BW 332 DEEP IMPACT.

Job Reports.

JOB
D ER E P O R T

REPORT
RB
JE O
The BW 332 DEEP IMPACT has been shown to achieve
a compaction depth of 4 m on job-site applications.

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 B O M A G J o b R e p o r t s B W 3 3 2 D E E P I M PA C T

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The most powerful single drum roller in the
world.
The BW 332 DEEP IMPACT has taken BOMAG to another level in soil compaction. With an operating
weight of 32 tonnes and extra powerful vibration forces, BOMAG design engineers were aiming to set
new standards for compaction at depth. Here we present the most important results following the
first year of on-site field experience:

The concept
To reach the maximum compaction depth simply
by increasing the weight of the roller was not the 1. BOMAG VARIOCONTROL
answer. New ideas were needed to channel the 2. BOMAG polygonal drum
force into the soil to optimum effect. Two technolo-
gies exclusive to BOMAG made the difference:
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 B O M A G J o b R e p o r t s B W 3 3 2 D E E P I M PA C T
BOMAG VARIOCONTROL
Conventional vibration systems on single drum
rollers use eccentrics to create the circular move-
ment of the drum. This means that every time the
drum rotates it also moves horizontally. Efficiency
losses occur due to friction between the drum and
material.
BOMAG VARIOCONTROL BVC, on the other hand,
generates purely linear drum oscillation. This
means that the vibratory forces are channelled
into the soil vertically. This provides the basis for
optimum depth effect.
BVC technology is the first concept which enables
a significant increase in vibratory amplitude. This
is measured at 3.3 mm with the BW 332 and is
over 80% larger than with conventional rollers.
The amplitude has a key effect on the compaction
depth. Furthermore, with BVC the amplitude auto-
matically adjusts to the compaction level already
achieved.
BOMAG VARIOCONTROL: pure linear drum oscillation.
The oscillating direction – and therefore the compaction depth – is
automatically controlled by BVC.
BOMAG polygonal drum
The polygonal drum was developed to enable
the vertical vibrations from the BVC exciter to be
transferred into the soil. Its plates allow the drum
surface to sit flat on the material to produce an
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excellent connection between the soil and vibra-
ting drum. Deformation does not occur at the
edges, which means there are no losses, as is the
case with standard round drums. Larger pressure
cones form under the plates compared to round
drums. To prevent any unwanted “capping” the
edges of the polygonal drum systematically loosen
the surface when rolling. So when the next plate
is applied the maximum force penetrates to great
depth.
The combination of polygonal drum, VARIOCONTROL
and maximum amplitude (3.3 mm) is the key to the
maximum depth effect of the BW 332.
Polygonal drum: sophisticated system of plates and wedge-like
geometry.
Site experience
In the first year of field operation, early BW 332
DEEP IMPACT series machines had to prove their
efficiency under the critical eye of contractors and
clients on 15 different construction sites. All in all,
the results were extremely impressive:
The BW 332 did not simply prove itself on large-
scale projects. Many of the projects were actually
smaller works. The BW 332 was able to demon-
strate that it can be operated and manoeuvred like
a conventional single drum roller and is easy to
transport.
Here are a few examples:
 Te c h n o l o g y

1. RWE Power.

The lignite deposits in the Rhine region are an important source of Germany‘s power supply. Here
RWE Power AG operates the Inden open cast mine, among others. Firstly, the overlying rock is
removed by large bucket wheel excavators to expose the coal seams underneath. The excavated
material is deposited by spreaders over mine areas where coal has already been removed. Deposited
material is not usually compacted.

Compaction is only carried out in special cases;
for example, if large volumes are to be removed
from an area that has just been covered. This was
the case, for example, for the new build of the
‚belt collection point‘ (a kind of „shunting station“
for the conveyor belt systems). Here, RWE Power
AG carried out trials with a BW 332, accompanied
and assessed by the renowned Prof. Dr. Düllmann
GmbH engineering consultancy.
Material: medium and coarsely grained sand;
densely layered
Height: approx. 40 metres, mainly loose layers,
tipping/settlement nearly completed

The BW 332 DEEP IMPACT at the Inden open cast mine; in the background, a „spreader“ depositing overburden.

