dynamic force combining with the static force of the roller provides the
total striking force to the soil.
Benford
f d Pedestrian Single drum vibratory roller owned by the DOR provides 920 Kg of
d l d b ll db h d f
centrifugal force at 3900 rpm and 65 cycles per second. This centrifugal force further
provides 7,480 Kgs. of striking force at contact soil.
A vibratory compaction has the following advantages over the conventional compaction.
• Light weight and smaller towing unit.
• Better mobility
• Less expensive
• Effective to greater depths.
Effective to greater depths.
Vibratory Rollers (cont……)
Vibratory Rollers (cont )
• These rollers are gaining popularity due to versatile
usages.
usages
• Very wide in type, size and compacting width, means of
providing vibrations.
providing vibrations.
• Single drum or dual drum.
ff
• Effective on
– Granular material (Rock to fine sand)
– Semi cohesive material
– High lift
• Smooth Drum / Padded Drum
Small Walk Behind Rollers
Small Walk Behind Rollers
• Width in the range 24 to 38 inches.
dt t e a ge to 38 c es.
• Suitable for
– Trench work
– Building Foundation
– for working in confined area.
• Vibrating Rollers are also available /modified as per the
work site conditions. e.g. drum extend beyond the rollers body ,
drums used as attachment to other equipment
drums used as attachment to other equipment
• Remote control Rollers available to work in deep
trench.
FACTORS INFLUENCING COMPACTION (VR)
• STATIC WEIGHT
– The depth effect is approximately proportional to the static weight of
the roller
• NOS. OF VIBRATORY DRUMS
NOS OF VIBRATORY DRUMS
– Nos. of passes decreases as the nos of drum increases
• ROLLER SPEED
– Less speed for high density requirement
• DRUM DIAMETER
– Related to static weight ; higher the weight larger is the diameter.
R l t d t t ti i ht hi h th i ht l i th di t
• FREQUENCY AND AMPLITUDE‐ CENTRIFUGAL FORCE
– More amplitude more depth of compaction; centrifugal force
p p p ; g
increases with the square of frequency.
• FRAME AND DRUM WEIGHT
– More wt better effect; more than limit dampens vibration
M t b tt ff t th li it d ib ti
Multi tyred Pneumatic
Rollers
ll
Multi tyred Pneumatic Rollers
• Available upto 200 ton gross weight.
• Surface rollers using Principle of kneading Action to effect compaction
S f ll i P i i l fk di A ti t ff t ti
below the surface. Better sealing
• Does n ot push the material ahead of it as it is in steel wheel roller.
• Front and Rear wheels are so placed to cover the complete surface.
Front and Rear wheels are so placed to cover the complete surface.
• Weight of the roller can be varied with the help of using ballast.
• Two tandem axles with 4‐5 wheels.
• for uniform compaction, Wheels oscillate to follow surface contour‐ no
b id i
bridging
• Wheels may be mounted slightly out of line with axle weaving action ‐
WOOBY WHEEL‐ more kneading action.
• Compactive effort is a product of wheel load, tyre size and tyre inflation
Compactive effort is a product of wheel load, tyre size and tyre inflation
pressure.
• The contact area increases when the inflation pressure decreases.
• Tyre Pressure‐ must be varied as per the soil type; on clay 90 psi can
compact 14” where as 150 psi can compact 9” only
compact 14” where as 150 psi can compact 9” only.
• Larger Dia wheel is easier to move than small dia wheel.
• Self propelled or towed type
Plate Compactors/Rammers
– Lift thickness is small ( 3 to 4 Inches).
t t c ess s s a ( 3 to c es).
– Moisture content is carefully controlled.
– Coverage is sufficient.
Coverage is sufficient
– Suitable for small works.
– For compaction of soils and asphalt
For compaction of soils and asphalt
concrete.
– Where large units are not practical.
Where large units are not practical
– Remote controlled compactors are
available.
g p
• A vibrator is a mechanical device that is designed to generate
vibrations. The vibration is often generated by an electric motor
/Gasoline or Diesel engine with an unbalanced mass on its
d i h ft
driveshaft.
• Concrete vibrators are used to consolidate fresh concrete so that
entrapped air and excess water are released and the concrete
settles firmly in place in the formwork
settles firmly in place in the formwork.
• An internal concrete vibrator (needle vibrator) is a steel cylinder
about the size of the handle of a baseball bat, with a hose or
electrical cord attached to one end. The vibrator head is immersed
in the wet concrete.
• External concrete vibrators attach, via a bracket or clamp system, to
the concrete forms. There are a wide variety of external concrete
vibrators available and some vibrator manufacturers have bracket
vibrators available and some vibrator manufacturers have bracket
or clamp systems designed to fit the major brands of concrete
forms. External concrete vibrators are available in hydraulic,
pneumatic or electric power.
SELECTION OF COMPACTOR
Compactor Zones of Application Compactive Effort
100% Clay Silt 100% Sand Rock
Sheepsfoot Static Wt, Kneading
Grid
Static Wt, Kneading
Vibratory
Static Weight Vibration
Static Weight, Vibration
Smooth Steel Drum
Static Weight, Crushing
Multi Tyred Pneumatic
Static Wt, Kneading
Heavy Pneumatic
Static Wt, Kneading
Vibratory Tamping Foot
Static Wt, Impact, Vibration
Towed Tamping Foot
Static Wt, Kneading
High Speed Tamping Foot
Static Wt, Kneading, Impact,
Vibration
Cat Tamping Foot Cat Rock Tamping Foot Static Wt, Kneading, Impact,
Vibration
Selection of compacting equipment depends on a
Se ect o o co pact g equ p e t depe ds o a
number of independent variables as below.
– Moisture content of the soil
– Soil type
– Equipment type
– Thickness of lift
hi k f lif
– Compactive effort or force
– Climatic conditions
Climatic conditions
The first two are of greatest concern to soil engineers or
project designers.
PRODUCTIVITY OF COMPACTORS
PRODUCTIVITY OF COMPACTORS
1. Volume of compacted soil
Q = (W×V×H×1000×E)/N
Where, Q = Hourly production (cum./h) volume compacted
V = Operating speed (km/h)
W = effective compaction with per pass (m)
H = Compacted thickness for one layer (m); this is
determined from the specification or from the tests.
N = No. of passes by compactor
E = Efficiency (refer to Job Efficiency table)
2. Area of compacted soil
Qa= (W×V×1000×E)/N
Where, Qa = Hourly area compacted (Sq m/h)
IT IS YOUR TURN
IT IS YOUR TURN
NOW
Satya Narayan Shah
B.Sc. In Mechanical Engineering (India)
MS in Manufacturing Engineering & Management (UK)
Contact: er.snshah@gmail.com
Er. Satya Narayan Shah August 22, 2010 34

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CONSTRUCTION EQUIPMENT

y To develop the potential strength of a

Er. Satya Narayan Shah August 22, 2010

August 22, 2010 Er. Satya Narayan Shah 6

August 22, 2010 Er. Satya Narayan Shah 7

9 Er. Satya Narayan Shah August 22, 2010

y Oldest form of mechanical compaction.

100% Clay Silt 100% Sand Rock

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