Asphalt Pro - July 2017

The Warm-Mix Asphalt Issue

asphaltPRO Production – Professionals – Products

Coastal Bridge Warms Up Louisiana Protect Your Great Idea

• Lindy Paving Institutes Aerial Mapping • Save Costs with Material Delivery Guide • American Asphalt Minimizes WMA Footprint

July 2017 www.TheAsphaltPro.com

UNMATCHED DESIGN

Heatec has been designing and building tank farms for over 40 years and each project has been unique in some way. That’s because each customer is unique. You have your own business model that may be slightly different or dramatically different from the other guys’.

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.

And we make it efficient and simple to operate. Heatec is unmatched when it comes to designing heating and storage systems for your asphalt plant. To find out more about our approach, visit us at www. heatec.com or give us a call at 423-821-5200.

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

CONTENTS

asphaltPRO July 2017

departments

36

Editor’s Letter 5 – There are No Secrets

Around the Globe 6

SAFETY SPOTLIGHT

10 – Children’s Book Reinforces Company’s Safety Culture

By Cal Beyer

MIX IT UP

12 – S.T.A.T.E. Testing Advances Hot Mix Testing Technology

By Sandy Lender

PROJECT MANAGEMENT

14 – A Tale of One Cold Feed System American Asphalt Serves Two Plants with One Footprint

By Sandy Lender

KEEP IT UP

20 – Save on Costs with Your Professional Guide to Asphalt Mix Delivery Part 1—Take a New Look at Haul Truck Maintenance

By Sandy Lender

12

28

42

46

PRODUCER PROFILE

28 – Coastal Bridge Hits the Right Blend

By Sarah Redohl

THAT’S A GOOD IDEA

36 – Save on Costs with Your Professional Guide to Asphalt Mix Delivery Part 2—Put in an Eye to Safety

By Sandy Lender

PRODUCT GALLERY

54 – This is What’s New for Paving and Pavement Maintenance This Season

By AsphaltPro Staff

OFF THE MAT

60 – DOJ’s Fraud Section Issues New Guidance on the Evaluation of Corporate Compliance Programs

By Lorraine D’Angelo & Silvia Zicherman

INTERNATIONAL SNAPSHOT 62 – Italian Painters Check the VFD From ALL-TEST PRO

NEW TECH

64 – Volvo Displays World’s First Fully Electric Compact Excavator

By Sarah Redohl

HERE’S HOW IT WORKS

66 – BOMAG’s RS500 with FLEXMIX

Feature articles 39 — Raise Funds for Industry’s Fallen

By AsphaltPro Staff

The Warm-Mix Asphalt Issue

asphaltPRO PRODUCTION – PROFESSIONALS – PRODUCTS

Coastal Bridge Warms Up Louisiana Protect Your Great Idea

42 — WMA Use Increases Gently

By Kent Hansen, Audrey Copeland, T. Carter Ross 46 — Nearmap Aerial Imagery Helps Lindy Paving Improve Processes From Nearmap and AsphaltPro Staff 50 — Innovation in the Asphalt Industry Part 1—How to Take Your Idea to the Next Level

By Brian Mack and Anna Quinn

• Lindy Paving Institutes Aerial Mapping • Save Costs with Material Delivery Guide • American Asphalt Minimizes WMA Footprint

JULY 2017 WWW.THEASPHALTPRO.COM

on the cover

Coastal Bridge warms up production with additional technology. See related article on page 28. Photo courtesy Kent Langley of Coastal Bridge Co., Port Allen, Louisiana.

It’s more than the high fuel efficiency.

It’s more than the 6 inch insulation.

More than the fact CEI has produced some of the most efficient asphalt heating & storage systems available, since 1969.

CEI backs its products. Period. With thorough engineering, high-quality manufacturing, dedicated service, worldwide parts support, and annual training, CEI offers you the kind of fullcircle support you’re looking for.

C E I E N T E R P R I S E S an Astec Industries Company 245 WOODWARD RD SE • ALBUQUERQUE, NM 87102 USA • 800.545.4034 • FAX 505.243.1422 • ceienterprises.com

editor’s Letter There are No Secrets

Back in 1995, Sandra Bullock starred in a cybercrime drama called The Net. It was based on the premise that people can learn things about your life, and then steal your identity. Less than a decade later, a real-world company—which shall remain nameless—headquartered in Chicago, neglected to inform employees in satellite offices that its CFO’s non-password-protected laptop computer had been stolen from the corporate office, and that employees’ personal information had been compromised. Imagine the surprise when multiple employees discovered they had new credit cards, and furniture purchases in the Chicago area had been made in their names.

My point is there are ways for people to learn about you and/or your business. Even your competition can learn about your operation in today’s Internet-based world. If you think ignoring public relations opportunities will protect you from “sharing secrets,” you are being short-sighted.

Think about this: For your competition to figure out how much tonnage you run in a given time period, the owner needs merely to send a worker to sit outside your gate and count the trucks leaving for the day. Multiply that number by the tons each truck carries, and so on.

Or he could skip paying a worker to do math for a day and look up some public records. How many jobs did you win last year? Those are also public record.

