Asohalt Pro - September 2018 issue

The Quality Control/Quality Assurance Issue

asphaltPRO PRODUCTION – PROFESSIONALS – PRODUCTS

Superior Gets Back to Nature iCones

• Engage Process Control • Meet OAPA’s Larry Patrick • Make Specimens Repeatable

SEPTEMBER 2018 WWW.THEASPHALTPRO.COM

UNMATCHED DESIGN

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That’s why at Heatec we take a comprehensive approach to designing your tank farm. That means we look at the materials you will be using, all the equipment that needs heat, the piping, and even future plans for expansion. Then we design a system that works for you.

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H E AT E C , I N C .

an Astec Industries Company

5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com

SM

Dedicated to Success.

© 2017 ROADTEC, INC. ALL RIGHTS RESERVED

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CONTENTS

asphaltPRO september 2018

departments

26

Editor’s Letter

6 — Does Domino’s Meet New QC/QA Standard

AROUND THE GLOBE 8

SAFETY SPOTLIGHT

10 - Rieth-Riley Controls Traffic with iCones

By Sarah Redohl

Mix It Up

14 - Produce Consistent Gyratory Specimens From Pine Test Equipment

Training

16 - Train Employees for New Skills From Volvo Construction Equipment

Pavement Maintenance

18 - RS Asphalt Invests to Seal with Success

By Sarah Redohl

Solve Your Problem 22 - Solve Dust at the Plant

By Sandy Lender

22

Producer Profile

18

26 - Superior Care Superior Asphalt takes 2017 Ecological Award with planning, environmental commitment

By Sandy Lender

Meet the State Exec 32 - OAPA’s Larry Patrick

By AsphaltPro Staff

That’s a Good Idea

38 - Save Water When Washing Aggregate

By Duncan High

16

Product Gallery

52 - Look at What’s New for Mix Production

International Snapshot

58 - International Reflective Measuring From Reflective Measurement Systems

Here’s How it Works

60 - Vögele’s Passive Remixing Insert with an Active Remixing Module

New Tech

62 - OEMs Improve Service with Online Parts Portals OEMs are leveraging online portals for parts and accessories to get them to contractors quickly and more easily

By Sarah Redohl

Off The Mat

66 - Tips to Build a Solid Construction Business Foundation

By Travis Crabtree 66 - Dynamex Decision Alters Independent Contractor Classification From Jacob Stein

Feature articles 40 - Three Steps Can Improve Your QC

By Ray Brown, PhD, P.E. 42 - Choose Process Control to Enhance Mix Quality

By Dan Ridolfi, PE

The Quality Control/Quality Assurance Issue

asphaltPRO PRODUCTION – PROFESSIONALS – PRODUCTS

Superior Gets Back to Nature iCones

46 - WMA Survey Says: Recycle the Mix From NAPA • Engage Process Control • Meet OAPA’s Larry Patrick • Make Specimens Repeatable

48 - Sunshine State Awards Good Work From ACAF

SEPTEMBER 2018 WWW.THEASPHALTPRO.COM

on the cover From top: Quality Control Supervisor Nate Voriganti, President Jeff Kresnak, Sara Kresnak, Lisa Schild, Kim Legge, Alex Rodriguez (in yellow hardhat), Gary Snieder, and Tony Stepek (in blue hardhat) make up part of the award-winning Superior Asphalt Inc. family in Grand Rapids, Michigan. See related story on page 26.

editor’s Letter Does Domino’s Meet New QC/QA Standard

Sometimes I use the television as background noise when editing late at night. Imagine my confusion when a brightly painted asphalt roller moved across the TV screen while an announcer talked about pizza. This caused me to pay closer attention during the next commercial break. Sure enough, one of the national pizza conglomerates is offering to patch potholes if the street upon which you drive between its establishment and your home causes you to mangle your food.

Ponder this with me.

I’m sure the corporate managers in Ann Arbor, Michigan, hire contractors local to the areas in question and purchase mix from producers in those same areas. Let’s face it: even something as simple as filling a pothole can come back to bite you. In today’s society, if a loose rock hits a windshield, someone’s getting sued for damages.

Beyond loose rocks, there’s an image to uphold. You can fill a pothole with substandard mix from some company that doesn’t know what it’s doing and suddenly all the contractors in the area get a bad name. This is one reason why our industry strives to follow guidelines and specs that improve quality overall. We want a consistently good product for the end user. We want safe and smooth roads all the time.

That’s the driving force behind this edition of the magazine. We’re looking in depth at quality control/quality assurance (QC/QA) because getting consistent results matters.

Your Domino’s franchise owner gets the QC/QA concept when it comes to making a nice pizza for you (hopefully). Your professional asphalt mix designers, producers and laydown contractors get the QC/QA concept when it comes to formulating, producing and placing top quality pavement.

Back in May 2017, the American Society for Testing and Materials (ASTM) subcommittee D04.25 began a work item (WK58842), which was titled “New Test Method for Automated Extraction of Asphalt Binder from Asphalt Mixtures.” A work item, by ASTM’s definition, is “a proposed new standard or a revision to an existing standard that is under development by a committee.”

I’ll give you an oversimplification of the project in the interests of space. The subcommittee basically looked at the quantitative determination of asphalt in mixes using the automated extraction method by solvent, stipulating that asphalt binder could also be extracted using test methods outlined in D1856 and D5404. The subcommittee members pointed out: “This standard does not purport to address all the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.”

This disclaimer begs the question, what was the purpose then?

Efficiency, for one. Prior to committee D04’s Ballot Item D8159-2018, the extraction methods required a lot of the worker’s time and could result in exposure to chemicals if the tech wasn’t careful. Now the testing arena has a new guiding document in newly published D8159-2018. If someone presents a new test methodology that speeds up results, that’s a step in the right direction. What industry needs to ascertain is whether or not that speed also gives repeatable, consistent results.

Speed of delivery coupled with consistent, repeatable quality is a hallmark of the asphalt industry. It’s intriguing to me that Domino’s Corporate felt the need to be a part of various cities’ maintenance budgets. I’m sure the marketing move will pay off for them if they hire quality-minded asphalt professionals to do the actual work.

Stay Safe,

Sandy Lender

6 // September 2018

September 2018 • Vol. 11 No. 11

asphaltPRO

602 W. Morrison, Box 6a • Fayette, MO 65248

(573) 823-6297 • www.theasphaltpro.com GROUP PUBLISHER Chris Harrison chris@ theasphaltpro.com PUBLISHER Sally Shoemaker sally@theasphaltpro.com (573) 823-6297 EDITOR Sandy Lender sandy@theasphaltpro.com (239) 272-8613 ASSOCIATE EDITOR Sarah Redohl sarah@theasphaltpro.com (573) 355-9775 MEDIA SALES Cara Owings cara@theasphaltpro.com (660) 537-0778 ART DIRECTOR Kristin Branscom BUSINESS MANAGER Susan Campbell (660) 728-5007

AsphaltPro is published 11 times per year.

Writers expressing views in AsphaltPro Magazine or on the AsphaltPro website are professionals with sound, professional advice. Views expressed herein are not necessarily the same as the views of AsphaltPro, thus producers/contractors are still encouraged to use best practices when implementing new advice.

SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the United Sates, Canada and Mexico to qualified individuals.

One year subscription to non-qualifying Individuals: United States $90, Canada and Mexico $125.00. For the international digital edition, visit theasphaltpro.com/subscribe/.

around the globe

Industry News and Happenings from Around the World AUSTRALIA

Visit Austroads Publications Online for the latest free PDF titled “Design and Performance of Foamed Bitumen Stabilised Pavements.” The 310-page document was published in July to address foamed bitumen stabilized (FBS) fatigue cracking within six trial sections paved with Austroads mix designs, how to include up to 20 percent recycled asphalt and more.

of a 2017 nationwide survey show nearly 39 percent of asphalt pavements that year were produced as energy-saving warm-mix asphalt pavements and nearly 79 million tons of recycled materials were used in asphalt pavements. A copy of the full survey report, including a state-by-state breakdown of data, is available at www.asphaltpavement.org/recycling. See related article on page 46.

ARIZONA

Check out the 14th Argus Bitumen Trading Asia, taking place Oct. 17 through 19 in Singapore. It’s co-located with Pavement Technology Asia. Get more information at www. argusmedia.com.

Rose Paving LLC, headquartered in Bridgeview, Illinois, acquired KFM Striping and Curb Company Inc., Phoenix, in June, and announced the launch of Rose Paving Phoenix as the company’s eighth office in the North America.

SWEDEN

ARKANSAS

SINGAPORE

Volvo Construction Equipment (Volvo CE), headquartered in Gothenburg, Sweden, and founded in 1832, announced its significant improvements in sales, earnings and order intake contributed to the Volvo Group having “its best ever quarter.” Volvo CE reported net sales in the second quarter of 2018 that were up by almost a third, rising 32 percent compared to the same period in the year before. The second quarter 2018 also saw order intake increase by 41 percent, while deliveries in the period were up 38 percent at 24,108 machines. Order intake in China was particularly strong, rising by 72 percent. The second quarter of 2018 saw a continuation of the improving demand in most major markets. In the year-to-date, Europe is up 8 percent, North America up 17 percent, South America up 28 percent, Asia (excluding China) up 19 percent, and the Chinese market rose 47 percent.

UNITED KINGDOM

Caterpillar announced delivery of its 50,000th articulated truck from its Peterlee, U.K. manufacturing facility since the start of the Cat® branded articulated truck manufacturing in 1985. Trader Construction Company, New Bern, North Carolina, received the Cat 745 during a ceremony held at the Peterlee facility where Carl Huddle, president of Trader, received the keys.

UNITED STATES

The National Asphalt Pavement Association (NAPA) announced in July the results

8 // September 2018

The Asphalt Emulsion Manufacturers Association (AEMA) and the University of Arkansas College of Engineering, have launched the third Asphalt Emulsion Certificate course with the following objectives: to discuss the fundamentals of asphalt emulsion, its uses and the tests run on it; to list the equipment and devices used to store and transfer the raw materials and the asphalt emulsion itself; to describe the steps and proper sequence to produce an asphalt emulsion soap solution; to recognize the components and parameters of asphalt emulsion mills; and to identify the tests and mechanisms for quality control of asphalt emulsion manufacturing. Visit https://www.aema.org/ page/ManufacturingCert for info.

CALIFORNIA

Make plans to attend the 2018 Argus Biofuels & Carbon Markets Summit Oct. 22 through 24 in Napa Valley, California. Visit https://bit. ly/2JBTDh2 to register.

COLORADO

The Rocky Mountain Asphalt Education Center offers its introductory course to Process Control and Owner Acceptance (PC/OA) of asphalt materials for all levels of technicians in January, March, June, August and October.

Visit https://bit.ly/2v1pgwd for information.

Check out the related article on page 42.

ILLINOIS

ALL-TEST Pro of Old Saybrook, Connecticut, will hold its motor diagnostic workshop

Sept. 17 through 21 in Chicago. For more information, call (860) 399-4222.

MISSOURI

• Byrne & Jones Construction, Bridgeton, Missouri, has added Brendan Dobbs of Swansea, Illinois, to its team of project engineers to assist with projects for the asphalt division. Dobbs has a degree in mechanical engineering from Southern Illinois University-Edwardsville.

• The WaterJet Technology Association, St. Louis, Missouri, has released a visual companion to its Industry Best Practices for the Use of High Pressure Waterjetting Equipment manual released two years ago. The video is a resource for new employee orientation. Check it out here: https://bit.ly/2v7SUz6.

TENNESSEE

You can win a trip to the 2019 Indianapolis 500® courtesy Firestone, a tire brand of Bridgestone Americas Inc., Nashville, and the official tire of the Verizon IndyCar® Series.

Off-the-road customers are invited to enter a sweepstakes via www.versabuiltotr.com to win round-trip airfaire for two, hotel accommodations for three nights and two tickets to the 103rd Running of “The Greatest Spectacle in Racing®” May 26, 2019. Your deadline to enter is Sept. 17, 2018. Good luck!

WASHINGTON, D.C.

• The National Hispanic Construction Association (NHCA) anticipates more than 100 Hispanic contractor business owners to participate in the NHCA Legislative Summit on Capitol Hill Sept. 26 and 27. To be part of this event, visit www.builtbylatinos.org.

• At the end of July, the U.S. Environmental Protection Agency (EPA) announced that Cummins Inc. will voluntarily recall roughly 500,000 model year 2010-2015 medium- and heavy-duty trucks to replace a faulty emissions control systems component that causes excess emissions of nitrogen oxides (NOx). This recall is the largest voluntary truck emissions recall to date.

The problem Cummins is acting to correct is the result of a defective part and does not involve a defeat device. Visit https://www. epa.gov/recalls/recalls-vehicles-and-engines for information.

safety spotlight

Rieth-Riley placed iCone systems in multiple locations along the 73-mile reconstruction project on the Indiana Toll Road.

Rieth-Riley Controls Traffic with iCones

Rieth-Riley Construction Co. Inc. has implemented a real-time message board to combat distracted driving, inform the traveling public and keep its crews safe.

W

When Rieth-Riley Construction Co. Inc. bid for a 73-milelong reconstruction project on the Indiana Toll Road, the Goshen, Indiana-based company brought some suggestions to the table for the design-build project. Among those ideas was the implementation of a real-time message board to inform the traveling public of traffic issues.

“They were very concerned about minimizing delays to the traveling public,” said Rieth-Riley Project Manager Jacob Kwilasz. “[The real-time message board] is ideal for high traffic jobs so drivers can receive real-time alerts of what is happening ahead of them.”

However, the system is not just about serving the customer. It’s also about keeping crews safe in work zones.

“Distracted driving is becoming a bigger issue day by day with all the gadgets we tend to have in our cars,” Kwilasz said. “Our crews like the idea of letting those in traffic know ahead of time to pay extra attention.”

Each system, manufactured and maintained by iCone, Cato, New York, included two message boards and eight smart traffic cones.

On this particular project, Rieth-Riley had as many as four real-time message board systems deployed at one time within different work zones along the project.

10 // September 2018

First established in 2008, iCone has been present on thousands of projects nationwide.

Rieth-Riley alone has used iCones on around a dozen other projects, including a job on I-94. On that job, the cones also measured traffic to determine when to schedule lane closures. “That ended up cutting a year off the calendar for that one job,” said iCone Managing Partner Ross Sheckler, adding that the success of the job not only saved time and money, but was also the focus of a case study by the Federal Highway Administration.

HOW IT WORKS

The smart traffic cones, made by iCone, contain sensors which can monitor the speed and number of passing vehicles to determine real-time traffic conditions and then transmit this information to the two message boards.

The iCones also contain batteries powered by solar panels on the cone. “They’re little computers out there, entirely selfsufficient unless they’re hit,” Kwilasz said.

safety spotlight Rieth-Riley placed the eight cones at 1-mile increments from the start of the work zone. The message boards were located 4 miles and 8 miles from the start of the work zone.

“As traffic slows by any of the iCones, it automatically transmits that message to the message board, which automatically updates its message,” Kwilasz said. “Instead of someone manually updating those message boards, they communicate directly with the cone.”

For example, if traffic begins to slow at the cone 1 mile from the start of the work zone, once it hits a certain point, the message board 4 miles out will notify drivers that traffic is stopped or slowed 3 miles ahead, and will notify drivers 8 miles out that traffic is slowed or stopped 7 miles ahead. If the cone 2 miles out starts seeing slowed traffic, it will communicate with the message board and update the distance at which drivers should expect to stop. When traffic conditions are clear, the message boards would display “Road construction X miles ahead.”

