By Jessica Porter, Contributing Author
Though automation in asphalt paving is not new, it’s advancing and making a major impact on the industry. Automation improves the paving process, results in higher-quality road surfaces, increases jobsite safety, helps recruit younger workers to the industry and enables data-driven project decisions.
“Key areas of impact include advanced machinery for consistent paving operations, software for streamlined operations, and real-time data and sensors to further support quality control,” said Brett Williams, senior director, engineering and technical services for the National Asphalt Pavement Association (NAPA). “These technologies collectively are advancing the industry to ensure our products perform at a high value that delivers for road owners and taxpayers.”
Components of the paving train are ripe for automation. Two-dimensional (2D) and three-dimensional (3D) paving systems improve how milling machines leave the surface. 2D systems allow machines to follow fixed references like curbs, string lines or existing surfaces. 3D systems accommodate uneven terrain using GPS and cutting-edge survey tools.
“3D systems now allow machines to be controlled by technology, which takes out the guessing game of how to adjust the machine in making minor changes,” said Mark Larranaga, director for intelligent paving for North America with Topcon Positioning Systems Inc. “The machine is controlled completely by the 3D system.”
Pavers have been automated since the 1990s, leveraging 2D technology to control the screed and produce a more consistent and smoother mat surface. Newer 3D automation technology allows the paver to move according to a design and enhances smoothness. Automated pavers also leverage systems that maintain the asphalt mixture level in front of the screed, as well as grade and slope control systems that ensure material is placed without manual adjustments.
Thermal mapping enhances paver automation using a camera to detect the temperatures on the mat surface. It identifies areas of thermal segregation in real time so that operators can analyze the information and adjust quickly. Rollers, the final machine in the paving train, can be equipped with intelligent compaction systems and GPS-based mapping to better monitor the process and ensure uniform compaction, according to NAPA.
Operators can determine how many passes are needed and how many times each section has been rolled. With some agencies instituting intelligent compaction specifications, contractors that leverage automation will be more competitive.
Paving automation using 3D technology is possible with LIDAR, which leverages lasers to measure distances and create 3D models. Traditionally, crews use survey instruments to collect points of interest, which gives the team an idea about the surface but does not paint the whole picture.
“To have a machine controlled automatically you need data,” Larranaga said. “LIDAR helps gather a lot of information to make determinations on how to approach a project at a mill-and-fill level or design level.”
Using mobile LIDAR, crews remain in their vehicles to collect surface information on asphalt, dirt or concrete surfaces prior to paving. Traditionally, crews walk the road surface to collect information, which has major safety implications. According to the Bureau of Labor Statistics, 94 to 143 workers are killed at road construction sites every year. To improve safety for road crews, some municipalities require the use of mobile LIDAR.
3D systems also improve safety by allowing operators to have a heightened awareness of the jobsite.
“They take out the human element of always being involved by allowing the 3D system to run the machine,” Larranaga said. “The operators are involved, but they have more of a heads-up approach instead of always looking down considering what the machine is doing.”
Data collection enabled by automation allows for predictive machine maintenance, which increases safety and prolongs the lifespan of equipment. Operators have exact records of the work performed by each machine, including run-time hours and the type of work completed. This data is pivotal in ensuring equipment is maintained optimally and on schedule. But maintenance on these machines goes beyond traditional equipment.
“Automated machinery often requires specialized knowledge for servicing advanced systems and software integration,” Williams said. “This includes tasks such as software updates and sensor calibration to ensure optimal performance.”
Automated equipment can help contractors attract a younger workforce. As skilled employees retire, cutting-edge equipment can help attract the technology-hungry younger generation to the industry. As more agencies begin to understand the value of automation, a tech-savvy workforce operating automated equipment will be increasingly necessary for success.
“In the next five to 10 years, we can expect significant advancements in automation for asphalt paving equipment, with more precise control systems, enhanced data analytics, and further integration between equipment and operational logistics,” Williams said. RB
Jessica Porter is a freelance writer and editor who specializes in construction. For more information, visit www.JessicaLynnePorter.com.