I contend there are no secrets in the asphalt business these days. Everybody is doing something that someone in another county or state is also trying out—or should be trying out. The concept of the rising tide lifting all boats still matters for the industry. The companies that hunker down behind closed gates refusing to answer phones give the impression that we, as an industry, have something to hide. Don’t be so afraid of Company XYZ down the street that you fail to get out in front of community relations issues. Company XYZ will turn out to be your ally when the mob comes with pitchforks, torches and the Channel 4 news crew. At least I hope the company down the street will recognize the need to be your ally before the mob turns on it.

I don’t want that to sound like I’m a harbinger of doom. My hope is this note will cause company owners to think on the ways proactive community relations campaigns can set the business up for continued success.

For example, at a marketing conference about a decade ago, I learned that Ford Motor Co. almost made a huge mistake in announcing its new-and-improved engine (and other) design when it purchased and upgraded Jaguar. Nobody cared about engine faults in their Jag. In fact, owners made excuses for their Jag being in the shop all the time because they loved their cars so much. What the marketing folks at Ford figured out was they needed a campaign that touted the awesomeness of being a Jaguar owner. They made a television commercial with Etta James’ sultry version of At Last for the bed, and it was so beautiful that I still remember it.

(Just to be clear, I do not own a Jag.) But the positive campaign spoke to car owners like nothing else could. That’s good PR right there.

Asphalt producers and contractors can take a note from Ford’s Jaguar campaign for proactive, positive messaging. Think about the good, environmentally sound, job-growing, infrastructure-enhancing projects going on within and without your gates this month. What have you done this week to let the general public near your business know that you’re supporting the economy? Or that you’re helping a local food pantry? Or that you’re making their road to school this autumn safer with a new mix design? You’re not giving company secrets to the competition by telling the community that you’re a good neighbor. But is your good name and good reputation currently a secret to everyone else?

July 2017 • Vol. 10 No.8

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) 289-5390 Art Director Kristin Branscom business manager Susan Campbell (660) 728-5007

AsphaltPro is published 10 times per year: January, February, March/ April, May/ June, July, August, September, October, November and December by Asphalt Pro, LLC, 602 W. Morrison, Box 6a, Fayette, MO 65248.

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-2.

Stay Safe,

Sandy Lender

www.THeAsphaltpro.com // 5

around the globe

Industry News and Happenings from Around the World Australia

Austroads released in April a report that assesses the pros and cons of high productivity vehicle (HPV) use on pavements, and proposes a method to consistently quantify pavement vertical loading of an individual vehicle design. You can download the free Report: AP-R541-17 at https://www.onlinepublications. austroads.com.au.

China

Back in February, China imported 312,000 tons of bitumen to different ports like Nanjing, Nanning, Qingao, Ningbo and Shijuazhuang, according to Petrosil’s Bitumart report.

Europe

European liquid products transportation specialist Eb-trans Group has joined Eurobitume as an associate member, and is the tenth organization to become part of the European Bitumen Association in the last 18 months. Eb-trans Group occupies a central position in the transportation and delivery of bitumen in France, Benelux, Germany and Spain. Source: Eurobitume

United States

HNTB Executive Vice President Paul Yarossi, P.E., has been named chairman of the American Road & Transportation Builders Association Transportation Development Foundation (ARTBA-TDF) board of trustees. Yarossi has been a volunteer ARTBA leader for nearly two decades, serving as 2011 chairman and as ARTBA-TDF vice chair since June 2014.

Source: ARTBA News

Hawaii

The drive along the beautiful Hamakua coast of Hawaii Island was recently improved with the resurfacing of Hawaii Belt Road from Pepeekeo to Hakalau.

The resurfacing project was within the southern section of Hawaii Belt Road on Route 11, which goes between Hilo and Kailua-Kona. In November 2014, Jas. W. Glover, Ltd. began the reconstruction and resurfacing project that totaled 5.6 miles. The crew coldplaned 2- and 4-inch depths and placed GlasGrid®, an asphalt reinforcement system, prior to the placement of the 2-inch thick State Mix IV surface course.

The project was completed in March 2017. Source: HAPI April 2017 Newsletter

Illinois

Elevance Renewable Sciences Inc., Woodbridge, Illinois, announced April 13, a licensing agreement with Chemtura specialty chemicals compa-

6 // july 2017

ny, for Elevance Aria® WTP lubricant technology and market development.

Iowa

The Asphalt Paving Association of Iowa will hold its summer meeting at the Bridges Bay Resort in Arnolds Park, Iowa, July 27 through 28. The family-friendly event includes the APAI Members’ Annual Golf Outing on July 28. Visit www.apai.net for info. Want more golf? The APAI Western Iowa Golf Outing is Aug. 29 at Majestic Hills GC in Denison, Iowa. Visit www. apai.et/2017golfoutings.aspx for registration.

Missouri

Your AsphaltPro staff, Fayette, Missouri, has teamed up with hall-of-famer industry consultant John S. Ball III of Top Quality Paving & Training, Manchester, New Hampshire, to bring you an online training course for each member of your asphalt paving crew.

Get lessons for best equipment operation, proper morning startup, building the launch pad, figuring yield, safety tips and more. This course is designed to give new crew members the basics they need, and to give veteran employees a refresher on best practices, all to improve your company’s quality output. Your purchase of the course gives you lifetime access on any device at any time to train any number of employees. Check out free previews of lessons or get started by clicking the green “enroll” button at http:// training.theasphaltpro.com/p/asphalt-paving-101.