Rieth-Riley also placed rumble strips 500 feet in advance of each message board to get the attention of drivers and ensure they see those messages.

According to Sheckler, information collected by the sensors within the cones is transmitted to iCone’s servers in New York, where they are run through a number of algorithms to determine

“[The real-time message board] is ideal for high traffic jobs so drivers can receive real-time alerts of what is happening ahead of them.” —Jacob Kwilasz the appropriate message to display. Direct communication between each sensor and iCone’s servers in New York means that if one sensor fails, they will still receive data from the other sensors to display on the message boards. iCone offers a handful of preset packages of what messages will display when, but it can also make tweaks as needed by the customer.

Common messages include “Stopped traffic X miles ahead,” detour recommendations, or specific instructions about merging.

“When things are really backed up, we want traffic to use both lanes and only merge when they get to the construction,” Sheckler said. The method iCone uses is called a dynamic lane merge. On the message board furthest from the work zone, they instruct drivers to use both lanes, and on the message board closest to the lane closure, they instruct drivers to take turns merging. “People tend to get mad when drivers zoom by in the empty lane after being told to merge, but what we’ve found is people behave really well when we give them specific instructions.”

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According to iCone, their cones can also transmit this information to the GPS navigation app Waze, known for offering users crowd-sourced information on traffic conditions and hazards.

Additionally, Rieth-Riley was able to work with iCone to ensure that specific people on the crew or with the toll road be notified by text or email in the event of a delay.

“We could have one person notified by text if the delay reaches 1 mile, and another notified by email if it reaches 2, and so on,” Kwilasz said.

This service also helps the toll road determine messages to display on its other message boards about upcoming road conditions. Users can also log in on iCone’s website to see the real-time status of their work zones.

THE FUTURE OF ICONE

Although this real-time message board technology offers a number of advantages already, this is only the beginning.

According to iCone, their cones can also transmit this information to the GPS navigation app Waze, known for offering users crowdsourced information on traffic conditions and hazards.

“We’ve heard crews talk about how the foreman will put their work zones on Waze at the start of the shift,” Sheckler said, “but if no one repeats that update for 15 minutes, that message disappears.”

However, iCone updates Waze about work zones every two minutes.

“Within a minute of turning on that message board, that update is in Waze, and it’s there until you turn that message board off.”

By the end of the year, iCone data will also go to Google, and eventually, directly to connected cars with integrated communications systems, like those Toyota and GM plan to roll out in 2021.

– BY SARAH REDOHL

Third Party Service and Support To set up the system on the Indiana Toll Road, Rieth-Riley subcontracted with Traffic Control Specialists. The systems can be deployed by around a dozen traffic control contractors iCone works with, including TCS, AWP, Colorado Barricade and Road-Tech Safety Services in under 30 minutes.

“We insist on working with professionals who will take care of the equipment and ensure they’re executed properly and will be able to handle any issues that arise,” Sheckler said. “You can’t screw up when implementing these technologies.”

www.THeAsphaltpro.com // 13

Mix it up

Make Consistent Specimens T

The financial well-being and the reputation of your company rides on every load of asphalt that goes out the gate. Every plant operator intends to ship good quality mix every time, but how can he be sure? How can he confidently state that each load meets the requirement?

Build confidence in what test data says by generating consistent test results. High variability in test results gives one pause in interpreting the meaning of those results.

The data says the mix meets the specification, but you could have a false positive. The results could indicate the material is out of spec. Adjustments may need to be made at the plant. Consistent test results over time lead to confidence, acceptance of good results and confident corrective action when the data says it is needed.

If you want to reduce the variability of your gyratory specimen test results, you must improve the uniformity of the asphalt specimens you produce. Here are a few basic tips for compacting better asphalt specimens.

adds variability, which leads to inconsistencies and has been proven to be unsuccessful.

MONITOR THE WEAR

Figure 1: Keep swivel frame base free of debris.

AASHTO T312 Section 4.2 New molds must have 149.90 to 150.00 mm internal diameter; in-service molds have a diameter of up to 150.2 mm.

AASHTO T312 Section 4.3 The diameter of end plates should be 149.50 to 149.75 mm.

HANDLE WITH CARE

Exercise care to prevent segregation when placing asphalt into a mold for compaction.

Segregation leads to non-uniform asphalt specimens. A common method for filling a mold is to use a funnel, but there are better ways that prevent the segregation that occurs when materials fall freely through a funnel.

Figure 2: End plate with a pocket. Note: Plate shown upside down for illustration purpose.

14 // September 2018

ANGLE IT

Ensure that your gyratory compactor is operating at an internal angle of 1.16° +/-0.02° as specified by AASHTO T312. A low angle of gyration leads to less compaction and higher air voids. A 0.1° drop in the angle of gyration lowers the bulk specific gravity of an asphalt specimen by 0.010 to 0.015.

AASHTO T312 Section 9.2 Place the mixture into the mold in one lift. Take care to avoid segregation in the mold.

1. Place the hot asphalt in a half round of PVC pipe. Lay the mold on its side. Slide the loaded PVC pipe into the mold. Then stand the mold upright causing the material to fall as a mass into the mold.

2. Place hot asphalt on a flexible sheet of Teflon™ material that can be rolled into a tube with a diameter of 150 mm or less.

Lay the mold on its side. Slide the rolled “tube” into the mold. Then discharge the material into the mold by standing the mold upright.

Monitor your mold and end plate wear and strive to keep all your mold assemblies consistent in size to produce consistent specimens. This provides for a minimum clearance between the end plate and the mold surface of 0.15 mm and a maximum clearance of 0.70 mm. If you had one mold/end plate assembly at the minimum and another at the maximum, you could expect to see a difference in bulk specific gravity of 0.020 per millimeter of difference.

AASHTO T312 Operate at an internal angle of 1.16° ±0.02° Figure 3: Clean under the mold clamp.

BE CONSISTENT Always use the same brand of non-glossy paper disks. Multiple studies have shown that paper disks with different surface textures and thicknesses will generate different specimen densities. Producing your own paper disks from random paper stock

• Get your gyratory compactor standardized annually by a qualified technician with properly calibrated equipment to measure internal angle of gyration.

• Clean molds and end plates after each specimen. Debris and binder buildup on mold end plate surfaces and on critical mold contact points can alter the angle of gyration applied to the specimen. Clean a mold with heavy asphalt residue by

• Clean mold and end plates after each use.

A buildup of binder residue can cause the end plates to bind with the mold during compaction, which may reduce the pressure imparted to the asphalt. WD-40 is an effective cleaner. Do not heat your molds and end plates in an oven to burn off the asphalt. High heat may cause them to deform.

• Clean the mold clamp assembly after each specimen. The mold clamps hold the mold in position during compaction. An improperly positioned mold may cause the ram foot to bind with the mold wall reducing the compaction energy imparted to the asphalt. See Figure 3.

ORIENT

Properly orient end plates in the mold. The base plates for the Pine 125X, G1, and G2 have lips that rest on a ledge at the bottom of the mold. An upside down end plate will lead to density differences if you are compacting to height. Top plates for the Pine 125X and GB1 have a beveled edge designed to face away from the asphalt material. Installing the top plate upside down may cause binding between the end plate and the mold that could affect compaction. See Figure 4.

LUBE IT RIGHT Figure 4: Base and top plate orientation. warming the mold to 140°F (60°C) and applying a solvent. WD-40 works well as a solvent and leaves a residual coating that inhibits corrosion. Do not use an ignition oven to remove binder reside from the mold. High heat will deform the mold making it unusable and unrepairable.

• Clean the ram foot carefully before each use. Debris between the ram foot and base plate will tilt the base plate, which will affect the angle of gyration applied to the asphalt. See Figure 1.

• Use end plates with pockets on the side that faces away from the asphalt. The pockets provide relief space for excess lubricant and debris so that it does not affect the angle of the plate and thus the internal angle of gyration. If you have pocketless plates, pockets can be milled into existing plates. See Figure 2.

• Maintain a clean compaction chamber. Debris between the mold and the surface on which it sits can affect the angle of gyration.

WD-40 is an effective cleaning agent to remove asphalt residue. See Figure 1.

PRESSURE MATTERS

Ensure your gyratory compactor is operating at 600 +/-18 kPa as specified by AASHTO T312 Section 4.1. A low compaction pressure leads to less compaction and higher air voids. A 10 kPa decrease in compaction pressure lowers the bulk specific gravity by 0.002 to 0.004.

AASHTO T312 Section 4.1 Operate at 600 ±18 kPa • Get your gyratory compactor standardized annually by a qualified technician with properly calibrated equipment to measure force.

Lubricate your machine according to the guidelines provided in the operation manual.

Too little and too much lubrication can negatively impact the performance of your machine, which could affect specimen density.

BE CONFIDENT

By adhering to these simple practices, you effectively improve the uniformity of the asphalt specimen for testing, which by and large will reduce variability. Consistent test results over time provide confidence in the material.

Shipping good asphalt mix often starts with the basics. Handle the asphalt with care, be consistent with consumables, be mindful of mold and endplate wear, operate at the proper internal angle and compaction pressure, be sure end plates are properly oriented in the mold, and be careful when lubricating your machine. These simple practices will improve uniformity, reduce variability and instill confidence in asphalt mix.

– FROM PINE TEST EQUIPMENT

www.THeAsphaltpro.com // 15

Training

Train Employees for New Skills Editor’s Note: You’ve seen simulators at big trade shows. Now see how a heavy civil construction and materials company has outfitted a mobile training center with two simulators to train workers on-the-job. Management at Allan Myers is thinking outside the box to recruit folks to the workforce and to enhance the workforce we have.

Inspired to give employees the skills to move ahead and confront the demand for an available workforce, contractor Allan Myers, Worcester, Pennsylvania, has launched a new three-year mission called Stepping Up. A fundamental tool of the program is the Myers Mobile Training Center, the result of a collaborative effort among Allan Myers, Volvo Construction Equipment (Volvo CE) North America, Shippensburg, Pennsylvania, and Volvo Financial Services (VFS).

Allan Myers has more than 20 locations in the Mid-Atlantic and 2,000 employees. It consistently ranks among the top transportation contractors in the region and has been recognized for outstanding safety and performance.

“When we look to the future, one of the biggest challenges we see is having trained craft professionals,” Director of Craft Development Bob Capps said. “With the United States’ renewed focus on infrastructure, the work is going to be available, but the problem is having a trained workforce—specifically heavy equipment operators, truck drivers and carpenters.”

A.Ross Myers, chairman and CEO of Allan Myers, explained how Stepping Up fits into the company’s culture: “We have ambitious plans that will require talented people across the organization—more operators, field managers, superintendents, safety professionals and everything in between. We believe that the best people in the industry already work here and our goal is to fill the new seats through training and promoting within.”

The Myers Mobile Training Center is a custom 38-foot Featherlite trailer outfitted with two Volvo advanced training simulators for excavator, wheel loader and articulated hauler operations.

Allan Myers researched training simulators across all major equipment manufacturers and found the Volvo CE simulators to be realistic.

“The Volvo simulators have the best motion base to really give you the feeling that you are in a machine,” Capps said. “We put some really experienced operators in those seats and they were truly surprised at how realistic it felt. The simulators put you into the situations you will encounter with a real machine.”

Allan Myers is one of a select few private contractors in the United States to bring this caliber of simulator training to their operators in a mobile format. The mobile training center is a substantial investment for the company, and to handle this unique finance need, it turned to the financial expertise of VFS, which it has trusted to finance equipment purchases.

“While the center was an atypical finance item, its purpose exemplifies what Allan Myers stands for and VFS stands behind,” said Matt Deloglos, regional sales manager of VFS. “We finance excavators, haulers and wheel loaders for Allan Myers, so it made sense for us to help

I

16 // September 2018

From left: Bill McGowan of Allan Myers, Danny Freeman of Volvo CE, and Andrew Hoffman of Allan Myers display the new Myers Mobile Training Center, which is a fundamental part of the new Stepping Up program at the company.

This Volvo CE advanced training simulator is stationed in the Myers Mobile Training Center where employees can try out new skills with lifelike 3-D graphics coupled with an electrically controlled fullmotion platform. the company ensure that it has the best trained operators to make it more efficient and safer.”

– FROM VOLVO CONSTRUCTION EQUIPMENT

FOCUS O N

S U C C E S S

2019 ASTEC CUSTOMER SCHOOLS

We succeed by helping you succeed. That’s why we strive to keep our

ASTEC CUSTOMER SCHOOLS on the leading edge. Our commitment to a leading-edge service experience has helped the ASTEC CUSTOMER SCHOOLS become the industry leading training experience.

The ASTEC CUSTOMER SCHOOLS cover more than any other asphalt industry training school.

Expect to enhance your grasp of key aspects of plant maintenance and operation through a unique combination of lectures and extensive hands-on classes. Instructors include Astec and Heatec Engineers and Service Technicians with decades of field experience. Breaks and evening events offer the opportunity to exchange information with fellow students, as well as with Astec service professionals and engineers.

During four full days of training, instructors and attendees cover topics including: • PLC Hardware • Calibration • Segregation and AC Content • Diagnostics and Troubleshooting • Trunnion Adjustment • Drum Flighting

And all plant components including: • Weighbridge • Drums • Heaters • Burners • Drag Conveyors and Silos • Baghouse and Airflows • Plant Controls • Blue Smoke

Your time at the Astec Customer Schools will also incorporate tours of the Astec and Heatec manufacturing facilities.

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Pavement maintenance

The 575-gallon tank has enabled RS Asphalt to accept larger sealcoating projects.

RS Asphalt Invests to Seal with Success

RS Asphalt expands its business offerings with the purchase of a new SealMaster tank.

Here, we talk about a sealcoating job they’ve done with their new tank in 2018.

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When a local bank reached out to Casey Greinermiller, president of RS Asphalt Maintenance, Elizabethtown, Pennsylvania, Greinermiller jumped at the opportunity to stripe and sweep nine lots and sealcoat another.

He was excited not only to be able to bring another satisfied customer to the full-service pavement maintenance company, but also because this job would require the company’s new 575-gallon tanker trailer from SealMaster, Sandusky, Ohio.

The new tank was an investment Greinermiller made last November after having to turn down too much work because he couldn’t offer water-based sealcoating services. The bank lot he was asked to

18 // September 2018

sealcoat had previously been sealed with a water-based sealer, so his oil-based sealer wouldn’t set atop the water layer.

“If I would have told them I could stripe but not seal, they probably would have gone elsewhere,” Greinermiller said. “But since I could do everything, that one call led to a lot of work and a satisfied new customer.”

HERE TO THERE

RS Asphalt Maintenance began in 1977 as Robert Stanley Asphalt Maintenance Inc. In 2015, Greinermiller purchased the business with intentions to grow the company and expand its services.

“I was turning down a lot of jobs because I didn’t offer water-based sealing. ...Being able to offer both means I can steer my customers in the right direction based on what’s best for their driveway or parking lot and still have their business.”

—Casey Greinermiller

We’ve been designing and manufacturing custom Pugmill plants in Tennessee for over 30 years.

STATIONARY

One of the first projects for which RS used its new tanker trailer was a large project for a chain of local banks.

