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Asphalt/bituminous mixture

Advanced asphalt slab roller compactor, MASTERCOMP

PAVELAB SYSTEMS Advanced electro-mechanical multi-size slab compactors, closed loop control system

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EN 12697-33 | ASTM D8079
Main features
  • Completely electro-mechanically operated 
  • 21'' All-in-one touchscreen PC controlled, PC and software included
  • PRO-COMPACT closed loop control slabs
  • Mould dimensions: 500 x 400 mm, 500 x 300 mm, 400 x 300 mm, 300 x 300 mm and 320 x 260 mm, 195 mm high, to be filled at 155 mm max.
  • Conforming to EN 12697-33, 5.3 method
  • Base and foot adjustable heating system available as accessory 
  • Includes the compaction procedure defined in the brand new EN 12697-33 method 7.3
  • Compaction direction in the longest (major) mould dimension to obtain specimens of the proper length conforming to Standar
  • Possibility to define user defined procedures as free combination of load and displacement controlled cycles
  • Customization of compacting cycle which can be saved and recalled from the data base
  • Vertical balanced sliding cover for easy access and complete three side view
  • Maximum compaction load 30 kN
  • User defined controlled linear speed up to 300 mm/sec and adjustable pause at the mould inversion point
  • Ideal for producing test beams for 4-Point Bending (EN 12697-24, EN 12697-26, AASHTO T321)
  • Moulds easy to install and to remove
  • Safety systems conforming to CE standards
*PRO-COMPACT closed-loop is an innovative mechanical and electronic control that combines orthogonality of the load, pendulum motion of the head and sinusoidal non-friction forward-reverse carriage movement. This results in an optimally compacted sample that features Planarity Regularity and hOmogeneity (PRO). The combined load/displacement compaction procedure provides at the beginning of the test a controlled displacement compaction, which can grant a flat surface of the compacted slab, followed by a load compaction phase, which can replicate the real compaction on the road surface.
General description
General description
The advanced slab roller compactor MASTERCOMP  can compact asphalt slabs to a target density applying specific loads corresponding to those of pavements rollers used in the highway construction.
The produced slabs can be used for:
- Wheel tracking tests, down to 38 mm thickness
- Cored to provide specimens for indirect tensile, static and dynamic creep tests.
- Cut into beams for bending fatigue tests.
 
The machine can be used with moulds 500 x 400 mm, 500 x 300 mm, 400 x 300 mm, 300 x 300 mm and 320 x 260 mm, 195 mm high (to be filled at 155 mm max) by completing it with the suitable accessories. Maximum compacted slab thickness varies with bitumen mixes composition.
The horizontal movement of the mould is applied by a brushless motor with user-defined controlled linear speed and adjustable pause at the mould inversion point. The longitudinal (major) mould dimension correspond to the compaction direction so it is possible to obtain specimens of the proper length conforming to Standards.
 
All versions feature a solid high stiffness steel frame, with ergonomic design and safety devices conforming to CE standards.

Featuring a compacting system by roller segment head radius 535 mm, the roller segment freely moves by simple friction for better compaction uniformity. A stepper motor moves vertically the roller segment under displacement and load control. The vertical load is applied orthogonally to the axis of the travel motion. The lifting machine cover permits an easy access to the mould area. In the “rest” position, the mould is closed to the operator while the roller segment is lifted and positioned at the back of the machine. 
The machine features a customized electronic card control with 21'' touchscreen PC.
 
Software
-21'' Touchscreen integrated PC
-Fully programmable PC software operating in Windows®
-Set up of customized compaction sequence as free combination of load/displacement controlled cycles
-Selection, customization and storing of test parameters
-Customization of the compacting sequence to be saved and recalled from the database
-Graphic display of displacement / force vs. number of passes or load vs. displacement

Unique feature
As recommended by new EN 12697-33 chapter 7.3, the combined load/displacement compaction procedure provides at the beginning a controlled displacement compaction, which can grant a flat surface of the compacted slab, followed by a load compaction phase, which can replicate the real compaction on the road surface.
 