New Hampshire

Immaculate Power Sweeping LLC, Pelham, New Hampshire, upgraded their fleet of sweepers with five newly designed Schwarze SuperVac Vortex sweepers this spring. Immaculate Power Sweeping is a family owned and operated business established in 1992.

New Jersey

The Construction Financial Management Association (CFMA) elected its 2017-18 executive officers, which are the highest-ranking volunteer positions within the organization, responsible for representing the interests of more than 7,800 members across North America. They are Chairman Samantha M. Hutchison, Houston; Vice Chairman Joe McLaughlin, Dallas; Treasurer Michelle Eastman, Indianapolis; and Secretary Asif Choudhury, Bethesda, Maryland.

North Carolina

The Road Information Program (TRIP) reported that population and economic growth have placed increased demands on North Carolina’s major roads

and highways. Its May 2017 report shows vehicle miles traveled (VMT) in the state increased 29 percent from 2000 to 2016, which is the ninth highest rate of increase in the United States during that period. Legislation passed in 2015 provided a modest increase in state transportation funding, but it appears over the next decade, North Carolina DOT is only able to fund 17 percent of the transportation projects needed to relieve traffic congestion, support economic development, improve traffic safety, and improve the conditions of state roads, highways and bridges. The DOT’s annual maintenance and performance report showed the Department is currently spending $1.3 billion each year to repair roads, highways and bridges, but needs to spend a minimum of $1.6 billion annually just to keep up. “Ideally, NCDOT should be spending $1.9 billion annually to improve the condition of its roads, highways and bridges.” Source: TRIP

Tennessee

Tennessee Road Builders Association Past President Steve Wright has received the highest honor from the American Road & Transportation Builders Association (ARTBA) this spring. Wright is the president of Wright Brothers Construction Company, in Charleston, Tennessee, and the sole recipient of the ARTBA Award for 2017. The award recognizes individuals for outstanding contributions that have advanced broad goals of the association.

Wyoming

The 54th Annual Petersen Asphalt Research Conference (PARC) 2017 will be hosted by Western Research Institute and will take place July 17 through 19 in Laramie, Wyoming. The organizers expect more than 150 attendees from different countries. Visit www.petersenasphaltconference. org for details.

Washington, D.C.

The National Stone, Sand & Gravel Association (NSSGA) announces Laura O’Neill-Kaumo has joined the organization as the association’s new senior vice president of government and regulatory affairs. She earned a bachelor’s degree from Eastern Michigan University and a juris doctor degree from the University of Miami Law School. NSSGA President and CEO Michael W. Johnson said, “Laura joins our team at the perfect time to help advance a significant infrastructure bill and influence an ever-changing regulatory environment.”

A FULL LINE OF EQUIPMENT & PRODUCT SUPPORT SOLUTIONS FOR ALL YOUR ROAD BUILDING NEEDS. PAVERS | MTVS | COLD PLANERS | STABILIZERS BROOMS | COMPETITIVE PARTS | GUARDIAN

© 2017 ROADTEC.INC. ALL RIGHTS RESERVED

roadtec.com 1.800.272.7100 423.265.0600

Dedicated to Success.

safety spotlight

Children’s Book Reinforces Company’s Safety Culture Lakeside Industries is a leading hot mix asphalt producer and paving contractor in the Pacific Northwest. The company has 12 divisions and two affiliated companies in Washington, Oregon and Idaho. Lakeside has approximately 700 employees and operates 17 hot mix plants and a rock crushing facility.

Lakeside Industries has a long history of safety. Over the past several years, the company has been promoting an exceptional safety culture based on engagement and empowerment of employees for safety awareness, hazard recognition, voluntary compliance and improved decision-making. The idea for a children’s safety book was spawned by an employee’s then 5-year-old son who had a book on construction safety that his mother took to share with her boss to help keep all the workers safe.

Risk Management and Safety Coordinator Melanie Foister further described this catalyst for the book: “Being that I work for the company in the office, and my husband is on one of the paving crews, it was important to our son to keep us both safe at work. So, I brought the book to my boss, Cal Beyer, director of risk management, and shared with him my son’s concern for our safety.” Foister continued, “Cal suggested that I write my own children’s book on safety in the hot mix asphalt and paving industry on safety at work, home and play.”

Foister expressed appreciation to the book’s creative team: co-workers Jaylynn Markwald, Jake Pittman, and Jaylynn’s friend, freelance illustrator Candace Strong. “We created a strong demonstration of our company’s safety culture,” Foister stated proudly.

Foister highlighted that, “the goals for this book were to reinforce the idea of a Safety 24/7 culture of safety at work, home, and play. We not only want our employees to go home safe from work each day, but also return to work safely each day as well.”

One of the co-authors, Superintendent Jaylynn Markwald, added, “We wanted to

L

10 // july 2017

share our ideas of WYE, which stands for ‘What’s Your Exposure,’ with our family, friends, and community so that everyone is conscious of their safety at all aspects of our lives.”

Markwald further shared that the entire creative team “wanted to make sure that the book featured each aspect of asphalt production and paving.” For example, “When the mom [in the book] talks about her day, she emphasizes specific job tasks that our employees do every day. Each task is extremely important to making our company safe and successful.” Markwald offered this as a main reason the book has been so well received: Every employee can relate to the story in some way shape or form.

Foister said she is proud that the book has been distributed initially at the company’s 56th Annual Safety Awards Brunch, the only annual company-wide event for employees and their families.