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 B O M A G J o b R e p o r t s B W 3 3B2F D6E0E0PF Ii M
n iPsAhCe Tr

Three trial strips were prepared and compacted gated depth of 5 m the layer density increased
with a different number of passes: 6, 10 and 16. In from loose to medium
total, 35 standard penetration tests were carried Q Lowering the ground level between 14 and 22 cm
out to a depth of 5 m before and after compaction Source: Prof. Dr. Düllmann, Geotechnisches Büro GmbH

to measure the compaction results. The ratio of

number of impacts before and after compaction is The trials substantiate:
termed the improvement factor. This improvement Q An extremely impressive compaction depth of 4 m

factor indicates the compaction effect of the roller Q Large increase in compaction in the middle sec-

used. tion between 1 and 2 m

Optimum compaction was achieved with 10 So BOMAG now offers an interesting alternative
passes. Additional passes had no further effect. to previous methods, e.g. drop plates or impact
compactors for use in open cast mines. Compared
The result with 10 passes to these methods, the BW 332 can be used far more
Q Deeper than 5 m an improvement factor of 3.2 flexibly and cost-effectively. Costs per m3 fall con-
was achieved siderably; surface area coverage increases. The
Q Between 1 and 1.5 m depth the improvement BW 332 can be operated in the same way as a
factor was 6.5 standard single drum roller.
Q At a depth of up to 4 m an improvement factor of

2 was achieved On the basis of these positive results, RWE Power

Q At a depth of up to 2 m the layers are upgraded plans to continue using the BW 332 in future for
to dense. Throughout nearly the entire investi- similar work.

Number of impacts in the standard penetration test N10 Improvement factor  [-]
0 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8
0,0 0,0

0,5 0,5

1,0 1,0

1,5 1,5

2,0 2,0
Depth [m]
Depth [m]

2,5 2,5

3,0 3,0

3,5 3,5

4,0 4,0

4,5 4,5

5,0 5,0

loose medium dense dense

7 before compaction before compaction

DPL results before and after compaction; 10 passes. Note: the Improvement factors  for 10 passes. Even at a depth of 4 m,
significant increase between depths of 1 and 2 metres. a  of over 2 is achieved – i.e. double the number of impacts.

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2. Metz (co.): warehouse in Zweibrücken.

Metz from Saarland is a typical medium-sized construction company. For the construction of a new
warehouse in Zweibrücken the soil had to meet load-bearing requirements. The problem: the uncom-
pacted fill was made up of sand stone (SU-GU). Normally, the material would have been removed,
replaced in layers and compacted: a lengthy and expensive operation.

So Metz decided to use a BW 332. The result: The ding the working width to 2.4 m 15% higher output
entire compaction work on a total of 12,000 m2 was gained compared to conventional rollers. The
was completed in just 3 days. Simply by exten- key advantage was however: no material had to be

0 10 20
0
7 11
8
11 11
8 17
13 14
50
12 22
13 21
14 24
17 23
11 10
100
12 17
12 20
15 23
13 23
17 24
150
14 19
Depth [m]

10 16
7 23
12 21
17 19
200
13 19
17
14 19
11 22
15 25
250
19 23
13 24
17 20
12 20
15 17
300
14 19
11 23
13 24
17 20
15 18
350

Metz, Zweibrücken project: the comparison of the number of impacts before (green) and after (red) compaction confirms the effectiveness of the BW 332
DEEP IMPACT up to a depth of 3.5 m.

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 B O M A G J o b R e p o r t s B W 3 3 2 D E E P I M PA C T

moved; direct post-compaction of the foundation
soil could be carried out. This meant that dozers
and loaders, etc., were unnecessary.
The S-BB engineering consultancy monitored
compaction using the standard penetration test.
Even at a depth of 3 m, an improvement factor of
1.8. was still noticed. An increase in layer density
was achieved at the required depth which means
that the BW 332 was producing the required load
capacity without the need to export materials. The
necessary loosening of the top 40 cm, typical for
the polygonal drum, was compacted afterwards by
a conventional single drum roller. Overall, the total
cost of the project was reduced significantly.