Machine control
-Vertical displacement of the roller segment by stepper motor, measured directly by linear transducer to verify in real time the specimen thickness to eliminate the errors due to the deformation of the machine structure
-Real time measurement and control with a closed loop logic of compaction load by two precision strain gauge load cells. The dual cell system permits to verify possible discrepancies of the compaction due to the wrong distribution of asphalt in the mould and any other unexpected malfunctions, with warning to the operator.
-The machine is fitted with sensors to confirm the mould in position and for the automatic setup of the horizontal travel.
MOULD DIMENSIONS: 500 x 400 mm, 500 x 300 mm, 400 x 300 mm, 300 x 300 mm and 320 x 260 mm, 185 mm high.
The longitudinal (major) mould dimensions correspond to the compaction direction, to obtain specimens of the proper length conforming to standards.
 
Upgrading options (to be specified at the time of order)
  • Heating system control for sector heads fitted with heating system
  • Base heating system, to maintain the mould and sample temperature
  • Roller segment vibrator, to simulate the on-site vibratory rollers. Adjustable frequency from 10 to 50 Hz
An alternative model is available, suitable for low-thickness slab, featuring molds height 155 mm, to be filled at 120 mm max (see model 77-PV40C05 / 77-PV40C06)
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Technical specifications

Models 77-PV41C05
77-PV41C06
 
Machine control By 21'' touch screen PC
(Included)
Operation Electro-mechanical
Max. vertical force 30kN
Load measurement by two load cells
Compacting device Roller segment radius
535 mm
Back and forth
horizontal travel
Adjustable by software:
300/320 mm
400 mm
500 mm
Trolley  speed Adjustable up to 300mm/s
Adjustable pause at
inversion point
Mould dimensions* 320x260x195** mm
300x300x195** mm
400x300x195** mm
500x300x195** mm
500x400x195** mm
Heated head Yes (optional)
Heated base Yes (optional)
Roller vibration Yes, adjustable frequency from 10 to 50Hz (optional)
Power rating 3000 W
Electrical supply 380 V 50 Hz, 3 ph or
220 V 60 Hz, 3 ph
Overall dimensions
(lxwxh)
1300x800x2040 mm
Weight approx.: 650 kg
 *To produce slabs down to 38mm thickness. Maximum slab thickness varies with bitumen mixes composition.
** Model 77-PV40C05 / 77-PV40C06 suitable for 155 mm high moulds is available

Ordering info

77-PV41C05
PAVELAB MASTERCOMP advanced multi-size electromechanical slab compactor
. For compaction of 500x400 mm, 500x300 mm, 400x300 mm, 300 x 300 mm and 320 x 260 mm slabs. Includes the compaction procedure defined in the brand new EN 12697-33 7.3. Includes the PRO-COMPACT control feature. Controlled by all-in-one touchscreen integrated PC, load and deformation measurement, software controlled mould travel, performing user defined free combination of load/displacement controlled compaction sequences. Suitable for 195 mm high moulds, to be filled at 155 mm max. Supplied without moulds and compaction sector heads (see accessories).
380V/50Hz/3ph+N
      

77-PV41C06
PAVELAB MASTERCOMP advanced multi-size electromechanical slab compactor. For compaction of 500x400 mm, 500x300 mm, 400x300 mm, 300 x 300 mm and 320 x 260 mm slabs. Includes the compaction procedure defined in the brand new EN 12697-33 7.3. Includes the PRO-COMPACT control feature. Controlled by all-in-one touchscreen integrated PC, load and deformation measurement, software controlled mould travel, performing user defined free combination of load/displacement controlled compaction sequences. Suitable for 195 mm high moulds, to be filled at 155 mm max. Supplied without moulds and compaction sector heads (see accessories).
220 V, 60 Hz, 3 ph