Foister stated, “We ensured that each of our 700 employees had a copy of their own, and an additional 50 copies were provided to each of our locations to share with recent retirees, contractors, neighborhood schools or libraries, and local businesses in their communities.” In addition, at least 800 copies will be distributed during the company’s student field trip program.

Markwald expressed how the book “ties everything together full circle, safety at work, home or at play and it embraces family.” She said her “favorite part about the book is if there is something in there that kids don’t understand, it requires an explanation, so when an employee reads the book they are reinforcing their knowledge about safety and setting a good example by teaching the children.”

Perhaps the biggest lesson in the children’s safety book is the importance of every employee playing a role in making safety a core value. When every employee focuses on sharing safety, a company’s

safety culture flourishes and employees share creative ideas to further promote safety. Foister and Markwald are friends on and off work. They both are proud of how they have provided a gift for Lakesiders of all ages that has been well received already throughout the company, the communities it serves and the construction industry.

– By Cal Beyer

Author Biographies Melanie Foister and Jaylynn Markwald work for Lakeside Industries. Melanie, previously a middle school teacher and mother of two, joined Lakeside in 2011.

She is the risk management & safety coordinator. Through her children always asking “why?” and her family’s practices of safety 24/7 at home, she was inspired to start a story. Jaylynn is a second-generation Lakeside employee beginning her career in 2006. She has worked in various capacities, including traffic control supervisor, assistant superintendent and superintendent. Jaylynn is a passionate safety advocate and serves as a long-term chairperson of her divisional safety committee.

Upcycle:

(verb) \uhp-sahy-kuh l\:

To reuse material in such a way as to create a product of higher quality than the original:

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THE ORIGINAL IS STILL THE BEST

The Roadtec “Shuttle Buggy” material transfer vehicle (MTV) provides unequaled performance to other MTVs and is required extensively by government road departments worldwide to achieve consistently high quality asphalt pavement. Pavement lifespan tests have shown that a temperature differential of less than seven degrees Celsius in the mat behind Ultradrum 50% UltraRAP the paver is key to A.R.E. even compaction and pavement durability.70% I t seems any plant these days can recycle, but have you ever asked

MegaRAP 100%

With Shuttle Buggy

Infrared imaging behind Buggy™ MTV in higher tests conducted in the about the quality ofthe theShuttle mix produced?

With RAP percentages U.S.comes as wellthe as inproblems Europe has shown that the machine easily and consistently of degradation of the mix. remixes to achieve temperature differential below the seven degree Celsius That’s why Gencorperformance developed the and MegaRAP threshold.

This proven has innovative led not onlyUltraRAP to the machine’s concepts, which can process 70% and 100% recycle without superheating popularity all over the world, but also allows contractors to earn maximum and degrading the quality of the mix. The result is a noticeably superior smoothness bonuses and win quality awards, while improving production. and consistent mix.

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Mix It Up

S.T.A.T.E. Testing Advances Hot Mix Testing Technology In the past, technology hadn’t paved the way for the successful use of ground tire rubber (GTR) in asphalt mix designs the way it has today. Now we have the means to grind tires “finer.” We can use advanced mixing chemicals that facilitate the use of wet process and dry crumb rubber modified asphalt cements (AC). We also employ the option of tanks that allow the specific heating and agitating requirements that facilitate the storage and use of these modified ACs. One of the more recent technological developments comes in the form of a testing device to extract asphalt binder from hot-mix asphalt (HMA) mixes and automatically separate the components for analysis. Rather than devoting days to traditional reflux extraction to determine binder content from an HMA sample, or relying on ignition ovens and correction factors, technicians at S.T.A.T.E. Testing LLC, Dundee, Illinois, use a new piece of equipment to accomplish the task more quickly. The Asphalt Analyzer manufactured by infraTest USA, Walpole, Massachusetts, avoids technician exposure to highly flammable and dangerous solvents such as trichloroethylene and can provide results in about 90 minutes. According to infraTest USA, the new PG model is equipped with a second solvent circuit allowing for the extraction of rubber modified asphalt mixes as a stand-alone procedure. This becomes more critical as rubber use in pavements increases, and as new processes are implemented for incorporation of the rubber.

I

Test at Full Tilt

S.T.A.T.E. Testing is a division of State Materials Engineering, and is an independent professional engineering firm specializing in consultation and testing of construction materials. President Jay Behnke, P.E., started the company in 1999 with the idea of providing engineering and materials testing services to both the highway and airport construction industry and public construction agencies. Its East Dundee and O’Hare labs are accredited by the American Association of State Highway and Transportation Officials (AASHTO).

The technicians continue to upgrade their training, with many of them maintaining the highest degree recognized in Illinois.

In first quarter 2017, the firm added the PG model Asphalt Analyzer. Technical Director and Senior Engineer Joe Pitlik, P.E., said the machine has had an immediate impact on lab operations.

“We are still working on agency adoption and specification, which will drive the volume of testing, but it has had an immediate impact on our lab operations,” Pitlik said. “The ability to rapidly and reliably determine AC and dust in RAP, RAS and mixtures is a tremendous help. Also, as we work on specification development for binder grading of AC from field samples—including both virgin and recycled AC components—it really improves our ability to get samples over to the binder testing lab with minimal effort and minimizes the exposure to solvent.”

