One of the most common questions I get from guys starting their own paving crews is: "How heavy of a machine do I actually need?"
It’s a valid question. In the compaction game, we see everything from tiny walk-behinds to massive earth-movers. The market spans from 1 ton up to 22 tons, and picking the wrong weight class can either leave you failing density tests or crushing the pipework underneath your grade.
I’ve operated the full spectrum. Here is my breakdown of the weight classes and where I actually use them on the job site.
1. The "Micro" Class: Under 1 Ton (approx. 2,200 lbs)
I usually refer to these as patch rollers.
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The Feel: These are typically light, gas or diesel-powered units.
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The Application: I use these strictly for tight squeezes—sidewalks, bike paths, and residential trench work. They don't have the horsepower for major production, but for popping into a backyard or fixing a utility cut, they are indispensable.
2. Light Duty: 1 to 6 Tons (approx. 2,200 – 13,200 lbs)
This is the most versatile category for general contractors.
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The Feel: These machines are simple and rugged. I’ve noticed they usually have a larger steel drum diameter relative to their frame, which gives a nice finish.
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The Application: This is my go-to for driveways, parking lots, and city street repairs. One thing I appreciate about this class is the gradeability (climbing power). I’ve taken 3-ton units up steep residential driveways where heavier machines would slide.
3. Medium Duty: 6 to 10 Tons (approx. 13,200 – 22,000 lbs)
Now we are getting into serious production numbers.
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The Feel: In this range, the technology jumps up a notch. I’ve found that the vibration systems here are much more adjustable.
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The Application: I utilize these for highway shoulders, secondary roads, and airport taxiways. You have enough weight to hit density on deep lifts of asphalt, but they are still nimble enough to maneuver.
4. Heavy Duty: 10 to 14 Tons (approx. 22,000 – 30,800 lbs)
This is the bread and butter for infrastructure work.
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The Feel: Stability is the key here. When you are running a 12-ton machine, it plants itself. The drive systems are powerful enough to push through loose soil without bogging down.
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The Application: I run these on main-line highway paving, railway bed construction, and port terminals. When consistent quality is the only metric that matters, this is the weight class I trust.
5. Super Heavy: 16+ Tons (approx. 35,000+ lbs)
These are the beasts of the industry.
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The Application: I rarely see these on asphalt. These "Giants" are almost exclusively for massive earthworks—compacting rock fill for dams or deep foundations where you need extreme ground pressure.
A Critical Pro-Tip: "Operating Weight" vs. Dry Weight
Here is a trap I see rookie buyers fall into constantly.
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The Spec Sheet: Manufacturers list "Operating Weight" (or Work Mass). This includes fuel, hydraulic fluid, water for the spray system, and the operator. It is not the empty shipping weight.
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Beyond the Tonnage: In my experience, weight isn't the only stat that counts. You need to look at the Static Linear Load (how much weight is actually pressing down per inch of drum width), the Amplitude, and the Frequency. I’ve seen lighter machines outperform heavier ones because they had better vibration mechanics and speed control.