Cost comparison to create load bearing requirements on loose fill

Area: 12,000 m² – height of fill 3.50 m

Variant A: Variant B:
compaction with a 12 t single drum roller compaction with BW 332 DI

Step 1 Step 1
Remove loosely placed soil Use the BW 332 to post-compact the existing
and place at the side fill with no further earthworks
Q Remove by bulldozer Q Compaction with BOMAG BW 332

12,000 m² x 3.50 m x 2.00 €/m³ 84,000 € 12,000 m2 x 3.50 m

x 180 €/h
2,000 m³/h
Step 2
Replace soil deposited at the side in layers
compacting each time (d = 50 cm)
Q Placement by bulldozer

12.000 m² x 3,50 m x 2,50 €/m³ 105,000 €

Q Compaction with a 12 t single drum roller
12,000 m2 x 3.50 m 10,650 €
x 85 €/h
335 m³/h

Total costs: 199,650 € Total costs: 3,780 €

Reduction in costs: 195,870 €

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3. Static compaction in Dresden.

BauCom from Bautzen had completely different reasons for wanting to use a BW 332. A new factory
hall was to be built in Dresden. The client: Globalfoundries, a computer chip manufacturer. The re-
quirement for the machine was the unusual feature in this case: only static compaction was permit-
ted as not even the slightest vibration was acceptable during production at the chip factory.

However, as 80 to 100 cm of the mixed, slightly 95% Proctor density requirement up to a

cohesive soil was to accomodate higher load-
bearing values, material would have had to be
removed, relaid in thin layers and compacted
assuming conventional compaction equipment was
to be used. This would not have been feasible in
wet weather.
To the surprise of BauCom, the contractor, and the
supervisor the BW 332 DI was able to achieve the
1 m depth safely in static operation. This meant
extensive earthworks were now not necessary
and despite a tight deadline the process was
completed on schedule. The sensitive production
of the electronics components was not interrupted
at any time. Vibrations were monitored and strict
limits adhered to throughout the entire construc-
tion phase.

The result:

Although the entire capacity of the machine was not required for this job, it certain-
ly demonstrated an interesting field of application. With its great weight and clever
drum geometry, the BW 332 DI can combine low vibration compaction and output
in static operation like no other roller.

If there are vulnerable structures in the area – e.g. like this pipeline – the BW 332 is also capable of operating very smoothly. VARIOCONTROL
allows the amplitude to be adjusted gradually. With the polygonal drum and extremely high linear load outstanding compaction performance is
achieved, if required, even without vibration.

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 B O M A G J o b R e p o r t s B W 3 3B2F D6E0E0PF Ii M
n iPsAhCe Tr

4. Locating voids along a railway line.

Maximum compaction power is required for the new Erfurt-Halle ICE route. The foundation soil is
void-rich gypsum keuper. The voids are to be filled to ensure structural load capacity. This is a difficult
task due to the extremely hard material, in parts as hard as concrete, caused by the leached gypsum.

So Heilit + Wörner, the contractor, tested the
BW 332 DEEP IMPACT. Two engineering firms
following the trials on behalf of the client and
contractor confirmed the roller‘s outstanding
performance. Under powerful vibration the voids
collapsed and were consolidated. The BW 332
DEEP IMPACT was used on this site for several
months, producing a load-bearing, safe substrata.
There is no more cost-effective alternative process
to compare with this method.
The entire process was documented with BOMAG
COMPACTION MANAGEMENT BCM 05. The BCM 05
creates complete compaction maps. With the aid
of a tablet PC and a GPS receiver it documents the
compaction achieved and number of passes in real
time. This ensured that no section was missed and
that all voids were compacted adequately. The
BW 332 is pre-equipped as standard for use wih
BCM 05.

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5. Berlin construction waste landfill site;
crushing operations.
In a site trial at the Großziethen landfill site at the gates of Berlin, the BW 332 showed unique
strengths.

For example, the BW 332 was used to crush More settlement

and compact building rubble. According to initial = more compaction
measurements, the landfill site volume could be = increased material/m³SHUKÄSSZP[L]VS\TL
reduced by 20% compared to using 26 t single
Longer landfill site life = higher turnover!
drum rollers, which had previously been consi-
dered as the strongest rollers. A clear financial
benefit for the operator and a plus for the environ-
ment: far higher volumes can occupy the availa-
ble space. And this means the landfill site life is Example calculation:

extended. The BW 332 was also able to compact

Total landfill site volume: 500.000 m³
in increases of 25% with ease. The powerful drive
Medium density: 2 t/m³
with dual drive pumps was optimised for use Additional compaction with BW 332 DI 10%
during tests at this landfill site. The modifications
were then included in the series.
Increased site capacity
On one hand, the drum grinding action has the due to compaction! 100.000 t
effect of increasing density; on the other, surfaces
compacted by the BW 332 are excellent to drive and safer. Sharp edges are broken down and the
on. Even harder rock (soil class 2) can be crushed material becomes finer-grained. A benefit for
by the BW 332. This makes this model particularly vehicles using pneumatic tyres: tyre damage and
interesting for mines: Haul roads are more durable associated costs are reduced significantly.