12 // july 2017

Left: Here you can see the extracted and captured ground tire rubber from a hot-mix asphalt sample. Photos courtesy S.T.A.T.E. Testing LLC, Dundee, Illinois. Right: One of S.T.A.T.E. Testing’s certified technicians runs the Asphalt Analyzer.

Behnke concurred that the testing company has been running tests at full tilt since adding the equipment in early March. Behnke explained that getting timely results on the pricy material of liquid AC in a mix design is a driving factor in design and control of HMA projects.

Rubber Makes it Flexible

GTR has been added to asphalt mixes to improve flexibility since the ’90s, however, the technology has improved over the last decade. GTR offers the advantage that it makes pavements less prone to both cracking and rutting. An HMA pavement needs to be strong enough to resist rutting under traffic but flexible enough to resist cracking caused by thermal and other stresses.

Each property, rutting on one side and cracking on the other, can be assessed by S.T.A.T.E. Testing. The net effect of rubber, when used properly, is to stiffen the mix without sacrificing flexibility.

“We have the Hamburg Wheel Test that is very repeatable and relatable to field conditions to tell us whether a mix will or won’t rut or strip,” Behnke said. “Now we need to determine a test for cracking. In my opinion, the one that correlates to field conditions the most and is the most repeatable is the DCT.” Behnke has great faith in the Disk-Shaped Compact Tension Test (DCT). The DCT is specified in ASTM D7313-(07) and is used to find the cracking point of asphalt mixes in either lab or field samples. The test is usually run at 10°C warmer than the low PG temperature point. For work in Illinois this generally means a target grade of PG XX-22 and a test temperature of -12°C (10.4°F).

Confirm It

Behnke explained that the Asphalt Analyzer PG model is important to the use of these new mixes because of the ability to separate out the rubber and confirm contents. Because we’re relying on the rubber to modify our asphalt, the agencies need to be able to confirm

or verify the amounts of rubber. Every process is a little bit different. Whether it’s terminally or plant blended with a wet process or dry crumb rubber, agencies need to know that they are getting what they paid for.”

Whether the mix has rubber or a combination of polymer and crumb rubber, or some other modified combination, the Asphalt Analyzer PG model separates each component and the modified binder is deposited into its own container to be tested. Technicians can assess the new performance grade and the percentage of the mix the binder comprises with confidence.

Behnke explained that the Asphalt Analyzer has assisted them in discovering “hidden” percentage points of binder that other test methods may have been unable to find. For example, the binder trapped inside absorptive aggregate or aged fractionated RAP gets pulled out of the aggregate during the combination of centrifuge and reflux process of the analyzer. Using vacuum pressure, rather than heat to dry back the aggregate speeds the process without the potential to break down aggregate.

“We’re at the place we should be at and the binder was there in the mix all along; we just didn’t know it and couldn’t prove it,” Behnke said. “Now we can prove it.” While previously mixes may have been resulting in AC contents being 0.1 or 0.2 percent low, more of the mixes check out at optimum AC content.

Quality Pays

With the motto of “Quality is our stepping stone,” S.T.A.T.E. Testing is forging a path to assist agencies in obtaining high quality, high performing pavements. S.T.A.T.E. Testing performs verification testing for several agencies in the state including the Illinois Department of Transportation, the City of Chicago and the Illinois Tollway. S.T.A.T.E. Testing is constantly involved in initiatives to improve quality such as the one with the National Highway Institute (NHI) on revamping its Transportation Construction Quality Assurance class.

Whether a sample to be tested comes from a S.T.A.T.E. Testing monitored project or a client’s project, the company stresses best practices for sampling and testing.

“Using proper procedures to select sample locations, and then best practice to actually perform sampling and testing is absolutely critical,” Pitlik shared. “The data is only as good as the means used to collect it. Proper lab accreditation and adherence to test standards are critical. Avoiding even the potential for bias is key to keeping the job in the engineer’s office and out of a lawyer’s office.”

Handling samples in an ethical manner shouldn’t be a practice just to avoid litigation; good QC/QA affects the contractor’s pay scale.

“As we move toward payment systems with incentives and disincentives, more and more challenges will be mounted and both the contractor and the owner need to be prepared to defend their results,” Pitlik finished.

S.T.A.T.E. Testing is currently installing two infraTest Asphalt Analyzers (one with rubber chamber and one without) for IDOT districts in Chicagoland and Peoria.

– By Sandy Lender

www.THeAsphaltpro.com // 13

project management

A Tale of One Cold Feed System American Asphalt Serves Two Plants with One Footprint

American Asphalt Co., headquartered in West Collingswood Heights, New Jersey, runs two plants side by side on its Burlington Township property. One is a 5-ton Stansteel batch plant. The other is a 400-TPH Dillman duo-drum. Putting the two on the same property made perfect sense from a permitting, footprint and cost standpoint, and inspired the intriguing idea of feeding both plants from one cold feed system.

Management at American Asphalt turned to Reliable Asphalt Products in Shelbyville, Kentucky, for some assistance with the setup. Here’s how Production Manager Chris Jennings made that all work out.