RS Asphalt Maintenance is a full-service pavement maintenance contractor, offering line striping, residential and commercial sealing, crack repair, patching and infrared seamless patching.

However, the company only offered oil-based sealing in a market that Greinermiller estimates is 80 percent water-based and only 20 percent oil-based.

The asphalt oil sealer Greinermiller uses is called LN-11 Equinox, comprised of 65 to 75 percent asphalt and 20 to 25 percent Gilsonite, and mineral spirits.

“That meant I was turning down a lot of jobs because I didn’t offer water-based sealing,” he said. Whether a customer requested water-based sealer, specifications called for sealer with sand mixed within the sealer, or the lot had previously been sealed with water-based sealer, it was a frustrating situation. “I’ve always wanted to offer both types of sealers because I wanted to offer my customers options.”

Additionally, Greinermiller wanted to advertise his sealcoating services and realized he wouldn’t be able to do that effectively without offering both oil- and water-based sealing. That’s why he decided to buy a new sealer tank.

He chose SealMaster after hearing good things about the company from others in the industry, but also because it was a matter

PORTABLE

SKID MOUNTED 931-388-0626 PugmillSystems.com www.THeAsphaltpro.com // 19

Pavement maintenance

Before and after sealing a bank drive-through. of convenience. “They have a location about an hour from me, so I could go see it and they were able to train me on operating it because it’s a different process than what I’m used to.”

Mike Tarvin, manager of SealMaster’s eastern Pennsylvania, New Jersey and southeastern New York regions, assisted Greinermiller, giving him tips for water-based sealing.

“We offer training on all new machines purchased,” Tarvin said.

“This includes equipment and application training to help ensure your success early on.”

Tarvin added that water-based sealing can be a bit more complicated from an equipment, maintenance and application standpoint.

“Because water-based sealant manufacturers recommend the addition of sand, it requires equipment that can handle this aggregate,” Tarvin said. Also, water-based machines often require more maintenance. “On water-based rigs, agitator bearings need to be greased, strainer baskets need to be cleaned and ball valves need to be replaced. Also, because the water-based products can freeze, care has to be taken to winterize equipment in northern climates.”

Additionally, Tarvin pointed out that water-based sealant tends to be applied in heavier coats and sometimes two or more coats for greater durability, and that water-based sealants should be applied at temperatures 50 degrees Fahrenheit or rising.

“Water- and oil-based sealing is similar when it comes to ‘best practices,’” Tarvin said. “In general, the transition from using oil to water is not a difficult one.”

OIL AND WATER

Since the start of the season, Greinermiller estimates he’s used the new tank on dozens of jobs.

“It really opened a lot of doors for me,” he said. “Being able to offer both means I can steer my customers in the right direction based on what’s best for their driveway or parking lot and still have their business.”

20 // September 2018

For example, he said, some jobs have specifications requiring sand mixed in the sealer for added traction. Oil-based sealer tanks have a different pump system, so sand cannot be added in the same way it can for water-based sealer tanks.

“We do offer a sand option with oil-based, but it isn’t mixed in,” Greinermiller said. “When the sealer is still wet, we dust black sand overtop that sticks to the sealer when dry and gives the same effect.

But that’s an added step in the process and an extra person on the job to throw sand.”

Greinermiller adds that the options are comparable in quality, however, the oil-based method does require an additional person.

There’s also, of course, whether the lot had previously been sealed with a water-based sealer, like the bank job above, in addition to customer preference. According to Greinermiller, some customers prefer the oil-based look, which is shiny and dries matte black. “It’s also a bit of a rejuvenator to replenish oxidized asphalt,” he said.

The asphalt emulsion, on the other hand, provides a layer over top of the asphalt and tends to stand up to solvents, such as oil, antifreeze and brake fluid, that might leak out of vehicles.

SAME, BUT DIFFERENT RS Asphalt Maintenance also owns two 200-gallon Marathon brand skid tanks mounted on the back of two pickup trucks. Although the spraying process is very similar between RS Asphalt’s oil- and water-based sealer tanks, the maintenance process for the equipment is a bit different.

Because the water-based sealer contains sand, the tank requires filter baskets which need to be kept clean and the sealer must be regularly agitated to keep the sand mixed in. If Greinermiller is sealcoating with the machine a lot, he cleans the filter every other day.

Regardless of how often he uses the tank, he’s also sure to agitate the tank daily.

Another difference between his previous workflow and the new one is, when sealing with asphalt emulsion, Greinermiller sprays two coats, whereas he only sprays one coat when applying oil-based sealer. However, since he can work faster with the new machine, it takes about the same amount of time.

Otherwise, the process is very similar.

“My top tip is still attention to detail,” Greinermiller said.

“We’re very careful when we’re trimming around sidewalks and we always spray straight lines at the end of the driveway or lot so it looks as nice as we’d want our own property to look.”

Ensuring a clean surface is also of the utmost importance. “That makes a huge difference in adhesion of the sealer,” he said. “If you seal over a dirt spot, nine times out of 10 that’s coming up, and fast.

The cleaning process is just as important as the sealing process.”

Greinermiller’s cleaning process is to use one or two nine-horsepower Billygoat push blowers and wire bristle brooms, and, if necessary for small areas where the push blowers cannot go, they use hand blowers.

BENEFITS IN SIZE AND SEALER

In addition to opening up new business, the new tank also makes it a bit easier to get sealer.

“Water-based sealer is more readily available than oil-based,” Greinermiller said. “If I’m on a job in Philadelphia and I can’t drive to Harrisburg to get the oil-based sealer I need, I know I can get my water-based sealer from another supplier.”

RS Asphalt uses SealMaster Polymer Modified MasterSeal for its water-based sealer because it contains no coal tar.

“That’s what I’ve been marketing for years with my oil-based sealing, so I wanted to find a water-based sealer that didn’t contain coal tar,” he said. “I’m not limited to using that type, but I’m happy with it so far.”

Another benefit with the tank he chose is that it expands the size of jobs he’s able to complete.

Since buying the new trailer, Greinermiller placed an advertisement in the local Clipper Magazine offering a discount on any type of sealcoating. The ad has resulted in a number of new leads, particularly on larger jobs like distribution centers and shopping centers. Jobs that he might not have been able to complete with 200-gallon tanks.

“With only 200 gallons, I’m limited in the scope of work I can do with those tanks,” he said. “With the SealMaster trailer, I can pursue slightly larger jobs.” The 575-gallon tank from SealMaster is the largest size tank he’d be able to tow with a regular pickup truck.

“I wanted to be able to hold as much sealer as I could without having to worry about my crew obtaining a different type of license to drive it,” he said. The new tank can also grow with Greinermiller as he expands into larger and larger sealcoating jobs.

“Another thing like about this trailer is that I can purchase a spray bar for the back of the tank, which would enable me to spray 9 or 10 feet wide off the back of the trailer so I could cover a lot more ground and pursue bigger jobs than I normally would,” Greinermiller said.

“Maybe for sealing season 2019,” he added.

– BY SARAH REDOHL

www.THeAsphaltpro.com // 21

Solve your problem

Solve Dust at the Plant

For the production side of the industry, there is no “Table 1” to guide company owners or safety directors in implementing engineering controls for protecting workers from respirable crystalline silica. This means you may be wondering how to assess dust exposure levels and protect workers from anything questionable you may discover, even if what you discover is not above permissible exposure levels (PELs). Anywhere you observe visible dust clouds at your facility, set up a way to monitor the actual exposure level at that location.

The Problem: You’ve Found Dust at Your Plant Site

If employees are exposed to respirable crystalline silica dust of 50 micrograms per cubic meter of air or more over an eight-hour time weighted average, their health could be negatively impacted (See 29 CFR 1926.1153). As of June 23 this year, the Occupational Safety and Health Administration (OSHA) required employers in general industry to be aware of the areas where the exposure limit may be exceeded and protect workers in those areas.

“It is the responsibility of the employer to ensure their employee exposure to silica dust is minimal, and at the very least below the PEL,” stated the representatives of Chemtek Inc., Research Triangle Park, North Carolina. “We believe employers should use all feasible methods of dust reduction to protect their workers from exposure.”

One Solution: Make Water Wetter

Both photos courtesy Chemtek Inc., Research Triangle Park, North Carolina

“Most [facilities] are continually spraying water on their roads to keep the dust levels down,” Chemtek representatives explained. One way to make water more effective is by adding something like the company’s silica dust suppressant. Here’s how that works.

“Adding NeSilex to those water tanks would make the water more effective in keeping the dust down and make the water last longer since there is better penetration into the dirt and less water would be needed for effective dust control. NeSilex is designed to enhance the effectiveness of water as a wetting agent. It also includes special agglomerating agents which target dust particles. As such, adding NeSilex to water in any dust control scenario would make the water more effective in controlling airborne dust. Using NeSilex in conjunction with a respirator would further decrease worker exposure to crystalline silica inhalation.

“NeSilex … has been tested in real world scenarios to show up to a 100 percent reduction in silica dust levels on construction sites. Simply adding NeSilex to any existing water spray down system will show a ‘good faith effort’ by employers to improve the health and safety of their employees in various construction scenarios.”

What methods have you put in place to reduce dust clouds at your facility? Let’s discuss it online https://www.facebook.com/AsphaltPro/.

– BY SANDY LENDER

22 // September 2018

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Asphalt Drum Mixers

Producer profile

The entire Superior Asphalt Inc. Dutton plant site is paved to keep dust to a minimum and the yard is swept daily. Trucks must adhere to a speed limit to help keep dust down as well. All photos by Robert Stone, Grand Rapids, Michigan, courtesy Superior Asphalt Inc.

Superior Care

Superior Asphalt takes 2017 Ecological Award with planning, environmental commitment

A

During the National Asphalt Pavement Association (NAPA) midyear meeting in Boston July 9, 2018, a ceremony honoring Operational Excellence Award recipients recognized the years of environmental stewardship built into the Dutton plant of Superior Asphalt Inc., Grand Rapids, Michigan.

The company won the 2017 Ecological Award, not just for streamlined production facilities that improve productivity and safety, but also for demonstrating the asphalt industry’s concern for environmental issues. Those issues are near and dear to President and Founder Jeff Kresnak’s heart.

Kresnak’s love of nature is reflected in the beautifully landscaped Dutton plant site; his sense of responsibility for protecting nature is reflected in his regard for the next generation. Look at his actions to see his philosophy at work.

26 // September 2018

First, Kresnak personally takes the time to strategically educate the next generation about nature and how we must continue to care for our world.

“Where the Red Fern Grows is the best movie that every kid needs to see,” Kresnak said. “I take copies of the movie to school districts for the fifth and sixth grade classes. It has everything good wrapped up in it from good morals, family values, work ethic, nature and story.”

Second, Superior Asphalt personnel took the time to strategically select and plant over a thousand trees at the Dutton site.

“We put in 100 to 150 different spruce trees,” Kresnak said. “On the perimeter we put in approximately 500 hybrid willows and approximately 500 hybrid poplar trees. We tried to surround the plant with beauty and trees. They grow fast… We’re trying to make

In addition to a retention pond to capture stormwater, the Superior Asphalt team has included berms and green areas around the plant. The facility is paved on a grade to direct the water. it look like the plant’s in a forest. And what a lot of plant owners need to know is this: The willows and poplars on high wind days stop the dust particles.”

“The true meaning of life is to plant trees, under whose shade you do not expect to sit.”—Nelson Henderson At the Dutton plant, a number of spruce trees were planted as more mature trees, balled and wrapped. Kresnak said any large nursery in your area will have such good stock available. As for the seedlings: “You can go online and buy the seedlings for under two dollars a piece,” Kresnak said.

NAPA management pointed out the native spruce trees require little water, saving energy and resources in the long run. As the trees grow, they work alongside stone signage and hardscaping sourced from the plant’s Portland, Michigan, operations to screen the plant from its neighbors in an industrial cul-de-sac.

Stopping dust particles is a hot topic these days. Kresnak advised plant owners that the best way to keep dust down is to pave the plant site. “Both of our facilities are 100 percent paved on a grade to direct the water.”

This helps with the control of stormwater runoff as well. “The cleaner you keep your facility, the less stormwater problem you’ll have,” Kresnak said. “When stormwater comes, you can’t direct everything. We have one 2-acre retention pond at the Dutton plant.

We have two smaller retention ponds at the Lansing plant.”

Quality Control Supervisor Nate Voriganti added they have included berms around various stations and a green area around the plant and retaining pond. He said they use porous asphalt in the city of Grand Rapids and in their parking lots.

“Where we do our truck washout, if there’s any clay or dirt that comes off the trucks, we’ll scoop it up and take that to our rubble pile,” Kresnak said. “Every day we run our brooms. At each facility we run a skid steer broom getting into the small spaces, under the drum, that kind of thing, and getting the large areas with a loader

www.THeAsphaltpro.com // 27

Producer profile

From left: Quality Control Supervisor Nate Voriganti, President Jeff Kresnak, and Jeff’s youngest daughter Sara Kresnak

Some Fast-growing Trees Hybrid Poplar (Populus deltoides x Populus nigra) ArborDay.org states “Their claim to fame is speed, with vertical growth of 5 to 8 feet per year not being uncommon….It also works well for visual screens and hillside or sand dune stabilization.”

Ameri-Willow (Salicaceae family; not Austree) ArborDay.org states “Depending on the cultivar, weeping willow trees can grow from 3 to 8 feet per year, making it one of the fastest of the fast growing trees.” “The Ameri-Willow is a unique hybrid tree-form…these grow about 6 to 8 feet in the first year nationwide.”

Quaking Aspen (Populus tremuloides) ArborDay.org states “It grows 40 to 50 feet with a 25-foot spread and average 2 to 3 feet per year.”

28 // September 2018

broom. We have buckets on the units to capture the dust particles and those go up to our RAP piles.”

The cleanliness seen around the plant extends to the lab. Both the Dutton and Lansing plants have fully loaded labs and both are accredited with Michigan Department of Transportation (MDOT) and with federal specs.

“Nate runs both labs,” Kresnak said. “He’s highly respected in the industry and has been working on asphalt designs for 30 years. He’s extremely conscientious that the labs are spotless and the designs are on the money.”

The Dutton plant participates in round robin testing and handles both plants for nationwide tests with the American Association of State Highway and Transportation Officials (AASHTO). “When we do tests, they are submitted nationally,” Voriganti explained. “The results assure that our testing procedures are in line with the rest of the country.”

Kresnak shared that it wasn’t a stretch to get the Dutton plant’s lab accredited. “It’s fairly easy when you have the right equipment and qualified technicians. We have up to date computer automation systems in place. Our technicians have extensive knowledge of procedures. MDOT performs lab assessment once every two years.

“We rely on NAPA for the tests of what amount of RAP is good for the mix,” President Jeff Kresnak said. Quality Control Supervisor Nate Voriganti shared the drum is designed to run up to 50 percent RAP, but they typically run about 25 percent.

Nate Voriganti is our quality control supervisor and is assisted

by Joe Weist. Nate has been with the company for 10 years and Joe 4 years.

“Nate and Joe make a great team,” Kresnak continued. “They are self-motivated and stay up on all the current technologies, materials and procedures. We don’t get many complaints about the performance of our material. We have many repeat customers and referrals because of their commitment to quality.”

Kresnak explained the team’s commitment to quality and cleanliness are things he’s proud of. “We clean every single day,” he said. “It’s spotless, which is really hard in this industry, especially when we get busy. It’s just like keeping up a house. The tables are cleaned out every night. The floors are swept and mopped every night. That’s where we start.”