77-PV40C05
PAVELAB MASTERCOMP advanced multi-size electromechanical slab compactor. For compaction of 500x400 mm, 500x300 mm, 400x300 mm, 300 x 300 mm and 320 x 260 mm slabs. Includes the compaction procedure defined in the brand new EN 12697-33 7.3. Includes the PRO-COMPACT control feature. Controlled by all-in-one touchscreen integrated PC, load and deformation measurement, software controlled mould travel, performing user defined free combination of load/displacement controlled compaction sequences. Suitable for 155 mm high moulds, to be filled at 120 mm max. Supplied without moulds and compaction sector heads (see accessories).
380V/50Hz/3ph            

77-PV40C06
PAVELAB MASTERCOMP advanced multi-size electromechanical slab compactor. For compaction of 500x400 mm, 500x300 mm, 400x300 mm, 300 x 300 mm and 320 x 260 mm slabs. Includes the compaction procedure defined in the brand new EN 12697-33 7.3. Includes the PRO-COMPACT control feature. Controlled by all-in-one touchscreen integrated PC, load and deformation measurement, software controlled mould travel, performing user defined free combination of load/displacement controlled compaction sequences. Suitable for 155 mm high moulds, to be filled at 120 mm max. Supplied without moulds and compaction sector heads (see accessories).
220 V, 60 Hz, 3 ph

Accessories

Interchangeable sector heads
77-PV42001 
Interchangeable sector head to produce slabs 320 mm long x 260 mm wide

77-PV43001 
Interchangeable sector head to produce slabs 300 mm long x 300 mm wide

77-PV44001 
Interchangeable sector head to produce slabs 400 mm long x 300 mm wide

77-PV45001 
Interchangeable sector head to produce slabs 500 mm long x 300 mm wide

77-PV46001 
Interchangeable sector head to produce slabs 500 mm long x 400 mm wide


Interchangeable sector heads complete with heating system
To be completed with 77-PV43012 Temperature control system (see Upgradig options)
77-PV42011 
Interchangeable sector head to produce slabs 320 mm long x 260 mm wide. Complete with heating system.

77-PV43011 
Interchangeable sector head to produce slabs 300 mm long x 300 mm wide. Complete with heating system.

77-PV44011 
Interchangeable sector head to produce slabs 400 mm long x 300 mm wide. Complete with heating system.

77-PV45011 
Interchangeable sector head to produce slabs 500 mm long x 300 mm wide. Complete with heating system.

77-PV46011 
Interchangeable sector head to produce slabs 500 mm long x 400 mm wide. Complete with heating system.


Moulds
77-PV42102 
Steel mould 320x260 mm, 195 mm high, to be filled at 155 mm max.

77-PV43102 
Steel mould 300x300 mm, 195 mm high, to be filled at 155 mm max.
77-PV44102 
Steel mould 400x300 mm, 195 mm high, to be filled at 155 mm max.

77-PV45102 
Steel mould 500x300 mm, 195 mm high, to be filled at 155 mm max.

77-PV46102 
Steel mould 500x400 mm, 195 mm high, to be filled at 155 mm max.

77-PV42002  
Steel mould 320x260 mm, 155 mm high, to be filled at 120 mm max.

77-PV43002  
Steel mould 300x300 mm, 155 mm high, to be filled at 120 mm max.

77-PV44002  
Steel mould 400x300 mm, 155 mm high, to be filled at 120 mm max.

77-PV45002 
Steel mould 500x300 mm, 155 mm high, to be filled at 120 mm max.

77-PV46002  
Steel mould 500x400 mm, 155 mm high, to be filled at 120 mm max.

Upgrading

Heating control system of sector heads fitted with heating system (to be specified at the time of order)
77-PV43012 
Compaction sector heating system. Adjustable up to 140°C


Heated base option (to be specified at the time of order)
77-PV41C00/UP 
Heating system incorporated in mould base support, to maintain test tempearture. Adjustable up to 120°C.


Vibrating roller option, adjustable from 10 to 50 Hz (to be specified at the time of order)
77-PV43042 
Vibrating roller option. For 50 Hz models

77-PV43044 
Vibrating roller option. For 60 Hz ph models

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