A

14 // july 2017

Serve the Customer American Asphalt Owner and President Bob Brown has performed the various jobs at the asphalt plant that his employees are required to do, thus he is aware of what his employees need when it comes to getting the job done right. In a promotional video for American Asphalt, Brown stated, “When I first bought this company, I had four employees and we had a 1-ton asphalt plant here. When I started, the previous owner stayed on and showed me how to operate the plant. So I have a real appreciation after running the plant, running the loaders, charging the bins, welding, wiring, fixing

motors at night, doing whatever it took for us to make asphalt every day, which makes it easy for me to relate to the people who work for me. I’ve done their job. I know how hard it is. I know how hot it is….I know what I’m asking them to do.”

Another element of operating an asphalt business that Brown has an appreciation for is the customer. Jennings made a point of stressing that the team added the 5-ton batch plant with 600 tons of storage capacity to the Burlington site and modified it to include a fifth hot bin to accommodate additional mix designs for larger customers while still providing commercial mixes that smaller and mid-size customers request.

Save on Costs, Space

Left and above: The RAP Dual Bin System you can see “crossing” the lower portion of the image is comprised of eight 10-foot by 22-foot cold feed bins that are partitioned in the middle to allow for two feed conveyors on the bottom of each bin. The bins are supported by formed legs and have double structural stiffeners to support the walls against the extra weight and pressure from the aggregates. Each side of the bin has a custom designed, heavy duty radial gate to allow for consistent flow. The feeders are equipped with a direct drive 5 horsepower motor and gearbox to deliver consistent power to the feeder without having to deal with belts, sheaves and pulleys.

All the feeders are equipped with variable frequency drives for optimal performance on all the mix requirements. The Dual Bin System is outfitted with two 30-inch by 200-foot collecting conveyors, which feed the materials to both plants you see here.

For example, the batch plant lets the team prepare ¼-inch nominal maximum aggregate size (NMAS) mixes, Jennings shared, but the team made some upgrades.

“We did a lot of modifications on this batch plant. By adding a fifth hot bin, we can accommodate intermediate and top mix designs for our larger customers as well.”

They also added an external recycle weigh hopper, which allows the plant to maximize recycled asphalt pavement (RAP) use.

“The external weigh hopper system is a nice addition to the tower in that it allows for accurate measuring and delivery straight to the pugmill,” a spokesman for Reliable Asphalt Products stated. “The pugmill was completely rebuilt with specialty components to optimize the mixing and wear capabilities. Reliable Asphalt Products also re-engineered the dust entry points and added a custom flop chute under the tower to feed the asphalt into the

drag slat. We also upgraded the hot oil system and added two additional AC tanks. We also added a new control system, which allows the plant team to take advantage of the latest plant operating technology.”

The theme of meeting their customers’ needs is evident in all of Jennings’ comments.

“Mr. Brown has taught us that the customer is who keeps us in business, so we want to be able to service everybody who comes to us,” Jennings said.

“Customer service with us is not a department; it’s an attitude,” Dave Sulkin said. He’s the vice president of sales and marketing. “So, from the top-down, everyone in the company has to understand what our definition of customer service is and what that’s supposed to look like, so when there is a client touch, we’re all aligned.

We’re dealing with a relatively unsexy product, and we’re giving it dignity. We’re treating it as it is—a luxury item.”

To make their luxury product available to more customers, the team at American Asphalt looked at adding another plant to its assets.

“Management was already interested in adding another plant to meet ongoing customer demand and load trucks quickly,” Jennings explained. “When we were deciding to go with another asphalt plant, we were looking for another piece of property to build on. It came back to where it would be more financially responsible to stay here [Burlington site]. We would also add only a couple more personnel instead of adding the five or more people another full plant and site would require.”

When deciding where to place the batch plant, management also looked at logistics.

“Charles Grote [of Reliable Asphalt Products] helped come up with the feed bins,” Jennings said. “We weren’t willing to totally rebuild the existing cold feed ramp and retaining wall and have two cold feed systems.”

Instead, the team took out the old six-bin system and installed an eight-bin, dual feed system in its place.

“One of the most important components of any plant is the cold feed system,” a spokesman for Reliable Asphalt Products said. “Being able to charge the plant with the needed amount of aggregate in a smooth and continuous manner is the first step in making good mix. The American team went with a dual feed system that allows both plants to use one set of bins. The RAP Dual Bin System is comprised of eight 10-foot by 22-foot cold feed bins that are partitioned in the middle to allow for two feed conveyors on the bottom of each bin.

The bins are supported by formed legs and have double structural stiffeners to support the walls against the extra weight and pressure from the aggregates.”

“We went from six cold feed bins to eight cold feed bins, and that covers all the types of stones that we’re going to need for the industry for EZ Street, and both New Jersey and Pennsylvania Departments of Transportation,” Jennings said.

Jennings said that also gives them room to have an extra bin or two in the event of emergencies. “We’ve prepared ourselves for any bin breakdown or a customer needing

www.THeAsphaltpro.com // 15

project management

American Asphalt recently added the 5-ton batch plant with 600 tons of storage capacity to the Burlington site and modified it to include a fifth hot bin to accommodate additional mix designs for larger customers while still providing commercial mixes that smaller and mid-size customers request. Plant Manager Chris Jennings shared that they use a single Komatsu loader to feed the system for the two plants, which also lowers their cost to produce. Decisions are focused on keeping costs down for production and the customer. “American Asphalt Company is committed to making the customer service experience its number one priority.” something completely different. We’re trying to avoid ever having to turn a customer away because of being overbooked.”