They also keep an eye on the consistency of incoming materials. “If you solely focus on outgoing material, you’re already too late. Communication with the plant operator, Tony Stepek, is key. Communication starts 24 hours before a job. We also keep pristine records regarding the material in our yard and mixes.”

Kresnak had high praise for his plant operator. “Seriously, he’s the best plant man in the United States of America. He’s

www.THeAsphaltpro.com // 29

Producer profile diligent, precise, a hard worker, loyal. He’s the kindest, most warm human being I’ve ever met. He’s worked for us about 10 years; came on when we opened our first asphalt plant. He’d been in the industry 15 years before.”

Of course the plant can’t run without a good ground crew, and Kresnak spoke highly of Tom Brower, who has too many jobs to have only one title. “Tom takes excellent care of keeping the plant clean and the area surrounding the plant clean. He’s a strong, diligent worker. He cares. And he does it all. You’ll see him doing everything from running the loader to the sweeper to a truck to anything the plant needs. He’s so diverse.”

As you can see, Kresnak has a business philosophy that melds with his environmental philosophy. He’s taking care of the world around his site as well as the people working the site. “It’s actually simple,” he said. “Maintain a super clean business all the way through. Landscaping, asphalt crews, the office, bookkeeping. If you keep all those areas clean, it’s hard to fail. Then make sure you’re sharing the profits and earnings of the company in the fairest way possible.”

Not every plant owner planned to pave his or her entire site before starting business. Not every plant owner has the manpower to plant 1,000+ trees next spring. But Kresnak had an idea for each plant owner interested in improving his or her environmental stewardship, or interested in reaching for an ecological award:

Quality Controls Cleanliness

The Dutton plant is a Gencor 300 TPH drum. Quality Control Supervisor Nate Voriganti said the plant typically runs between 80 and 85 percent capacity with zero blue smoke. Minimizing starts and stops minimizes waste.

30 // September 2018

To maintain cleanliness efficiently, the team at Superior Asphalt adheres to the following best practices: 1. Sweep yard daily 2. Trucks: observe speed limit to reduce dust, engines off when waiting for delivery 3. Loaders: no spillage from bucket to reduce waste 4. Organize schedule to minimize start-ups/shut-downs during the day 5. Take AC tank deliveries prior to open of business to minimize odor complaints 6. Trees reduce noise and dust; collect pollutants from ground water

Stacking conveyors build piles of material.

“Stand out in front of the plant and ask themselves if this is how well they take care of the outside of their own house. Is this how well they take care of the inside of their own house? And would they mind if this plant was 200 or 400 feet from their house?

That’s how we improve.”

– BY SANDY LENDER

Superior Asphalt’s President Jeff Kresnak said, “I’m a fussy, neat guy.

I want my plants to look the way my paving jobs look. We don’t leave crumbs behind.”

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Meet the State Exec

Meet the State Exec: OAPA’s Larry Patrick talking. I mentioned to Jay that I was interested in some of the books that Asphalt Institute was publishing. Within a few days, there was a box full of those books sitting in Miller’s office with my name on the box.

Not only did this jump start my interest in asphalt but also started a friendship between Jay and I since 1972. I can’t thank Miller Ford or Jay Hensley enough for their friendship, guidance and mentoring all these years.

How long have you been the executive director of your state association? I started at OAPA April 11, 2011, so it has been 7 years.

Larry Patrick Oklahoma Asphalt Pavement Association, Oklahoma City, was founded in 1971. Now, the association boasts 148 members, including 27 producer members accounting for 95 percent of the asphalt tonnage let to contract in Oklahoma.

O

OAPA has been led by Executive Director Larry Patrick for the past six years. AsphaltPro spent some time getting to know Patrick and learning about how OAPA is working to promote the asphalt industry in the state of Oklahoma.

How long have you been in the asphalt industry? 44 years Do you have a degree related to the industry? I studied civil engineering at the University of Arkansas. My interest in asphalt actually started in my freshman year at Arkansas. My counselor was Dr. Miller Ford and one of the classes he was teaching was asphalt pavements. I had a meeting with Miller to go over my schedule. Jay Hensley, at the time the Regional Engineer for Asphalt Institute, was sitting in his office.

Miller introduced Jay and I, and we started

32 // September 2018

How many producer and/or contractor members are in your state association? The breakdown of our membership is: Producers: 27 Laydown: 9 Aggregate: 4 Refinery: 7 Consultants: 24 Associates: 50 Governmental: 27 Total: 148 What are the top two or three ways you have increased membership in the association?

One thing that has been interesting is how some of our new members have come from project meetings, when issues have occurred. A contracting agency has called for us to do an evaluation on a project, meeting with all parties, and the contractor has seen what we can do. The contractor joins because they see the value of being a part of the association.

We also use our two day annual conference as a stepping stone to association membership. We extend a one-year free membership to a first time attending company. This has lead companies to join and when they see the benefits, they in turn get more involved in OAPA. Our members are another reason we have such a strong membership. They en-

courage their suppliers, vendors and companies that perform services for them to be a member of OAPA. We have really concentrated on the consultants. We have reached out to the Oklahoma ACEC to help recruit consulting firms. OAPA has been showing the benefits of asphalt pavements, new technology such as PaveXpress, and just helping troubleshoot to these firms.

OAPA encourages the use of our members among our members. This does nothing but strengthens OAPA and its members.

What is your favorite method for recruiting new asphalt professionals to the industry in general? We are doing several things to help bring new folks into the industry. We have a scholarship/internship program with both the University of Oklahoma and Oklahoma State University, where one student for both schools receive $5,000. Of course, with that comes some strings in which they have do 140 hours as an intern with our member companies. In this internship, the student will have to work so many hours with an asphalt plant operation, laydown crew, asphalt cement lab and terminal, mix design lab, pavement design along with so many hours with us here at OAPA. We also always attend career fairs at both OU and OSU. We are there not only to push the OAPA scholarship/internship program, but also many of the students will leave their resumes with us that we in turn share with our members.

We also participate with the Oklahoma City Public Schools in their career day with many in the construction community. That gives us a chance to show what opportunities there are in the construction field. Not everybody is geared for college and this gives students a chance to see, climb and hear how equipment is used at a construction site. All the companies involved will bring equipment to OSU-OKC where the meeting is held.

In what month do you hold your annual meeting? April

LEFT: Patrick and his wife, Gayla, are avid fishermen. “We love being on the water every chance we get,” Patrick said. MIDDLE: Patrick at a committee meeting during NAPA’s Annual Meeting. RIGHT: OAPA participates in the Oklahoma City Public Schools Career Day every year by setting up a booth to show what opportunities young people have in the asphalt industry.

Do you have a trade show or expo in addition to your annual meeting? We have an annual conference at the end of February each year. This is a two day conference in which we focus on technical issues with breakout sessions geared towards construction, engineering and safety. The conference has grown from a one-day session with about 170 attendees to the twoday session with last year’s attendance topping out at 450 people. We also have an exhibit hall for companies to display their services and equipment. We also have our awards luncheon on the first day. This gives OAPA the opportunity to honor the previous year’s pavement award winners.

We also have an annual golf tournament, which we split from year to year between Oklahoma City and Tulsa. Not only do our members attend, but also many folks from contracting agencies will come and play. This has been a great networking tool between membership and the contracting agencies.

At our annual meeting in April, on the last night, after dinner we have a live auction in which our members will donate items. This is probably one of the most fun things I have witnessed with our members.

Do you have a staff that assists in preparing the annual meeting? OAPA has a staff of two: Communication Director Ni-

cole Smith and Administrative Assistant Chante Kizer. These two people are not only my right arm, but my left arm too. I cannot say enough on how they help and actually take care of things not only with our meeting and conference but just in running OAPA. Does your staff hold educational seminars or webinars for members separate from the annual meeting and conventions throughout the year? OAPA has been involved in a series of lunch-and-learns and workshops with the city of Oklahoma City, several of the Tribal Road Programs, Local Technical Assistance Programs as well with some of the Oklahoma Department of Transportation field divisions. We are also available anytime to our members to have workshops with their employees and operations. Staff is always there to help with registration, getting sponsors and setting the meeting space for these meetings.

About how many member asphalt projects do you visit per year? Right now, I am spending about 50 percent of my time in the office with the rest being out in the field. During the time in the field, I am going to projects or plants. Sometimes it involves me going to a Field Division, just visiting to see what issues or troubles they are seeing.

About how many member asphalt plant tours are you a part of per year? When we visit with both the Senators and members of Congress in Washington D.C. and at the State Capitol, we always make sure to invite them to tour a plant or project visit. About once a year, one or two of their staff will take a tour.

About how many member asphalt open house events do you attend per year? About one a year. One thing that has occurred since I have been at OAPA, is when ODOT Field Divisions are having an open house or employee event, OAPA has been receiving invites from the Division Engineers.

About how many state agency or DOT meetings do you attend per year? OAPA has a very close relationship with ODOT, Oklahoma Turnpike Authority (OTA), and many cities and counties. I have lost track of how many times we meet, which is a good thing, whether officially or unofficially. They know all they have to do is call; I will meet with them wherever they need me too. I also appreciate the door swings both ways.

On a scale of 1 to 5 (1 being none at all; 5 being very much), how much of a threat to your members’ marketshare/livelihood is the concrete industry in your state? I would say three and a half to four. Oklahoma has a history of 80 percent asphalt to 20 percent concrete.

www.THeAsphaltpro.com // 33

Meet the State Exec

LEFT: Patrick (left) participates in the 2016 TCC Fly-In with Jay Hansen of NAPA and Aaron Parker and Tim Caudle of Silver Star Construction Co. RIGHT: Tim Caudle, Silver Star Construction Co.; Larry Patrick, OAPA Executive Director; Senator Jim Inhofe, Larry Lemon, Haskell Lemon Construction Co.; and Aaron Parker, Silver Star Construction Co. Of course, this has fluctuated over time from 78/22 or as high as 90/10 asphalt to concrete but has been, for the most part, 80/20.

Could you share an example/anecdote of a time when the concrete industry encroached on the asphalt marketplace in your state? There is a 20-mile section of a turnpike which was originally built as an asphalt pavement back in 1952. It has performed outstandingly for 65 years with the maintenance measure by OTA. OTA has a program called Driving Forward which is an expansion program for the turnpike system. A 20-mile section of this turnpike is being expanded from four lanes to six lanes. Alternate designs were looked at with LCCA being run on both pavements types. The pavement designers came back with the LCCA showing asphalt would save money but also, with phasing, would save in user costs.

It ultimately went concrete. The good news is we are hearing of asphalt perpetual pavements coming out of design that are either new alignment or replacing concrete sections, in which OAPA has been a part of the design strategy.

On a scale of 1 to 5 (1 being none at all; 5 being very much), how much difficulty are your members having in finding qualified workers for their asphalt paving or production crews? I would say four. Oklahoma’s economy has been geared towards the production of oil and gas. Right now, we are seeing an increase in drilling with horizontal drill-

34 // September 2018

ing into the shale plays. When we see the increase in drilling, the construction field is the one that suffers. These workers flock to the oil patch because of the higher pay, even though the oil patch is cyclic in nature.

As the oil field slows we see these workers come back to construction, but they are always waiting for the next discovery and drilling gets hot and heavy.

Could you give an example of a way your state APA assists members with workforce development? OAPA has the Oklahoma Asphalt Quality Initiative. OAQI is an initiative our membership took on, not by any outside entity pressure. It’s just our industry stepping up to the plate to improve our quality. Basically, this requires producer/laydown members to perform an assessment of their operation by the completion of a checklist. Once completed, I will go in and do the same evaluation with my own checklist. Once scored, I will sit down with upper management to go over areas of improvement and training needed.

This may be as simple as spending time with the crews or bringing someone in to help with some training from a national level.

If a member calls me at any time to ask me to do some training, we make sure to work with their schedule to get it done.

On a scale of 1 to 5 (1 being none at all; 5 being very much), how involved are your state elected officials in transportation issues such as funding and infrastructure improvements? Three. We are very lucky in Okla-

homa. Our delegation in D.C. understands and “gets it” how important transportation is to Oklahoma. Oklahoma is a major crossroad for moving goods and services across the U.S. with I-40, I-35 and I-44 all intersecting here. That’s not even talking about the secondary roads coming out of Texas.

As for the Oklahoma legislative efforts, this past legislative session, they were very protective of the funds for transportation. As a result, ODOT will have full funding for fiscal 2019.

On a scale of 1 to 5 (1 being none at all; 5 being very much), how involved are your asphalt members in transportation issues such as funding and infrastructure improvements? Three and a half. Like I said, our delegation gets it. We always go to the TCC Fly-In and see the folks on the state side. We also team up with Oklahoma ACPA and Oklahoma AGC when it comes to funding. We can set our differences aside because if the funding is not there, it won’t matter what pavement type.

Could you share an example of a time when your state APA hosted elected officials to educate them on the need for highway funding, asphalt materials, construction workforce development, etc.? Best example was when Senator Jim Inhofe took a tour of a plant and quarry in Tulsa, Oklahoma. At the time, he was the Chair of the Senate EPW committee. He did not realize the hurdles a contractor has to go through to build a heavy high-

OAPA awarded the NAPA Quality in Construction Award to ODOT at this ODOT Commissioner Meeting. Pictured from left: Ken Wert, Haskell Lemon Construction Co.; Larry Patrick, OAPA Executive Director; Greg Love, ODOT Commissioner; Dan Overland, ODOT Commissioner; Paul Rachel, ODOT Division 3 Engineer (retired); Jay Lemon, Haskell Lemon Construction Co.; and Paul Green, ODOT Director of Operations. way construction project. One of his questions was about the workforce. He was asking what the number of employees back five years ago and what was it now.

When the host said 500 five years ago and now 325, it caught the Senator by surprise. He wanted to know why, of course and what could be done to increase the numbers of workers. The host said, more funding. We explained to the Senator, the companies as well as other contractors in Oklahoma were only working to about 25% to 30% capacity. If the funding was there, we could do more. He took that example back to Washington.

job is spreading “the gospel” of how good of a product we produce. We have a product that is sustainable, durable, offers an ease of construction and most of all, it’s smooth. I if can promote the previous ideas to contracting agencies and most importantly, the driving public, that frees our members to build and manage their businesses while building the best roads for Oklahoma.

GET TO KNOW LARRY PATRICK

What do you find most enjoyable about your job as an executive director of a SAPA? It would have to be the relationships, not only with our members but contracting agencies, academia, NAPA, APA and of course SAPA.

What do you see as the most important part of your job as an executive director of a SAPA? The most important part of my

What has been the most rewarding experience for you during your time as the executive director? It’s two fold. One is to see OAPA grow and strengthen. I have been working in highway construction in Oklahoma since 1983 and right now OAPA is stronger than I have ever seen since I have been in the industry.

Secondly, one of the best marketing tools, as I learned when working in the consultant world, is becoming the “trusted advisor.” That is the position OAPA is at. It is a great feeling to have contracting agencies and members reaching out to OAPA to answer their questions.

Why did you join the asphalt industry?

Like I said earlier, my interest was started with meeting and developing a relationship with Jay Hensley. Then one summer, I had an internship with the Arkansas Highway Department, now ArDOT, working in an asphalt lab and a plant location in Northwest Arkansas. I was testing mix, aggregates and soils. I was hooked after that. I could not get enough and after 44 years, and I still don’t get enough. It is still fun and I am still learning.

