Big Tech Roundtable 2026 | Part 2: What Problems Does Intelligent Compaction Fix?

This is part 2 of our Big Tech Roundtable 2026 discussion about all things intelligent compaction. This part of the conversation focuses on the actual specific advantages that intelligent compaction technology provides in real-world jobsite settings.

Also, use these links below to jump to other parts of this round table discuss to find what you're most interested in learning about:

• PART 1: What Makes Intelligent Compaction Intelligent?
• PART 3: Data, Integration, And Interoperability.
• PART 4: Forcasting Future Compaction Technologies.

ROI And Problem-Solving: What Does It Actually Fix?

Asphalt Contractor: What is the most common and/or costly compaction mistake your system prevents? Give us a real-world scenario -- what can go wrong without IC, and how does your technology change that outcome?

Tim Kowalski, HAMM: The most common mistakes are over-rolling and under-rolling. Once calibrated, our system helps operators stay much closer to the target density throughout the process. Over time, this consistency results in longer-lasting pavements and helps contractors qualify for quality bonuses. Without IC, it is easy to unknowingly damage roads due to inconsistent compaction. IC provides measurable consistency and documented proof of proper compaction throughout the job.

Justin Zupanc, Volvo CE: One of the most common and costly mistakes we see out there is over-compaction, which is easy to do if you’re just guessing. If an operator makes unnecessary extra passes, especially when the mat has cooled outside the optimal temperature window, they risk fracturing the aggregate within the mix (not to mention wasting time).

When you fracture the material, you compromise the structural integrity of the pavement, which can lead to premature cracking, rutting and, ultimately, a failed job that requires expensive rework. On the flip side, under-compaction leaves too many air voids, which is just as bad.

Without IC, an operator is relying heavily on their gut feeling or a static rolling pattern that doesn’t account for changing jobsite variables like how long it’s been since the paver laid the mat. With IC technology, they see exactly when they’ve hit their density targets and know to stop rolling, preventing the wasted time and material damage of over-compaction.

Eric Booth, Dynapac: Seismic Asphalt adjusts vibration frequency of the drum, so helps reduce the possibility of over compaction, which damages the asphalt. Dynalyzer and Nexus help the operator insure complete compaction coverage of the asphalt. This leads to uniform compaction and less likely to have future issues from under-compacting the asphalt.

Kevin Garcia, Trimble: Compaction is the last thing that happens to a roadway. By the time the roller touches it, 99% of the project cost and time has already been spent, which makes getting it right non-negotiable. When it goes wrong, it goes wrong quietly, and it compounds.

The most common mistake isn't dramatic; it's running the same roller pattern on every job without knowing if it's actually delivering the compaction you need. Mat conditions change (temperature, mix, lift thickness), but a fixed pattern doesn't. That's where you see both over-compaction, where extra passes start crushing aggregate and shortening pavement life, and under-compaction, where you leave air voids in the mat and invite early failure.

Instead of relying on a pattern and a few cores or gauge readings that touch well under one percent of the job, the roller is effectively measuring compaction across the entire mat in real time. Operators see percent compaction in the cab and adjust while the mix is still workable, so they hit spec consistently without over-rolling—and owners get a lot more confidence that the pavement will perform the way it's supposed to.

There's a safety dimension here too. When compaction readings are visible from the cab throughout the job, an inspector doesn't need to walk an active paving zone for the full operation — early validation that the numbers are tying out is enough.

John Gravatt, BOMAG: The BOMAP mapping system provides operators with real-time visibility to compaction parameters to help:

1. Ensure adequate / consistent roller coverage.
2. Avoid compacting at improper temperatures (avoid tender zones, prevent rolling cold asphalt, etc)
3. Identify weak spots in sub-grade with proof-rolling to measure stiffness.