While the change extends the feed system about 60 feet further than it reached before, it saves the space, conveyors and related mechanisms of adding a second feed system for the second plant. With the dual feeds, each stacked bin holds a total of 100 tons. Fifty tons go to the feeder for the drum plant; 50 go to the batch. “We have 16 bins in reality,” Jennings said.

At this time, they use a single Komatsu loader to feed the system. One loader for two plants lowers their cost to produce, making them a low-cost provider.

“We have multiple loader operators that we switch out,” Jennings said. “Our loader operators are very intelligent guys—they are top notch. The ideal situation is they feed to the center of the bins.”

Jennings’ next project is to receive and install labels to make all bins and stockpiles error-free. “I have labels being made for both sides of bins so the plant operator and loader operator know which stone to refill. We are always looking for the latest advancements and technologies available to keep us one step ahead of our competition.

“American Asphalt Company is committed to making the customer service

16 // july 2017

experience its number one priority. Our core values are based on treating everyone with the acronym RIGHT. Respect, Integrity, God honoring, Honesty, Trust.

Every employee is empowered to be able to make our customers feel not only important, but a vital part of our team by treating them RIGHT. By maintaining constant contact with the customer, we keep our production teams informed of the status of every job, even while the job is in progress. The more we communicate, the better we and the customers become. We want American Asphalt Company to be the producer of choice.

By adding another plant and 600 tons of additional silo storage capacity, we have demonstrated to everyone in our area that we take our customers’ needs very seriously.”

A spokesman for Reliable Asphalt Products spoke highly of the American Asphalt team’s commitment to quality and commitment to their customers. “The American Asphalt team strives for operational excellence, and this project has showcased the American vision and passion for that goal. Under the direction of Bob Brown and management of Chris Jennings, the American Asphalt team has created a unique plant layout that will greatly

increase production ad contribute to their continued success as a company. American overcame issues with both permitting and plant layout space with such an innovative design. The fact that they were able to add a 5-ton batch plant and silo system without rearranging the existing facility is amazing. From start to finish on this project, the American Asphalt team has done a tremendous job in both planning and execution. By focusing on a plan to better serve their customers, American Asphalt has set itself up to be a leading organization in the industry both locally and nationally.”

– By Sandy Lender

American Asphalt uses the RIGHT acronym.

R = respect I = integrity G = for honoring God H = honesty T = trust Employees are empowered to make decisions within the RIGHT core values, and the company has the employee’s back.

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keep it up

Whether you’re an independent truck driver with your own commercial vehicle, like Steve Murray, pictured here, or a driver in a company that maintains a whole fleet of trucks for daily delivery of perishable mixes, keeping each vehicle in optimum working order is an important piece of the paving puzzle. With new engine emissions regulations and electronic data logging rules out there, advanced technology can either help or hinder the regular maintenance regimen. Photo courtesy John Ball of Top Quality Paving & Training, Manchester, New Hampshire.

Save on Costs with Your Professional Guide to Asphalt Mix Delivery Part 1—Take a New Look at Haul Truck Maintenance For the 2017 paving season, we dive into an essential area of project management for asphalt professionals: safe and timely delivery of hotmix or warm-mix asphalt (HMA/WMA) to the paving site. During this eight-part series, you’ll get some back-to-basics best

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practices to share with veteran and new haul truck drivers, in addition to new tips, ideas, and case studies with logistics and technology that will enhance your bottom line. Producers have streamlined processes at the plant; contractors have nailed down best practices in the work zone. Now it’s

time to harness the potential you’ve been missing when it comes to mix delivery and haul truck fleet management.

Let’s start with minimizing downtime. At first, that sounds like an old discussion of routine maintenance; but we’re going beyond the routine with this series.

The crew won’t be excited to re-hire you if you tear up the equipment. Instead, remove the trailer hitch on those weeks when you’ll be hauling asphalt.

Keep in mind, according to the Federal Motor Carrier Safety Administration (FMCSA), you must display a periodic inspection decal that proves your commercial motor vehicle (CMV) has been inspected within the past 12 months, but that decal doesn’t prevent “surprise” roadside inspections. In other words, the decal proving you’re in compliance merely protects you from being cited for a violation of periodic inspections. Operating a commercial vehicle means a state or federal inspector can stop you if they notice something that appears unsafe.

This behooves you to perform routine maintenance for best and safest operation in between your mandatory periodic inspections. Drivers must prepare a driver vehicle inspection report (DVIR) at the completion of each day’s work, and must turn those in to the company, but that’s only half the story.

Maintenance is Your Responsibility

The haul truck driver is responsible for delivering sand, aggregate, millings, or a hotbox of one to five tons up to a body of 20+ tons of 300°F perishable asphalt mix. That’s heavy duty hauling for the road-building industry, which means the truck has got to be up to par.

One of the most important items to ensure is working on your truck is the backup alarm. Many companies have instituted the policy that a haul truck with an inoperative backup alarm will not be allowed on a job.

This means an independent driver could show up with a load of material and get kicked off the job, making him financially responsible for 18 or so tons of cooling mix.

Of course there’s more than a backup alarm to check prior to each shift to en-

sure your haul truck meets your state’s department of transportation (DOT) requirements for legal operation (See Sidebar “The Daily Walk-Around” on page 26).

Independent driver Steve Murray of Steve Murray Trucking, Hooksett, New Hampshire, has a routine even after he’s completed his daily inspection, but before he gets to the jobsite.