– BY ASPHALTPRO STAFF

www.THeAsphaltpro.com // 35

Improved Efficiency INCREASED PRODUCTION V-Flights Shower Material Along the Edge of the Notch as Well as the Tip

V-flights Allow for a More Even Veil of Material

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S TA C K T E M P E R AT U R E C O N T R O L S Y S T E M V-Pac U.S. Patent No. 8,863,404 B1

To meet market demand, we change mix design often. The frequent changes push our plants to the limit. ASTEC suggested we add the V-Pac stack temperature control system. We started using the V-Pac system and, without a doubt, it has improved efficiency and increased our production capability.

Clarke DeHart,

Production Manager, CR Jackson Inc. Operating the V-Pac Stack Temperature Control System since 2011

That’s a good idea

Save Water When Washing Aggregate W

Water use restrictions and permitting challenges continue to increase, making it harder for operations to find ways to stay profitable while using fewer resources.

As a result, aggregates and mining operations are moving toward new technology to conserve natural resources while increasing long-term savings and return on investment. Here’s how.

REDUCE WATER USE

One way the industry has adapted to conserve water is through the use of settling ponds. Advanced washing systems, such as Haver & Boecker’s Hydro-Clean, when paired with a settling pond, can reduce water consumption by as much as 75 percent over traditional washing systems. That allows operations to cut their water use and limit their water treatment requirements and necessary equipment. It also makes an advanced washing system more favorable as governments push aggregate producers to use new technology to meet new restrictions.

Plus, this new washing system can pump water at very high pressures—as high as 2,000 pounds per square inch—through spray nozzles in a matter of seconds—at 211 gallons per minute.

That’s a huge benefit to operations running under strict restrictions. The equipment’s high-pressure jets effectively remove fines and dirt from deep crevices, such as marine limestone or porous rock. The advanced washing systems can be used to wash prescreened materials, which have small fines sticking to the larger particles. This is accomplished by washing the material initially and conducting a final rinse over a vibrating screen.

CUT ENERGY CONSUMPTION

Producers can save as much as 15 percent in energy costs by switching to new washing systems. Part of this is due to the speed at which the new washers complete a cycle. On average, alternative washing methods, such as log washers, retain materials for three minutes or more while materials stay in a high-pressure washing drum for just seconds.

TOP: When paired with a settling pond, the Hydro-Clean 1000 washing system from Haver & Boecker can reduce water consumption by as much as 75 percent over traditional washing systems. BOTTOM: Taking feed material as large as 6 inches (150 millimeters) into its 40-inch vertical drum, the Hydro-Clean 1000 employs 2,000 psi high-pressure nozzles, rotating at 90 rpm, to remove silt and clay particles as small as 63 microns from mineral mixtures.

SALVAGE WASTE

Advanced washing systems can restore value from what might have previously been deemed waste. This reduces waste streams and breathes new life into vital resources, while putting more money in the producer’s pocket. Advanced washing systems can do a lot to reduce an operation’s environmental footprint, as well as help improve profits. Work with a manufacturer to determine the best fit for each site and its unique characteristics.

– BY DUNCAN HIGH

38 // September 2018

Duncan High is the division manager of processing equipment technology at Haver & Boecker Canada. His 28 years of experience with the company helps him lead a team focused on providing customers processing equipment solutions to help them get the highest possible production rates and reliability. For more information, contact him at (905) 688-2644.

SILO STORAGE

A NEW CHOICE  OUR MAIN DRAG CONVEYORS ARE LARGER AND

WIDER to allow conveyors to run slower yet convey the proper mix to silos. Larger and wider conveyors have a stronger section modulus than bridge beam designs.

 SPLIT RETURN ROLLERS COME STANDARD.

Much easier and cheaper to replace just the roller in the future as compared to cutting shafts, replacing rollers, and bearings.

 REJECT CHUTE OPENS THE ENTIRE WIDTH of the

conveyor so asphalt doesn’t pass over the reject chute.

 HYDRAULIC TAKE UP ON THE HEADSHAFT OF MAIN

DRAG CONVEYOR CHAIN so entry point of asphalt into the tailshaft ALWAYS stays the same. This prevents premature wear of chain.

 AUTOMATIC CHAIN TENSION INDICATOR alerts

plant operators when its time to tighten the chain.

 REX PLANTETARY GEARBOXES for all conveyors.  ALL OF OUR SILOS COME STANDARD WITH 3/8”

CONE LINERS AND ONE ROW OF RECESSED WALL LINERS. Recessed wall liners don’t allow the problematic wear spot to occur that other silos have seen in recent years.

 ALL SILOS ARE WELDED 100% INSIDE AND OUTSIDE with laser guided sub-arc machine. This makes the strongest union of two pieces of metal.

 ALL SILOS COME WITH SAFETY GATES STANDARD.  3 TON BATCHER COMES WITH EASY ACCESS AIR

CYLINDERS on outside of batcher and safety cage to prevent pinch point. Split batcher allows for even distribution of asphalt in silo.

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C

Conducting laboratory tests, analysis of test results and preparation of quality control/quality assurance (QC/QA) reports are all important aspects to ensure a satisfactory asphalt mixture is constructed. Qualified technicians must perform this testing in an acceptable laboratory. Most state departments of transportation (DOTs) have requirements for the technicians, inspectors and QC managers to be certified under a DOT certification program. This helps to ensure the ability of those involved in the work (technicians, inspectors and QC managers) to achieve a satisfactory product.

States also have requirements for certification of these laboratories to ensure that these laboratories are acceptable to conduct this testing. There are three specific areas where projects could be deficient in testing and summarizing data. These three areas include: 1) insufficient analysis of data; 2) lack of adequate visual observations; and 3) insufficient analysis of test data and timely dissemination of the QC/QA report.

STEP 1:

Analyze Data The analysis of data for most projects simply involves reporting the test data and providing a comparison of this data to the specification requirements. Comparison of data to specification requirements is important but more analysis is needed to better describe the quality of material. If sufficient analysis is not performed, it is very difficult to adequately describe the overall quality of pavement from the test results in the report.

One method to summarize and analyze the data is to plot the test results on control charts. Some DOTs require control charts be plotted while other DOTs have no requirements for preparing control charts. These charts can be used to summarize the data and to show trends in the data. These control charts are developed electronically and are seldom printed any more.

Typically, individual test results along with running average of test results are plotted to summarize the data and to show trends. The

40 // September 2018

BY RAY BROWN, PHD, PE

plot of individual test results provides a good summary of all test results that can quickly and easily be observed for all testing. The running average plot is very useful in identifying trends in the data so that adjustments can be made to improve the process as the project progresses. Even if the DOT does not require that control charts be plotted, it is advantageous for the laboratory data to be plotted to help show and understand the overall quality of test results being produced.

STEP 2:

Observe Visual observations are an important component of the QC/QA program and can be used along with laboratory test results to provide a good evaluation of the overall quality of construction of asphalt mixture. Many times, visual observations can indicate areas that might need to be further tested.

Testing without visual observations greatly reduces the probability of adequately evaluating the overall quality of a paving project.

Visual observations should be made to identify segregated areas, to evaluate quality of longitudinal joints, to evaluate transverse joints adjacent to bridge structures, to identify areas of bleeding, to identify pulling and tearing of the mat, and to identify other problem areas. In many cases additional testing in these observed deficient areas might be helpful in confirming the detected deficiencies. Many problems can be identified by visual observations before they will ever be identified by random sampling and testing.

Segregation is one issue that is almost always found through visual observations and not typically identified by routine sampling and testing. Testing can often quantify the amount of segregation, but these segregated areas must typically be identified visually first.

STEP 3:

Report Correctly One deficiency of many projects is the lack of sufficient effort in the preparation of the report of results and the timely dissemination

of these testing/inspection reports. Most reports present the test data along with specification requirements but only have limited discussion of the test results and observed deficiencies. The report should state all test properties that are not in spec and discuss actions to be taken as a result of these out-ofspec results. The report should also discuss observations of any deficiencies in the constructed asphalt pavement and steps taken to address these deficiencies. These reports should typically be prepared and disseminated within 24 hours of the time that construction was accomplished unless the specifications state otherwise.

The QC/QA report is not always completed in a timely manner. If prepared properly, the QC/QA report should be useful after completion of construction and after traffic has been applied to identify potential causes of any observed pavement performance problem.

THREE STEPS

Three best practices have been discussed to help ensure a quality asphalt pavement is constructed. These three steps include improved analysis of data, importance of visual observations, and improved and timely submission of the QC/QA report. Addressing these three steps does not take much additional effort on an individual project but will significantly help improve the overall quality of work.

Ray Brown, PhD, P.E., received his BS and MS degrees in civil engineering at Mississippi State University and his PhD from Texas A&M University. He retired after working for approximately 20 years for the U.S. Army Corps of Engineers and approximately 20 years for the National Center for Asphalt Technology (NCAT). He has honorary titles from Auburn University including Professor Emeritus of Civil Engineering and Director Emeritus of NCAT.

W

BY DAN RIDOLFI, PE

Why do we perform or invest in process control at our hot mix asphalt (HMA) plants? To answer this question, we need to set a goal for the process control program. A well designed and implemented process control program should improve quality, prevent failures, reduce cost, and add value to HMA plant customers. If a process control program is implemented to simply satisfy an owner’s specifications you are missing an opportunity.

The term LEAN six sigma is used to describe a method of continuous improvement. Improvement can be efficiency gains or quality gains. Let’s separate LEAN six sigma into to two parts: LEAN manufacturing and statistical process control. Both look to improve “waste” through a disciplined systematic process. Interestingly, both six sigma statistical process control and LEAN manufacturing have their roots in Japanese auto manufacturing.

LEAN MANUFACTURING

LEAN aims to improve efficiency by eliminating waste that results from disorganized process. For example, LEAN manufacturing would be used to incrementally increase a plant’s tons per hour without sacrificing quality and ensuring every ton produce is sold. Process, in this case, could be the equipment to produce asphalt, the sales program, plant scheduling, the billing of products, the quality control program, and any step before, after and in between. LEAN projects start with a simple statement of current condition and a description of the target condition.

At right is an example of a LEAN problem statement tool. The process including people, equipment, environment, machinery and materials is mapped.

Below that is an example analysis form.

This form deploys an evaluation technique called the five whys where you do exactly as the name states. You keep asking why.

42 // September 2018

An example use of this technique might be getting to the root of why trucks are backing up in the yard waiting to be loaded.

Ask why trucks are backing up in the yard.

Customers are all sending their trucks at once. Ask why. They are scheduled that way. Ask why again. I think you get the point. Speaking from personal experience, when people use the five whys the outcome is simple and insightful.

Other LEAN techniques include Bottleneck Analysis, Kanban (where the production, customer and supplier schedules are optimized), Muda (where you optimize products from customer perspective), Kaizen (incremental improvement), and many more.

The internet is full of articles and techniques for LEAN manufacturing. There is a LEAN technique to aid in improving nearly any production process.

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If a process control program is implemented to simply satisfy an owner’s specifications you are missing an opportunity.

SIX SIGMA STATISTICAL PROCESS CONTROL

The term six sigma relates to the number of standard deviations (sigma) where nearly 100 percent of the results are within a desired range. Simply stated, six sigma intends for a process to have zero failures.

Quality control team members will recognize this emphasis on consistency.

A six sigma statistical process control (SPC) is data driven. The godfather of six sigma SPC, W. Edwards Deming, is quoted as saying, “Without data, you’re just another person with an opinion.” Data is key in statistical process control. It is import-

ant to not make assumptions, but rather let data describe what is happening.

In HMA production we regularly measure aggregate gradation, binder content, and volumetric properties like voids in mineral aggregates (VMA) and air voids.

These properties are required by specification to be maintained within a certain consistency level, because they relate to pavement performance. SPC starts by looking at data in sets. Here is a real world example.

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44 // September 2018

In addition to charts, statistical measures of test results such as average, standard deviation, percent within limit, confidence interval, and more all describe consistency measured values and help predict likely future values.

On May 22, an HMA plant produced HMA with 6.0 percent binder. The next day that same plant produced the same HMA with 5.5 percent binder. You might conclude the plant is out of control with a 0.5 percent swing.

When we apply basic SPC and we evaluate 18 results including the data from May 22 and May 23, you get a different perspective. In the SPC chart on page 44 the blue line represents each test, the solid red line is a rolling average of tests, and the red dashed lines are the specification range.

When you look at the May 23 test in context of the other tests, we conclude that test is odd, because the plant had been consistently producing HMA at 6.0 percent binder. Another test should have been run to confirm there was not a sampling error.

In addition to charts, statistical measures of test results like average, standard deviation, percent with limit, confidence interval, and more all describe the consistency of measured values and help predict likely future values. It is logical to see how using control charts and statistical measures can help understand a plant’s ability to make a product within specification.

the results; check. Decide what to do next; act.

A PDCA process helps a plant eat the elephant one bite at a time.

Performing or investing in process control at the HMA plant offers a producer an all-encompassing tool, a mindset if you will, for bringing higher quality control into the picture. By implementing systems of the LEAN six sigma, the producer can find and correct areas of inefficiency, and can bring the infor-

mation of data sets to bear on decisions that affect all the elements of mix design and production. The goal for the process control system is to increase quality, of course, and should bring continuing improvement in reduced waste, fewer failures, enhanced value for your plant customers. All of which will improve the financial performance of an HMA plant.

For more information, contact Dan Ridolfi of LASTRADA™ at www.lastradapartners.com.

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CONTINUOUS IMPROVEMENT

Either independently or together a LEAN manufacturing project and an SPC program are used to transform businesses through a continuous improvement process. A continuous improvement process systematically makes incremental improvements that over time add to big changes to an operation. A common continuous improvement process is a plan, do, check, act process (PDCA).

You start by identifying what you want to improve; plan. Apply a solution; do. Measure

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WMA Survey Says: Recycle the Mix

A

Asphalt pavement mix producers continue to apply technologies and innovations to make long-lasting asphalt pavements more energy-efficient to produce and more resource responsible. Nearly 39 percent of asphalt pavement mixture produced in 2017 was produced as warm-mix asphalt at reduced temperatures, which decreases energy demands, reduces air emissions and improves compaction at cooler temperatures.

Of all the materials recycled in the United States, nothing is recycled as consistently as asphalt pavement mix. The latest survey of asphalt mix producers finds that more than 99 percent of the asphalt pavement material removed from roads and parking lots in 2017 was put back to productive use, primarily in new asphalt pavement mixes.

The National Asphalt Pavement Association (NAPA), in partnership with the Federal Highway Administration (FHWA), has conducted the survey of the U.S. asphalt pavement mix production industry for each construction season since 2009. Over the years, the survey has documented increases in the use of recycled materials and warm-mix asphalt (WMA).

Asphalt mix producers continue to make significant use of energy-saving WMA technologies. In 2017, 147.4 million tons of WMA was produced at reduced temperatures; that represents nearly 39 percent of total asphalt pavement mix production, and a 777 percent increase since 2009.

The use of WMA had tracked at about a third of all asphalt mix production since 2013. The increase for 2017 is attributable to an increase in the tons of WMA used by state departments of transportation (DOTs). Companies that produce WMA reported that about 42 percent of the asphalt pavement mix produced for DOTs was produced at reduced temperatures using warm-mix technologies.