BOMAG technologies like VARIOCONTROL AND ASPHALT MANAGER prevent several real-world mistakes:

1. 1.    Prevents the use of the wrong amplitude setting by automating and optimizing the setting.  Incorrect settings can lead to multiple issues:
   1. Amplitude too low can lead to a slow density growth rate per pass – this could lead to inability to achieve the proper density
   2. Amplitude too high can lead to crushing of aggregate and mat damage
2. Prevents drum bounce (have you ever heard a roller operator turn on vibration on a cold mat?  The rattling sound it makes is known as drum bounce or double hit, and can be extremely destructive to an asphalt mat)

AC: Contractors are running thinner margins than ever. Make the business case: what are the hurdles your IC solution actually requires to adopt, and what does a realistic return on that investment look like -- in reduced rework, fewer core samples, avoided penalties, quality points, or other measurable terms?

Volvo: The biggest hurdle isn’t the hardware — it’s trust. Operators who have been doing this work for years rely on instinct, and shifting to a data-driven approach takes some adjustment.

From an ROI standpoint, the value shows up in a few different ways. Operators can reach their targets faster, which also means lower fuel consumption and minimal machine wear. More importantly, it significantly lowers the risk of failing a density requirement, which can lead to costly penalties or rework.

It’s easy for an operator to lose track of the edge of a rolling pass and have too much or too little overlap. If they’re continually rolling over the same area, they’re burning more fuel, adding wear to the machine and taking time away from other tasks. With the labor challenges contractors are facing, this adds up in both additional costs and missed opportunities. We’ve done testing with and without a system being visible to the operator and noticed as much as 30% improvement with Compact Assist. There is an upfront cost to these systems, but when you look at the associated value, they pay for themselves.

Dynapac: Well, Seismic Asphalt is basically free with any Dynapac Heavy Tandem Roller, as it’s a standard feature. Giving the contractor up to fuel savings of about $3,500 a year if they run 1,000 hours, is quite a benefit for just having Seismic Asphalt on the roller. 

Trimble: The ROI case starts somewhere contractors don't always expect: the inspector. Third-party compaction inspection on a public project can run up to $1,500 per day. When real-time compaction data is visible from the cab throughout the paving operation, the inspector doesn't need to be on site for the full job. Early validation that the roller pattern is working and numbers are tying out is sufficient. That reduction alone pays down the technology investment quickly.

The system itself is designed to be learned in about ten minutes. The display is intuitive—the target is always green. Below target is one color, above target is another. The premise is simple: roll it till it's green. This generation of workers responds to that kind of interface, and it removes a significant onboarding burden from crews.

There's also a paving process efficiency argument that's easy to overlook. When compaction is optimized, the roller(s) keeps moving and the paver doesn't have to stop. When the compaction operation runs in harmony with the paving process, the surface is finished sooner with a higher quality product and fewer issues to address.

On the access side, a large upfront capital outlay isn't the only option anymore. Subscription models let you carry the cost as an operating expense rather than a capital expenditure. You're always on the latest hardware, and you're covered if equipment gets accidentally damaged. It's an opportunity that's not talked about enough.

BOMAG: Great question!  In the past, our industry did not necessarily have a shortage of good roller operators.  Today, we have found a different market, one in which contractors struggle to find those operators.  The ASPHALT MANAGER and VARIOCONTROL technologies are designed to take the expertise of that 30-year veteran operator and put it into the machine’s control.  Then combine that with a pass count system like BOMAP, which is essentially a GPS navigation system for compactors, and you’ve set a novice operator up to achieve the exact same results as that 30-year veteran.  With a pass count reduction and density consistency improvement to boot, payback might not be measured in number of jobs, but rather a single job.

HAMM: Many of the benefits are already reflected in the question: reduced rework, fewer cores, lower penalties, and increased bonuses through real-time density visibility. Additionally, contractors can analyze machine utilization data such as fuel consumption, maintenance costs, and idle time. As margins tighten, contractors are paying closer attention to this information to identify efficiencies and gain a competitive edge.

AC: Labor and operator experience gaps are a growing challenge across the industry. How much does your IC system close that experience gap -- can a less seasoned operator achieve consistently spec-meeting results with your technology, or does it still require significant operator skill to get full value?

Dynapac: Seismic Asphalt takes no training, as it is the default setting, and is ready to go when the roller is turned on and rolling. Actually, the first thing we tell even experienced contractors that are new to Dynapac rollers with Seismic Asphalt, is to expect that is sounds different and feels different. When vibration frequencies are lowered, and the drum is matching the resonant frequency for the asphalt, there is a noticeable difference to the operator. They don’t feel all the shaking and less noise than traditional rollers as the compactive energy is going into the asphalt, and not being wasted as excess shaking and noise.