In action: reducing building rubble volumes with the BW 332 DEEP IMPACT.

Compaction with a Compaction with

26 t roller BW 332 DEEP IMPACT
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 B O M A G J o b R e p o r t s B W 3 3 2 D E E P I M PA C T

The BW 332 DEEP IMPACT in operation at Besseringen.

6. Backes, B51 Besseringen.

For the new construction of the B51 on the Besseringen bypass the client‘s specifications were clear: as
the subsoil made up of fine-grained (silty) sand was only in loose layers as deep as 3 m, 1 m of soil was to
be removed and replaced with a 0/200 rock fill. This structure was to act as support for the embankment.
An EV2 of 80 MN/m² was specified on the surface layer.

After consulting with the BOMAG application spe-
cialists, Backes (from Tholey) decided to submit an
alternative offer:
Q No material removal
Q Compaction of the existing soil with the BW 332
Q Thus, increased layer density and in turn suf-
ficient storage conditions
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Q Compensation for the required settlements with
0/200 rock fill to achieve the required height
The client first had to be convinced of the robust-
ness of this alternative proposal, so a trial field
was prepared. The three tracks were worked with
6, 8 and 10 passes. For the trials, the water con-
tent was slightly less than the optimum 12.2 %; The depth effect depends on the number of
the dry density was 1.7 t/m³. The engineers from passes:
the geotechnical office of Dr. Jung and Lang made Q 1.2 m with 4 passes

the following findings: Q 1.6 m with 6 passes

Q 2.0 m with 8 passes

Q The material can be compacted with the se- (Note: more passes may have increased com-
lected method paction; see experience at RWE Power)
Q In just 4 passes a mean compaction rate of Q The reduction in volume of this material can be

100% DPr can be achieved calculated at 10%

Q The required load capacity was also achieved

after 4 passes; more passes had little additional
benefit
Q In contrast, the settlements and number of im-
pacts of the standard penetration test continued
improving with more passes
The engineers’ final recommendation:
“After 8 passes there were no more areas at risk
of settlement to a depth of at least 2 m. Proceed-
ing according to the construction contract by
adding rock fill would not have ruled out areas still

6. Pass

5. Pass

4. Pass 1 Pass
4m
3. Pass

2. Pass

1. Pass
1. Übergang

Where a 10 t roller requires 6 passes, the BOMAG BW 332 succeeds in just one.

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 B O M A G J o b R e p o r t s B W 3 3 2 D E E P I M PA C T

at risk of settlement. Therefore, the embankment

would have had to have been constructed later on.
The rock fill is no longer required due to compac-
tion with the polygonal roller.

This means that the BW 332

Q has sped work up considerably
Q the job has been managed more cost-effective-
ly, as no material has to be shifted
Q ensures greater site safety than conventional
methods
The construction engineers also wrote:
“Measurements verify that the settlement risk in
the subsoil is removed beforehand by using the
BW 332 polygonal roller for compaction.”
The BCM 05 was also used here to ensure surface
covering quality control of compaction.
In the end, the construction work carried out with
the BOMAG BW 332 DEEP IMPACT was to the
complete satisfaction of the client, supervisor and
contractor alike. In addition, there were two other
winners: the taxpayer will benefit from a better
road costing less; and the environment from less
pollution in terms of energy consumption, noise
and resources thanks to reduced material trans-
portation.

The BW 332 DEEP IMPACT provides the answer to

some of the urgent issues of our time.

So to end:

The results from the compaction trials show that higher quality can be attained
in terms of density of the sandy layers in the subsoil. This is due to the depth
effect achieved using a BOMAG single drum roller with polygonal drum; more-
over, this is greater than the result specified in the construction contract.
Geotechnical office of Dr. Jung and Lang

BOMAG compaction specialists

will of course be happy to answer
any queries you may have

Dipl. Ing. H.J. Kloubert, Dipl. Ing. Manfred Darscheid,

hans-josef.kloubert@bomag.com manfred.darscheid@bomag.com
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