“The use of warm-mix asphalt technologies has become just another part of our

46 // September 2018

FROM NAPA

147.4 million tons of WMA was produced at reduced temperatures; that represents nearly 39 percent of total asphalt pavement mix production. business,” stated Craig Parker, 2018 NAPA Chairman and Executive Vice President of Silver Star Construction in Moore, Oklahoma. “During 2017, more than half of all asphalt pavement mixtures in 16 states were produced as warm-mix asphalt, and in eight of those states, more than 75 percent was produced as warm mix. Road owners are clearly seeing the benefits these technologies bring to our product, and they are willing to support innovations in asphalt pavements.”

WMA is produced using technologies and additives that reduce the production and placement temperature of asphalt pavement mixes, reducing the amount of fuel used in the production process. The most common technology is plant-based foaming, which injects a small amount of water into the asphalt during production.

A number of environmental, worker safety and construction benefits have been realized through the adoption of WMA. Also, according to the survey, nearly 79 million tons of recycled materials were used in new asphalt pavement mixes during the 2017 construction season, which was similar to the amount of these materials used in 2016. Ground tire rubber, steel and blast furnace slag, and recycled cellulose fibers were among the “other” recycled materials used in addition to recycled asphalt

pavement (RAP) and recycled asphalt shingles (RAS) in new asphalt pavements in 2017. The use of RAP and RAS alone resulted in cost savings of more than $2.2 billion compared to the use of virgin materials.

“Through engineering, performance-based specifications, and improved RAP processing, production equipment, and procedures, we are creating asphalt pavement mixtures that successfully incorporate reclaimed and recycled materials,” NAPA President Mike Acott said. “However, there is still room to improve, and we are supporting research and education efforts to keep the use of these cost effective, environmentally friendly asphalt mixtures growing.”

The survey found that more than 76.2 million tons of RAP and nearly 950,000 tons of RAS were used in new asphalt pavement mixes in the United States during 2017. An additional 3.9 million tons of RAP and RAS were used as aggregate, in coldmix asphalt, and other road-building activities. The survey also found that at year-end 2017 about 103.5 million tons of RAP and RAS was stockpiled for future use across the country. Reclaiming RAP for use in future pavements saved nearly 50 million cubic yards of landfill space during 2017.

Although national use estimates were not calculated, respondents to the survey reported recycling some 1.5 million tons of ground tire rubber, slags, cellulose fiber, and other reclaimed and waste materials into nearly 7.5 million tons of asphalt paving mixes.

The survey was conducted in the first quarter of 2018. Results from 238 companies with 1,158 plants in all 50 U.S. states, the District of Columbia, and American Samoa, along with data from state asphalt pavement associations for 32 states, were used to compile the report. A copy of the full survey report, including a state-bystate breakdown of data, is available at www.asphaltpavement.org/recycling.

For more information, contact T. Carter Ross at cross@asphaltpavement.org.

www.THeAsphaltpro.com // 47

Sunshine State Awards Good Work

A

Asphalt Contractors Association of Florida (ACAF) announced Halley Engineering Contractors Inc. won the District 6 and the 2018 winners of Statewide Resurfacing—Urban its annual Excellence in Pavement Awards in Florida, at the FROM an- ACAF Excellence in Pavement award for nual awards banquet June 16. The award winners are selected for its project on SR 5/Biscayne Blvd. their outstanding quality in asphalt paving. ACAF was founded from NE 151 St. to NE 196 St. in in 1957 to represent the asphalt industry in Florida and has been Miami-Dade County. Tonnage: recognizing companies for decades with these awards.

20,582. Lane Miles: 25.2.

“Florida’s asphalt pavement industry is committed to building Lane Construction Industries quality pavements that deliver high performance and drivability won the Special Projects District to the public,” 2018 ACAF President Dan Weekley said. “It’s our 1 award for its project on SR 64 at mission to improve the quality of asphalt and expand its use. We CR 663 railroad crossing from west accomplish that by continuing to promote safety, quality conof CR 663 to east of CR 663 in struction, employee improvement, and by working with our cusHardee County. Tonnage: 289.02.

Lane Miles: 0.17. tomers to provide the best product for their needs.”

These winning awards are selected from member companies Lane Construction Industries that have submitted projects completed by the first of the current won the Special Projects District year. Asphalt is the primary form of highway pavement in Florida.

7 award for its project on SR Anderson Columbia Company won the A.P. Bolton District 3 award for its project on SR 8 east of SR 71 to east of CR 69A in Jackson County. Tonnage: 46,692.

Lane Miles: 30.2.

Ajax Paving Industries won the Resurfacing-Urban District 1 award for its project on SR 758 Bee Ridge Rd. from Siesta Dr. and from SR 45 to Dunn Dr. in Sarasota County.

Tonnage: 30,927. Lane Miles: 26.75.

C.W. Roberts Contracting Inc. won the Resurfacing-Rural District 3 award for its project on SR 2 from CR 177 to Ten Mile Creek in Holmes County. Tonnage: 11,033. Lane Miles: 3.92.

D.A.B. Constructors Inc. received honorable mention for Roads & Streets—Non-FDOT District 7 for its project from the west end of Ft. Island Trail to Dixie Shores Dr. in Citrus County. Tonnage: 7,975.29.

Lane Miles: 1.11.

D.A.B. Constructors Inc. won the Roads & Streets—FDOT District 5 award for its project on SR 48, MP 8.634 to 9.999 in Sumter County.

Tonnage: 12,834. Lane Miles: 6.827.

D.A.B. Constructors Inc. won the Special Projects District 5 award

48 // September 2018

for its project on Bike Trail from SW 49th Ave. to Santos Trailhead in Marion County. Tonnage: 5,731.68.

Lane Miles: 10.07.

574 from East Ida St. to west of 30th and from east of 38th St. to 39th St. in Hillsborough County.

Tonnage: 495.82. Lane Miles: 0.38.

Duval Asphalt Products Inc. won the Roads & Streets—FDOT District 2 award for its project on SR 103 from Normandy Blvd. to the railroad tracks at US90 in Duval County. Tonnage: 7,897. Lane Miles: 6.0.

The Middlesex Corporation won the District 8 and Statewide A.P. Bolton Excellence in Pavement award for its project from Osceola Pkwy. to Kissimmee Park Rd. in Osceola County. Tonnage: 61,329.

Lane Miles: 38.8.

General Asphalt Company Inc. won the Special Projects District 4 award for its project at Belle Glade State Municipal Airport Runway 9/27 Rehabilitation in Palm Beach County. Tonnage: 5,145.9. Lane Miles: 0.71.

General Asphalt Company Inc. won the Roads & Streets—FDOT District 6 award for its project on SR 997/Krome Ave./NW 177th Ave. north of 8th St. from MP 0.657 to MP 5.121 in Miami-Dade County. Tonnage: 29,441. Lane Miles: 17.9.

Halley Engineering Contractors Inc. won the Resurfacing—Rural District 4 award for its project on SR 93 (I-75) from north of SW 14th St. to south of I-595 Interchange in Broward County.

Tonnage: 16,437. Lane Miles: 7.58.

P&S Paving Inc. won the A.P. Bolton District 2 award for its project on SR 19 from Marion County Line to Barge Canal Bridge in Putnam County. Tonnage: 31,320. Lane Miles: 22.25.

Preferred Materials Inc. won the Resurfacing—Urban District 2 award for its project on SR 26/ Newberry Rd. from NW 80th Blvd. going east to SW 38th St. in Alachua County. Tonnage: 29,597.

Lane Miles: 17.4.

Preferred Materials Inc. won the Roads & Streets—FDOT District 1 award for its project on SR 600 between Walker Rd. and Jersey Rd. in Polk County. Tonnage: 13,339.

Lane Miles: 5.4.

Preferred Materials Inc. received an honorable mention for Roads & Streets—Non-FDOT District 5 for its project on SR 408 from the

east side of Lake Underhill Bridge to Yucatan Dr. in Orange County.

Tonnage: 24,000. Lane Miles: 7.02.

Ranger Construction Industries Inc. won the Rural Resurfacing District 1 award for its project on SR 60 from the east of CR 630 to Kissimmee River Bridge in Polk County. Tonnage: 24,261. Lane Miles: 24.52.

Ranger Construction Industries Inc. won the Special Projects District 1 award for its project at Lakeland Linder Airport Taxiway “G” in Polk County. Tonnage: 3,159.

Ranger Construction Industries Inc. won the Roads & Streets— FDOT District 4 award for its project on SR 786 from SR 710 to the C-18 Canal in Palm Beach County. Tonnage: 31,651. Lane Miles: 1.91.

Ranger Construction Industries Inc. won the Special Projects District 4 award for its project at PBIA Airport Runway 10R-28L in Palm Beach County. Tonnage: 5,136.

Ranger Construction Industries Inc. won the Resurfacing—Rural District 6 award for its project on SR 90 from west of Loop Rd. to west of Everglades Preserve and from east of Collier Circle to west of Krome Ave. in Miami-Dade County.

Tonnage: 20,202. Lane Miles: 19.6.

V.E. Whitehurst & Sons Inc. won the District 2 and Statewide Resurfacing—Rural Excellence in Pavement awards for its project on SR 100 from Bradford County Line to 8th Ave. in Union County.

Tonnage: 10,710. Lane Miles: 6.85.

V.E. Whitehurst & Sons Inc. received honorable mention for Roads & Streets—Non-FDOT District 2 for its project on 180th St. from US129 to CR 49 in Suwanee County. Tonnage: 7,133.8.

Lane Miles: 9.05.

– From ACAF

NO TIME FOR DOWNTIME. When you call, we answer.

It’s what we do.

We are here. 365/24/7 •

Your call links you to the world’s largest inventory of in-stock parts for asphalt plants. It links you to a seasoned team of 40 experts, ready to help. It links you to world-renowned service, ready to deliver.

It links you to ASTEC.

800.251.6042 • www.astecparts.com

Dependable Performance CONSISTENT MIX

FOR MORE INFORMATION VISIT ASTECINC.COM/UNIDRUM

DILLMAN UNIDRUMÂŽ

When it was time to buy two new plants, a Dillman UNIDRUMÂŽ plant was the best fit for us. We like the Unidrum because of its very consistent, homogenous mix and very low maintenance. The Unidrum plants provide more uptime with less routine maintenance.

Slavic Mokienko,

General Manager, R. E. Pierson Materials Corp.

Operating Four UNIDRUM Plants

product gallery

Look at What’s New for Mix Production • Ensures asphalt pumpability; and • Provides variable temperature and shear rate capability for complete viscosity profiles.

For more information, contact (508) 9466200.

AMMANN

ADM offers heavy-duty drag conveyors with material transport ratings up to 500 TPH. Quality starts way back at the quarry and refinery. It continues at the asphalt mix plant. For this edition focused on quality control and best lab practices, it only makes sense that we present some of the latest and greatest offerings for the production of a mix that’s on spec.

Q

ADM

Asphalt Drum Mixers Inc. (ADM), Huntertown, Indiana, offers a full line of drag slat conveyors for all of its asphalt plants, or to be paired with plants from other asphalt plant manufacturers. The conveyors are designed to handle material transport ratings as high as 500 tons per hour (TPH) with reinforced weld-on slats and chrome carbide wear liners on the slat floor and along the sidewalls. ADM designed the conveyors with a segmented sprocket de-

52 // September 2018

sign, which allows for easy access to the stairway, handrail and maintenance platforms. Full-length hinged steel casing covers come standard on the drag slat conveyors and optional blue-smoke recovery systems mount on the conveyor to reduce emissions from silo tops.

For more information, contact Mike Devine at (260) 637-5729.

The Ammann ABP HRT (High Recycling Technology) asphalt-mixing plant is designed for asphalt manufacturers who need to incorporate large proportions of recycled asphalt (RAP) without sacrificing production capacity and quality. The HRT is a “2-in-1” plant, featuring both a warm and cold recycling system that can be used simultaneously. The plant became available in the North American market about a year ago. It is manufactured by Ammann, a family owned, Swiss-based company.

There are two warm recycling systems to choose from: A conventional concurrent flow dryer for RAP additions of up to 60 percent; and the RAH100, from which 100 percent recycled materials can be used.

Foamed bitumen, pigments and other additives can be used.

The most striking visual difference between the HRT and traditional plants is the vertical stacking of the RAP-bearing components. This configuration is designed to reduce wear and sticking and shortens the travel distance of hot RAP material.

AMETEK

AMETEK Brookfield, Middleboro, Massachusetts, offers the DV2TRV Viscometer to measure the viscosity of highway asphalt binders at mixing and compacting temperatures. It uses AMETEK Brookfield’s Thermosel System as defined by the Strategic Highway Research Program (SHRP).

The features include: • Adheres to ASTM D4402;

The ABP HRT from Ammann is designed to incorporate large percentages of RAP in mix designs.

MOBILE MONITORING NEW FEATURES Recon system is a mobile monitoring system created

by Heatec for monitoring equipment at an asphalt plant. The system provides real time status of asphalt storage tanks, and hot oil heaters directly to a smart phone.

The latest version mirrors your heater’s BurnerLogiX™ management system on your mobile device. The messaging feature keeps you updated with over 80 different messages, allowing you to easily monitor the status of your heater. With added clarity, monitoring your plant has never been easier. *Fireye® is a trademark of UTC Fire and Security Company

800.235.5200 www.heatec.com

H E AT E C , I N C .

Get alert messages directly to your phone, tablet or PC. Record trending data of temperatures, levels, and alarms.

Recon now gives the option to display metric units or conventional U.S. units.

Easily add the system to a new or existing plant. *some plants may require additional equipment.

an Astec Industries Company

5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com

product gallery

The Generation 3 from Astec uses a flow splitter plate to force liquid AC to encounter the water spray nozzles within the system.

ASTEC

Astec Industries, Chattanooga, Tennessee, released the Generation 2 warm-mix system December 2017 to allow producers to make WMA mix designs without chemical additives. The Gen3 apparatus is installed inline. It uses a flow splitter plate to ensure the heated AC encounters both water spray nozzles in the system. As the liquid AC enters the Gen3 manifold, it is directed above the splitter plate adjacent to two water injection valves. Electric over air solenoids open and close self-cleaning water valves to inject water. As water flashes to steam and mixes with liquid AC, it foams and expands through an orifice plate and into the mixing device.

For more information, contact Astec Parts at (800) 251-6042.

BUTLER-JUSTICE

Blue Smoke Control, a division of Butler-Justice Inc., Anaheim, California, offers the X-VOCS System, which features proprietary technology designed to remove odors and VOCs such as Hydrogen Sulfide (H2S) from the hot-mix asphalt process. Introduced in late 2017, the system is best applied to existing or new installations where

long-term odor and VOC control/containment is important. The X-VOCS incorporates a five-stage filtration system. In the first three stages, a series of filters remove over 95 percent of target particulates down to 0.3 microns. In the final two stages, carbon filtration beds remove remaining odors and volatiles, according to the manufacturer.

Maximum emissions control can be achieved when paired with the company’s patented Blue Smoke Control Collector, which is designed to target and eliminate “blue smoke.” Those systems are operating in hundreds of plants worldwide.

For more information, contact Mike Butler at (714) 696-7599.