Trimble: Technology doesn't replace operator skill, but it does change what skill is required. A less experienced operator using a compaction profiling system knows in real time whether the mat is meeting a target. They're not relying on intuition built from years of watching how a roller feels. The system gives them the same information a veteran would have internalized, they just get it on a screen instead of through experience.

The bigger argument, though, is about what happens to experienced people when you give them better tools. We hear consistently from contractors that technology adoption plays a meaningful role in employee retention — people who can learn new things and move into more skilled roles are more likely to stay. In an industry with a real labor shortage, that matters as much as the productivity gains.

BOMAG: The VARIOCONTROL and ASPHALT MANAGER technologies absolutely assist new operators improve results, as mentioned above in Part 2 Q2.

HAMM: Ease of use has been a key focus in our system development. If a system is difficult to set up or operate, it will not be adopted by operators. Some skill is still required, but we provide training to ensure operators are comfortable, efficient, and confident using the system. The technology significantly shortens the learning curve for less experienced operators.

Volvo: This is a massive challenge we hear about across the entire industry. Contractors are struggling to find and retain experienced operators. The veterans who have been in the seat for decades have a built-in understanding of temperatures, times and how different mixes react. They can almost feel when a mat is done.

Newer operators simply don’t have that history or experience, which is where IC bridges the gap. By utilizing a system like Compact Assist, they have an easy-to-read visual guide right in front of them. It acts like a digital safety net that significantly shortens the learning curve.

Instead of relying on trial and error, the technology gives them immediate visual feedback. If they’re exposed to these tools early, a less seasoned operator can achieve consistent, on-spec results much faster than they ever could have in the past.

AC: Beyond density and pass counts, are there sustainability or material efficiency arguments to be made for IC adoption? Does your system help contractors reduce fuel consumption, extend mat life, or lower their environmental footprint in any measurable way?

Trimble: Yes. When you compact to a measured compaction target instead of a fixed pass count, you stop when the work is done. No extra passes on a mat that's already at target means less fuel, less wear on the roller, and less mechanical stress on the pavement. Those are real, measurable reductions, even if the exact numbers vary by job.

There's also a paving process efficiency gain. When compaction is optimized, the roller keeps moving and the paver isn't stopping and starting. Every paver stop risks a bump in the mat; when everything runs in harmony, you finish sooner with a smoother surface and fewer callbacks.

The longer-term story is road life. Research shows a 1% improvement in compaction can extend pavement life by 10% or more. A road that lasts longer needs fewer rebuilds — which means less material, less equipment mobilized, and less disruption. Contractors using integrated 3D workflows are seeing 10 to 20% reductions in material waste. Compaction is one piece of that, but a consequential one.

BOMAG: Yes, there are certainly sustainability arguments:

1. Pass count reductions help save fuel and machine use.  Productivity increases, so costs decrease.
2. Optimizing compaction: if compaction is achieved more consistently and density is achieved within the temperature window with the minimum number of passes, the reliability of that roadway can be increased, resulting in a longer service life.

HAMM: All IC systems can save contractors money, depending on how effectively they are used and monitored. Reducing passes directly lowers fuel consumption. Improved consistency in density leads to longer-lasting pavements, which reduces lifecycle costs. Ultimately, IC saves time—and time is money.

Volvo: Absolutely. There’s a very strong efficiency and sustainability argument to be made here. Beyond just getting a smoother, longer-lasting road, IC fundamentally reduces the amount of time a machine spends running.

When you eliminate the guesswork, operators don’t make those “just to be safe” extra passes. Fewer passes mean less time running the machine, which directly translates to less diesel burned. With fuel prices being a constant headache for contractors, cutting down on waste here is a measurable win for the bottom line. It also lowers the environmental footprint of the jobsite and reduces unnecessary wear and tear on the compaction equipment itself.

Dynapac: Seismic Asphalt offers up to 25% fuel savings compared to a non-Seismic roller.

CLICK HERE: PART 3: Data, Integration, And Interoperability.