IPC GLOBAL

IPC Global’s Pavelab50 PaveAnalyzer is an automatic asphalt analyzer designed for the separation and extraction of bitumen, filler and aggregates from asphalt mixtures by closed-system solvent extraction. Fully compliant with the new ASTM D81592018 Automated Extraction of Asphalt and EN 12697-1 and benefiting from the latest environmentally friendly technologies, the Pavelab50 PaveAnalyzer makes the extraction process safer, faster and easier with almost zero emissions coming from the extraction process, according to the manufacturer. The totally integrated system includes a washing and extraction chamber, high speed centrifuge, solvent recycler, aggregate dryer and balance all-inone unit minimizing the footprint, improving safety, reducing variability, and saving laboratory and operator time, according to the manufacturer.

For more information, contact ipcglobalsales@controls-group.com or info@ controls-usa.com.

KPI-JCI

The X-VOCS asphalt plant odor control system from Butler-Justice was introduced in 2017.

54 // September 2018

KPI-JCI and Astec Mobile Screens, Yankton, South Dakota, launched their latest patent-pending hybrid technology in their GT440 mobile horizontal shaft impactor (HSI) at ConExpo in March 2017. This hybrid unit offers rugged performance with environmentally-friendly features. While operating in line power, the GT440 has significantly lower operating costs, reduced

The GT440 mobile horizontal shaft impactor from KPI-JCI and Astec Mobile Screens offers patent-pending hybrid technology. permitting, reduced noise levels, creates no engine emissions, has the ability to run indoors and does not require refueling. All of the components are included onboard to allow operations to easily switch the power supply.

“This hybrid technology is truly revolutionary, our customers can benefit from electric power without sacrificing the convenience of a diesel power unit, all at the push of a button,” said Stephen Whyte, product manager for KPI-JCI and Astec Mobile Screens.

For more information, visit https://www. kpijci.com/equipment/track-mount/andreashsi-plants/.

LIBRA

Libra Systems Inc., Harleysville, Pennsylvania, has released a new version of its Automatic AC Tank Switching Module, available for the PlantWise Drum Mix Control System. The enhanced module controls all fill, return and supply valves, as well as the AC pump and truck unloading. Tank levels are also monitored, including critical limits. Dynamic, color-coded graphics provide at-a-glance status pertaining to valve changes, material flow, tank levels, temperatures, interlocks and any alarm conditions that require the operator’s attention.

Manual control of heaters, agitators, etc. can be turned on and off through the software. The Automatic AC Tank Switching Module is fully integrated with the Plant-

This screen shot shows the new version of Libra’s Automatic AC Tank Switching Module.

AUTOMATED SOLVENT EXTRACTION: DOT Evaluation of the infraTest Asphalt Analyzer, the newly approved ASTM test method for performing automated extractions on Recycled Asphalt Materials (RAP) acknowledges, “Advantages of the Asphalt Analyzer include reduced technician time needed to complete the extraction and provides significant exposure risk reduction to harmful solvents during the test.”

The Asphalt Analyzer process saved overall about 1.5 hours of staff time per extraction.

During extraction the technician was free to perform other tasks. The unit dried the sample and at that point the sample was ready for gradation, absorption, and specific gravity testing. The Asphalt Analyzer procedure allowed for quick and accurate turnaround of test results.

Risk Assessment showed that the Asphalt Analyzer scored in the low risk range since the Asphalt Analyzer reduced the time and volume of solvent solution needed while running the test, providing further exposure risk reduction. It is concluded that the machine can provide superior risk controls, leading to improved health, safety and efficiency conditions.”

To learn more visit: www.infratestusa.com

ASTM D8159-2018D SAFEST SOLVENT EXTRACTION PATENTED CLOSED VACUUM SYSTEM AUTOMATIC CRUMB RUBBER EXTRACTION MOST ACCURATE EXTRACTION METHOD RESULTS IN 50-90 MIN USED BY 10 DOT’S AROUND THE USA

WWW.INFRATESTUSA.COM

www.THeAsphaltpro.com // 55

product gallery Wise automatic blending process, including material use totals and the capability to control the entire plant without manual buttons.

For more information, contact Greg Fleisch at (215) 256-1700 x123.

Troxler

PINE

The Rotary Asphalt Wheel Tester (RAWT)

by Pine Test Equipment Inc. was designed to determine the rutting performance of all HMA mix types. The accuracy and predictability of this accelerated test method remained ambiguous until the City of Los Angeles shared the results of 14 years of use and 15,000+ SGC rut wheel tests of many different HMA mix types. Now an integral part of the City of LA’s Pavement Preservation program, the results were featured in the September 2016 edition of AsphaltPro. Independent research conducted by Dr. Hussain Bahia of the Modified Asphalt Research Center (University of Wisconsin Madison) on the speed, accuracy and repeatability of the new rutting test method was presented at the June 2018 ASTM meeting in San Diego. The short test time allows for expedited quality control and acceptance.

For more information, contact Dave Savage at (724) 458-6393.

The Accu-Shear® from Stansteel/Hotmix Parts is installed in the asphalt injection line prior to the plant mixing zone. phalt cement (AC). The shearing process promotes total blending and homogenized flow for warm-mix asphalt (WMA) production.

The Accu-Shear is also engineered for in-line blending of rejuvenators, latex, emulsions and most liquid chemicals on the market today with the optional four-port additive manifold.

For more information, contact Rick Rees at (800) 826-0223.

TRANSTECH

The flagship product from TransTech Systems Inc., Latham, New York, the Pavement Quality Indicator (PQI), is what put the company on the map in 1998. The PQI is the non-nuclear pavement density gauge offering precise pavement density and moisture measurement in 3 seconds, according to the manufacturer. With the PQI, you don’t have the hassle of regulatory training and certifications. There is no radiation threat with the product, which means after a day of work just place it in your truck and you’re done. Help TransTech celebrate 20 years of non-nuclear density technology.

For more information, call (800) 724-6306 or visit www.transtechsys.com.

The Rotary Asphalt Wheel Tester from Pine has more than 14 years of proven performance with the City of Los Angeles.

STANSTEEL

The Accu-Shear® from Stansteel/Hotmix Parts, Louisville, Kentucky, is designed for multiple liquid additives and features advanced in-line water foaming of liquid as-

56 // September 2018

You can let the plant know how the mix is performing in real time with a non-nuclear pavement density gauge from TransTech.

The Troxler Moisture Measurement System (MMS™) (Model 3630) is a real-time method of moisture measurement for quality-oriented asphalt plants. It launched in May 2017 to provide accurate moisture content through a noncontact “scan” of combined virgin aggregate. This helps plants more precisely control binder addition, resulting in cost savings and a better quality product. It also allows operators to better manage the burner temperature during drying to enhance product quality and save energy/reduce emissions.

The MMS measures virgin aggregate on an inclined conveyor belt and provides a continuous moisture content reading. Measurements are displayed in a plant’s control room or transmitted to its control system.

This data, when used in conjunction with weigh bridge data, allows the plant to make asphalt more like the mix design.

For more information, contact Miguel DeJesus at (919) 719-1836.

VIKING

Viking Pump offers electrically heated asphalt pumps to complement its industry leading asphalt pumps fitted with integral heating jackets. Introduced in 2015, electric heating provides an alternative for heating asphalt and bitumen.

Electric heating offers a number of advantages over steam, heat transfer oils or external electric heat tracing, including: • Lower installation costs in remote locations when steam or hot oil is not available or requires long piping runs.

• Reduced environmental costs by eliminating hot oil leaks.

• Reduced energy costs with heat source in pump vs. external heat tracing.

• Simplified service by eliminating hot oil or steam pipe connections.

• Improved safety by eliminating hot oil or steam piping leaks.

Viking also offers a simple and effective temperature control system. It includes a thermocouple with thermowell for mounting in the bracket port, and a controller which powers all heat cartridges on one pump.

For more information, contact Gus Purcell at (910) 276-4343.

UNPARALLELED RAP TECHNOLOGY TAKE RECYCLING TO UNPRECEDENTED LEVELS Ammann focuses on technologies that incorporate high percentages of RAP – and considerably reduce operating and materials costs in the process. These technologies aren’t baby steps – they’re significant advances that can greatly impact your business.

And they’re PROVEN technologies that are in use at hundreds of plants around the world.

Ammann RAP products include: • Counterflow dryers that enable use of 100 percent hot recycled material • Parallel-flow dryers that can use up to 60 percent hot recycled material • Middle ring dryers for the use of up to 40 percent recycled material • Various cold addition systems for the use of 25 to 40 percent recycled material • Retrofit options to start or improve your recycling effort Ammann’s experience gained during the installation of countless recycling systems worldwide will ensure you find the right solution. We have the cost-saving technology, and it’s yours for the asking.

For additional product information and services please visit : www.ammann - group.com PMP-1590-00-EN | © Ammann Group

international Snapshot

Survey results from all main state roads in Estonia showed the condition of reflective markings.

International Reflective Measuring The Estonian Road Administration (ERA) carried out a pilot project in 2017 to measure the retroreflectivity of road markings on all main state roads, altogether 3721.6 kilometres, in Estonia. Retroreflectivity of a material is one technology used to enhance the readability and perception of information displayed in low-light and night-time conditions.

The retroreflectivity of road markings provides visual guidance to assist a driver’s awareness of lanes and road edges. It grants an effective traffic flow, comfortable driving experience and a safe traffic environment. Easily seen road markings improve road users’ safety, especially in lowlight and night-time conditions.

ERC Consulting Ltd. and Reflective Measurement Systems Ltd. carried out a pilot project for ERA, measuring the retroreflectivity (RL) of road markings on all main state roads. Retroreflectivity surveys were carried out using the RetroTek-M Retroreflectometer. The RetroTek technology is designed to carry out surveys across the full lane width and at all traffic speeds. Data that is collected includes retroreflectivity of road markings (lines, sym-

T

58 // September 2018

bols, arrows etc.) and presence or absence of road markers. The RetroTek technology is the next generation in dynamic traffic-speed mobile retroreflectometers.

The uniqueness of the technology lies in its capability to survey across the full width of a traffic lane in one pass, surveying up to 6 different road asset types. The technology can identify right and left lines/markers, as well as center lane road markings in one passing.

The survey results from all main state roads were categorized according to their condition as follows: - Very good – RL > 100 [mcd/m2/lx] - Good – RL = 80 to 100 [mcd/m2/lx] - Satisfactory – RL = 60 to 80 [mcd/m2/lx] - Bad – RL < 60 [mcd/m2/lx] In summary, of all surveyed main state roads, immediate renewal (where the RL value is below 60) is needed on 7.7 percent of measured roads. That is a little under 300 km. At the same time, another 15 percent (546.5 km) of measured roads have a relatively low RL value (RL = 60 to 80).

This successful pilot project was followed up with another survey; ERC Consulting Ltd. along with Reflective Measurement Systems Ltd. also carried out the ERA 2018

Reflective Measurement Systems Ltd. provides the RetroTek technology to measure the reflectivity of markings. retroreflectivity survey of approx. 2,400 km of secondary roads. In the future, the Estonian Road Administration plans to continue with regular surveying. The survey results help plan the renewal of road markings for oncoming years. The aim is that the markings placed on roads will provide sufficient reflectivity even on low-light times.

– FROM REFLECTIVE MEASUREMENT SYSTEMS

Retrofit Controls

A Heart Transplant for Your Plant

The control system: it’s the heart of your plant, reaching every aspect of your operation.

ASTEC Retrofit Controls expand and improve your capabilities with an all new control system customized to fit your needs. It’s like a heart

‘‘

Pictured from left to right Roy Bryant, Plant Foreman Ricky Pendergrass, General Superintendent Bailey Watkins, Asphalt Plant Manager

When our outdated controls started to give us problems, we knew it was time to upgrade.

We chose Astec because of the service.

Astec has the absolute best service.

your Includes an updated A Stransplant T E C , for IN C .plant. an Astec Industries Company 4101Control JEROME Center, AVENUE Power • CHATTANOOGA, TN 37407 USA • 423.867.4210 • FAX 423.867.4636 • astecinc.com Center and all new The new system communicates timing and electrical switch gear.

tolerances when switching mixes extremely well. Now we know when the mix is in tolerance; therefore, we waste less asphalt.

— Bailey Watkins Asphalt Plant Manager, Fred Smith Company

ASTEC, INC.

’’

an Astec Industries Company 4101 JEROME AVENUE • CHATTANOOGA, TN 37407 USA • 423.867.4210 • FAX 423.867.4636 • astecinc.com

Here’s how it works

Step 2 The grate system between the baffles breaks up cold crusts as they enter the insert.

Step 1 A material transfer vehicle delivers the asphalt mix between the hopper insertʼs two baffles.

Step 3 The mix travels to the base of the hopper insert. The wider front encourages material to flow from the front of the insert to the back.

Step 4 The trapezoid-shaped opening on the bottom of the insert reblends the mix as stones move along the sides of the insert.

Step 5 Asphalt material is then discharged onto the conveyor of the asphalt paver.

Vögele’s Passive Remixing Insert with an Active Remixing Module Hopper inserts can be helpful to increase the volume of asphalt material you can carry, but they can also assist in avoiding segregation of your asphalt mix. That’s the idea behind the passive remixing insert with an active remixing module from the team at Vögele, a division of Wirtgen America, Antioch, Tennessee. Here’s how it works.

With the use of a material transfer vehicle, asphalt mix is delivered to the hopper insert. It can be loaded between two baffles located within the insert, which limit gradation segregation. The maximum capacity of the insert, when filled only between the baffles, is 17 tons. However, operators can also overflow the baffles, as the company literature states, to make use of the full 23-ton hopper.

H

60 // September 2018

“Anytime you create a pile, you allow larger stones to roll on the sloping face until they stop, and they stop when they hit the wall of the insert,” said Laikram “Nars” Narsingh, manager, commercial support and development for Vögele. “The baffles allow material to funnel straight into the flight chain to prevent larger stones from rolling to the sides.”

Between the baffles, there is a grate system to break up cold crusts as they enter the insert. This combats not only gradation segregation, but also thermal segregation by allowing smaller clumps to absorb heat from the hotter surrounding mix.

The grate system is located more than a foot beneath the top of the baffles to allow operators to pile asphalt on top of the grate so that the increased weight forc-

es the material through the parallel grate bars, which are spaced between 3 and 8 inches apart.

After passing through the grate, the mix travels down to the base of the hopper insert. Since the front of the insert is wider, material flows from the front of the insert to the back of the insert to minimize thermal segregation. This wider, overhanging front of the insert also expands its total capacity.

The material then passes through the trapezoid-shaped opening on the bottom of the insert, which also aims to reblend mix naturally as stones move along the sides of the insert, and is then discharged onto the conveyor of the asphalt paver.

For more information, contact Narsingh at (615) 501-0600.

new tech

OEMs Improve Service with Online Parts Portals W

We live in a world where millions of people have free access to twoday shipping via Amazon. Some markets even have same day delivery. It’s no surprise to say online shopping has made our lives a little easier. Now, asphalt paving and production companies can begin to take advantage of that speed and simplicity when buying equipment parts and accessories.

Also known as digital aftermarket sales, many OEMs have begun to offer parts online that are shipped directly to the customer. This can reduce lead times, increase price transparency and offer customers a wider array of parts. It’s also one of the top ways OEMs can take advantage of technology in the construction sector, according to a recent report by McKinsey & Company.

“Online ordering can potentially have a positive economic effect for customers and dealers,” said Volvo Construction Equipment Product Manager Jeff Logan. “For customers, if they realize they need a part at the end of the day or after hours, they can start the ordering process right away instead of waiting for the morning. And having customers play a role in ordering frees dealers from some of that work, allowing their employees to focus on other tasks.”

24/7 ACCESS

Volvo CE, Gothenburg, Sweden, has offered online ordering of parts and accessories since 2010. The service, available to customers in North and South America, is used by around 30 dealers and 1,100 customers, though Logan said that number is constantly growing.

Customers gain access the system by their dealer, and can order parts directly through their dealer via the portal 24/7. The dealership will also review each order for accuracy before sending the order onward.

Dealers can also customize the online portal, by highlighting certain pieces of equipment or parts and, later, adding logos to their pages.

62 // September 2018

“Previously, customers typically needed to order parts through the more traditional method of contacting their dealer in person or by phone,” Logan said. “I think as the younger generation that grew up with technology comes up through the ranks of the construction industry, [ordering parts online] will become ubiquitous.”

Although online parts ordering doesn’t improve the shipping timeline, it can improve the customer’s ordering experience.

“For instance, if a customer logs on after hours and starts the process, that saves them the time they would have spent the following morning doing that after the dealership opened,” Logan said. The online parts portal also allows customers to buy accessories, like lubricants, brake cleaner and other chemicals that are not in Volvo’s parts book.

Telematics also play a role.

“With the Volvo CareTrack telematics system and the ActiveCare Direct machine monitoring and fleet utilization reporting system, customers can see potential issues with equipment earlier, allowing them to be more proactive in ordering parts before a machine goes down,” Logan said. “With online ordering, they can be even more proactive. For example, if they get an alert after the dealership is closed, they can go online to review parts and start the order.”

Volvo CE will also be opening a parts distribution center near Toronto, and is exploring additional distribution centers in the U.S., Logan said.

PARTS: ONLY THE START

Caterpillar Inc., Peoria, Illinois, launched My.Cat.Com November 2016.

The website offers Cat® customers the ability to view useful information about their fleet, but also provides parts lists and links directly to Caterpillar’s online parts ordering portal, Parts.Cat.Com. Since its launch, over 10,000 customer companies have used My.Cat.Com, according to Brent Steffen, IoT Product Manager in the Digital Enabled Services Division of Caterpillar Inc. Thousands of end users use the system on a monthly basis.

“The full array of information and insights in My.Cat.Com works together to help customers be more efficient in managing their fleets, scheduling and performing maintenance, learning about operating tips and tricks for their fleet, and getting in contact with the right dealer representative when they need it,” Steffen said.

Cat customers can access My.Cat.Com free of charge to view a wide variety of Caterpillar and Cat dealer-provided information about their equipment—on Cat and non-Cat machines, connected to telematics or not, owned, rented, or leased. To access basic telematics data, including hours, location, utilization and health alerts, they must have a subscription to Cat telematics.

“In the telematics and IoT space, our customers have choices. Caterpillar provides an array of options from freemium to premium.

For our more advanced customers who re-

quire more frequent data, expanded telematics equipment management, or site productivity capabilities, they can upgrade to our VisionLink® offering and select the plan that best aligns with their needs,” Steffen said.

Customers can also use the portal alongside their dealer to schedule service, request a quote, rent equipment and, of course, purchase parts. My.Cat.Com also houses an advice center with operating videos, safety tips, operation and maintenance manuals and reference guides.

Cat customers can register at https://my. cat.com, and then contact their Cat dealer to gain access to the correct information.

“For Volvo CE, it means we can support our customers locally more efficiently, more economically and with far shorter lead times,” Kalfholm said.

Although Kalfholm said Volvo isn’t using 3D printing on a large scale yet, there is great potential.

“In my opinion, it’s likely to have as big of an impact in manufacturing as turning or milling did during the Industrial Revolution,” Kalfholm said. “While it’s not possible to provide a timeline, for our industry, the growth is exponential.”

– BY SARAH REDOHL

PLAN FOR THE FUTURE

Although My.Cat.Com is already quite robust in its offerings, Steffen said this is only the beginning.

“My.Cat.Com has a full-featured roadmap for future development that builds on the visibility of information and improving the daily workflows our customers manage every day to help them be more efficient and productive,” Steffen said. “We plan to enable more customization by the user, centralize more information so our users spend less time searching for answers, and deliver a more integrated experience across our digital properties.”

Volvo CE is also innovating to further improve parts delivery. They’ve been experimenting with 3D printing, mostly for plastic parts related to the cab but plan to expand into steel printing and creating tools for its dealers.

“Our 3D parts are made to be the same as conventionally manufactured ones,” said Daniel Kalfholm, Volvo CE’s project leader of purchasing for aftermarket products.

“There are no major differences in the way they function.”

“The advantages [of 3D printed parts] are huge,” Kalfholm said. “For the equipment manufacturer, it’s faster and more cost-effective to have a single line of production from idea to reality. But it is the customers who really benefit.”

For example, if a part has moved out of serial production or is too expensive to produce through conventional methods, 3D printing can be used to produce those parts.

3D printing can also eliminate the need for a minimum order that injection molding and casting methods often require, and can offer parts replacement on a local level.

www.THeAsphaltpro.com // 63

ALL ASPHALT PLANT COMPONENTS 100% BUILT IN USA SPECIALIZING IN

disassembly, relocation, fabricate complete asphalt plants, and startup of asphalt plants

210-240-8395

patrick@Ahernindustries.com P.O. Box 690513 â&#x20AC;¢ San Antonio, Texas 78269

www.ahernindustries.com

40 years of experience in the asphalt plant industry!

64 // September 2018

advertiser index Ahern Industries . . . . . . . . . . . . . . . . . . . . . . . . . 64 Almix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ammann . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Asphalt Drum Mixers . . . . . . . . . . . . . . . . . . . . . . 24 Astec, Inc . . . . . . . . . . . . . . . . . . . . . . 17, 36, 49, 59 B & S Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Butler Justice . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Chemtek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 ClearSpan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 CWMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Dillman Equipment . . . . . . . . . . . . . . . . . . . . . . . . 50 E.D. Etnyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fast-Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Gencor Industries . . . . . . . . . . . . . . . . . . . . . . . . . 4 Heatec, Inc . . . . . . . . . . . . . . . . Inside Front Cover, 53 Infratest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

KPI-JCI-AMS . . . . . . . . . . . . . . . . . . Inside Back Cover Libra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Meeker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Pine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Process Heating . . . . . . . . . . . . . . . . . . . . . . . . . 55 Pugmill Systems . . . . . . . . . . . . . . . . . . . . . . . . . .19 Reliable Asphalt Products . . . . . . . . . . . . . . Back Cover Roadtec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 13 Stansteel . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 41 Systems Equipment . . . . . . . . . . . . . . . . . . . . . 11, 61 Tarmac International, Inc . . . . . . . . . . . . . . . . . . . . .21 Top Quality Paving . . . . . . . . . . . . . . . . . . . . . . . . 65 Transtech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Willow Designs . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Wirtgen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

AsphaltProâ&#x20AC;&#x2122;s advertiser index is designed for you to have quick access to the manufacturers that can get you the information you need to run your business efficiently. Please support the advertisers that support this magazine and tell them you saw them in AsphaltPro magazine.

www.THeAsphaltpro.com // 65

off the mat

Tips to Build a Solid Construction Business Foundation Starting a business in any field can be an involved and complicated process, but the construction industry can be even more arduous. New construction business owners don’t necessarily need years of related experience in the industry, but they will need a solid and well-studied plan of action.

Recent studies show that almost half of all new businesses fail within the first five years; for the construction industry, only around 35 percent make it past five years. The statistics may seem grim, but somehow over one-third of new construction companies did succeed, so it’s possible (and preferable) to be part of the positive stats.

Even with the competition of both new and established construction businesses, the United States is still one of the top markets for the construction industry in the world with over $1 Billion spent on new projects in the last 10 years. This means there’s plenty of room for new businesses to grow and succeed if the business owner is prepared and plans ahead.

Before hiring employees and bidding on jobs, there are some initial building blocks that must be put in place: 1. Create a business plan.

Every business needs a blueprint for how it will grow and succeed.

The business plan is your guide for growing your business and includes strategies for how you’ll succeed and what it will cost to run the company.

2. File the paperwork to form an LLC or C-Corp with your state.

Although the majority of small businesses formed in the United States are limited liability corporations, you may want to discuss the differences and benefits between an LLC and C-Corp with your tax professional.

S

*Note: Even though you do not technically have to incorporate yourself in order to do business as a contractor or handyman, forming an LLC will protect your personal assets in the event that your business is ever sued. Additionally, if you own any of the worksites or projects where you are working, you may also want to consider creating an LLC for each project. For example, if you purchase a house with the intent to repair and resell it, you can make that project/house its own LLC. This will further protect your business and assets in the event that anything happens during that particular project so that it does not impact your other projects.

3. Obtain the necessary insurance for your business.

In addition to liability insurance, you may also need insurance for your employees and equipment, and an umbrella policy. The annual premiums can run between $2,000 and $5,000.

4. Dot your I’s and cross your T’s.

After you build the foundational blueprint of your business through a plan, you must also address the administrative details. In addition to filing the proper paperwork with the state, ensuring that your employees are properly classified (W2 employees or independent contractors) is a key issue to think about from the beginning. Check out the article on the differences between fulltime employees and independent contractors at https://theasphaltpro.com/articles/tips-to-properly-classify-your-employees/. You also need to be careful to follow all of your state’s regulations with regard to documentation. In short, you have plenty of I’s and T’s to keep dotted and crossed.

By Travis Crabtree, president and general counsel of online business filing company Swyft Filings and counsel with the law firm of Gray Reed & McGraw LLP, Houston, Texas. His law practice focuses on assisting startup and technology companies with all of their legal needs.

Independent Classification Changes

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The California Supreme Court’s ruling in Dynamex Operations West, Inc. v. Superior Court of Los Angeles, No. S222732 (Cal. Sup. Ct. Apr. 30, 2018) alters the way California businesses must classify independent contractors, even those employed through a sub-contractor. It disrupts California’s established tradition of using independent contractors in many industries.

In a unanimous ruling April 30, the California Supreme Court adopted a new standard to test whether a worker should be classified as an employee or an independent contractor. The new standard in Dynamex uses the “ABC Test,” which assumes that workers are employees unless they can meet the three primary requirements for an independent contractor. The worker must: • be free from the control and jurisdiction of the hiring company regarding performance of the work; • be able to perform work that falls beyond the domain of the hiring company’s business; and • be regularly engaged in a recognized trade that is independently pursued.

While Dynamex establishes a new standard, it also interprets existing law, and has a retroactive effect.

66 // September 2018

The difference between an employee and an independent contractor is especially significant for those industries that frequently use subcontractors, such as construction, janitorial, transportation and delivery. For example, a construction company may classify its own workers as employees but may use sub-contractors who classify their workers as independent contractors. The misclassification liability will attach not only to the construction company but will also result in personal liability for the individual owners of the construction company.

California employers may be liable, at a minimum, for penalties of 1.5 percent of the wages, 40 percent of Social Security and Medicare (FICA taxes) not withheld, and 100 percent of the matching FICA taxes not paid by the employer.

Fortunately for many California employers and the individual owners of California businesses, there are sensible asset-protection steps that can be taken to protect assets from lawsuits and plaintiffs’ claims.

By Jacob Stein, Esq., managing partner of Aliant LLP. Over the past 20 years Jacob has completed over 3,000 asset protection transactions for both individuals and businesses. To learn more, visit www.maximumassetprotection.com or call (818) 933-3838.

RAP IS WORTH WHAT IT REPLACES.

From Equipment to Application Any recycled product is worth what it replaces. To fully realize the value of RAP, you must process it back to its original mix design. As an Astec Industries group of companies, KPI-JCI and Astec Mobile Screens are leaders in RAP processing. We pair that with a wide selection of crushing, screening, and material handling equipment required to fractionate RAP and ensure the highest quality materials throughout the recycling process.

Learn more at kpijci.com

KPI-JCI and Astec Mobile Screens

Astec Industries Companies

700 WEST 21ST STREET • YANKTON, SD 57078 USA • 800.542.9311 • FAX 605.665.8858 • kpijci.com

GENCOR 250-TON ASPHALT STORAGE SILO

RAP-15328

• SAFETY GATES • ELECTRIC HEAT ON CONE

ASTEC STATIONARY ADDITIVE SILO

ASTEC PORTABLE COATER PARALLEL-FLOW DRUM PLANT

RAP-15410

RAP-15071

RAP-15379

• NOMINAL 450BBL • APPROX 1558.6 CU FT IN BARREL, 243.7 CU FT IN HOPPER: 1802.3 CU FT TOTAL • AERATION SYSTEM

• 10’6’’ DIAMETER 18’ BARREL 9’ CONE 12’’ OPENING • SUPPORT STRUCTURE W/ LADDER INSPECTION PLATFORM

• 8X45 DRUM SHELL RUBBER AIRPLANE TIRE TRUNNIONS. • JET STYLE BURNER NOMINAL 120MBTU ON NATURAL GAS, HYDRAULIC ERECT SLINGER INLET, NO BELT • PORTABLE 4 BIN COLDFEED 8X14 24’’ FEEDERS EDI-CURRENT INDIVIDUAL SCALPING SCREENS UNDER BINS TANDEM AXLE

HEATEC HOT OIL HEATER

25,000GALLON COILED AC TANK

RAP-15380

RAP-15392

• HEATEC HOT OIL HEATER • YEAR 1997 • MODEL HCS-175 • 1.75MBTU CAPACITY • POWER-FLAME COMBO BURNER

REBUILT GENCOR HY-WAY HOT OIL HEATER

• • SKINNED AND INSULATED • SKID MOUNTED • TAKEN OUT OF SERVICE BEGINNING OF 2018 REPLACED WITH MORE AND LARGER TANKS

3Qualified listings 3Complete retrofit capability 3All types of component reconditioning

• 1.0MBTU CAPACITY • PRESSURE TESTED COIL • REBUILT POWERFLAME BURNER • UPDATED CONTROL BOX

GENCOR PORTABLE RAP SYSTEM

RAP-15086 • NEW INSULATION & METAL JACKETING • REBUILT PUMP • NEW MOTOR • PRIMED & PAINTED

GENCOR STATIONARY PULSEJET BAGHOUSE

RAP-15337

• GENCOR HAMMERMILL CRUSHER • 75HP MOTOR ON CRUSHER • 8X15 BIN OPENING • BIN EQUIPPED WITH GRIZZLY,

PARTIAL EXTENSIONS AND BOTTOM HALF OF BIN LINED W/PLASTIC • 15HP MOTOR • 36IN FEEDER

STATIONARY SINGLE LEVEL CONTROL HOUSE

RAP-14885

• NOMINAL 75,000CFM • ESTIMATED MID 1990’S MODEL YEAR • KO BOX, DUCT, AND AUGER • 3 SECTION HOUSE, BAGS NEED REMOVED FOR TRANSPORT • SINGLE MOTOR EXHAUST FAN W/ STACK MOUNT DAMPER

• 360 DEGRE VIEWING • NOMINAL 12X12 • NO CONTROLS

3Custom engineering 3Experience with all types of plants 3Complete plants and stand alone components VIEW ALL OUR INVENTORY ONLINE AT:

Inc.

PO Box 519, Shelbyville KY 40066 • Fax 502.647.1786

www.ReliableAsphalt.com 866.647.1782