• Rinse the truck off with a 1,000-pound pressure washer.

• Make sure the windows and mirrors are clean for visibility.

• Make sure the lights are working.

• Clean the body so there’s no residue.

• Then go to the job for instructions.

To track maintenance activities, drivers and mechanics have the help of modern technology. Even before large original equipment manufacturers (OEMs) joined forces to standardize data points, they were developing telematics to gather information on the way engines run, to detect faults in equipment, to schedule maintenance actions, to streamline machine safety, to monitor emissions controls, and to gather data for fleet management.

These are concepts that cross the entire equipment fleet; they’re not unique to the haul trucks in the yard. For instance, the team at Volvo Construction Equipment has telematics packages standard on 7 articulated haulers, 23 excavators, 11 wheel loaders, and as an option on two pavers, 2 soil compactors, 4 asphalt compactors, 4 compact wheel loaders and 8 compact excavators. Then the Volvo Trucks team has the Gateway telematics system to monitor and gather data for commercial vehicles.

Other OEMs have recently released telematics solutions for on-highway trucks. In March, Caterpillar announced its on-highway truck fleet solution complementing telematics that are already standard on their construction equipment.

Their VisionLink interface will now combine telematics information from virtually all assets on a jobsite including on-highway trucks, giving customers a powerful asset management tool, as well as keeping customers’ heavy duty trucks compliant with federal regs concerning an electronic logging device (ELD), which will be discussed in more depth in a future installment of this series.

www.THeAsphaltpro.com // 21

keep it up Telematics is, at its core, machines talking to machines. Back in the mid-2000s, OEMs recognized that many contractors have mixed fleets, which meant the end user had mixed data coming in on different types of screens.

Different machines were failing to talk to one another in different languages. That had to be reconciled some way.

By Feb. 5, 2010, a team of OEMs developed and released a “first” standard with a set of data points—hours, odometer, fuel, location, date/time and machine identification information—that all OEMs could incorporate in a telematics package. The idea was to let all OEMs’ machines talk to each other in the same language when “talking about” those specific data points. Fleet managers know there are more data points than the six listed in this paragraph, and OEMs kept working to make the standard more robust for the end user. The International Organization for Standardization (ISO) published the final standard—15143-3—Nov. 30, 2016.

This gives contractors and fleet managers confidence that the data-monitoring across the fleet is gathering, interpreting and delivering information in a uniform manner.

You’re Responsible…

Except When You’re Not

No matter what tier level your engine is, you are responsible for keeping it, and the components surrounding it, in top working condition. You’ll want to test the freezing point of the coolant before winter—every winter.

Check the belts and hoses on a regular basis, too. Make sure the air cleaner indicator gives you a good reading.

Consider the new after treatment systems available now. You want to monitor whichever system your engine manufacturer uses and perform basic maintenance as the OEM recommends. Pay close attention to the type of lube oil the manufacturer recommends, which we’ll discuss further in just a moment.

The team at Wolter Group LLC, Brookfield, Wisconsin, reminds you, “The after treatment will not function properly unless you use the specific low ash oil.”

Something to be aware of when dealing with your Tier 4 engine is liability. While you can take care of routine cleaning and checks on your own, error codes indicate problems that may require professional help. During

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the “What’s Now” Speaker Series that took place on the CASE Construction Equipment stage during CONEXPO-CON/AGG 2017, Dave Piech, who is the vice president for engine compliance NAFTA, CNH Industrial, shared emissions regulatory news and what he anticipates for future emissions standards.

He mentioned onboard diagnostics (OBD) and liability.

OBD offers advanced—and advancing— technology to assist operators, but the “right to repair” comes into question. If you receive a warning light or fault code from your OBD regarding your Tier 4 engine, you may be breaking the law if you make the repair yourself. Piech explained that changing the way an engine runs has both safety and environmental impacts. “If anybody goes in and adjusts how an engine runs, that may be a violation of the law,” he said.

Wolter Group states on its website: “It is best to check with the engine manufacturer representative first before replacing the oil or coolant. Additionally, if there is an error code flashing on the display, your best bet is to call the nearest servicing dealer so they can diagnose and fix the problem.”

Part of your responsibility in maintenance is to change the fluids and filters under the hood regularly. Think about oil changes for a moment, because even this

Under the PC-11 standard, you’ll find new oil specified for your Tier 4 compliant engine. If you pick up the API CK-4, it is designed to work optimally with older and newer engines.

If you pick up the FA-4, it is designed to work optimally for the 2017 engines.

tried and true, routine maintenance item saw change as of 2016.

As fleet managers may have recently learned, heavy duty engine oils (HDEO)— labeled API CK-4 and FA-4—are part of the nomenclature in the Proposed Category 11 (PC-11) oil standard that hit the marketplace December 2016. PC-11 is the category in which we find the CK-4 and FA-4 specs. Some of the goals of upgrading from the former CJ-4 oils to the PC-11 category are to protect engines no matter what level of shear stress the oil will undergo in the engine, to protect against oil breakdown due to oxidation under higher operating temperatures, and to safeguard fuel economy.

We’ll lean on the Shell ROTELLA® Products website at rotella.shell.com for a breakdown of what’s different about the high temperature high shear (HTHS) viscosity oils available to the marketplace: In order to meet goals for more fuel-efficient engines and fewer emissions, many next-generation engines will run at higher operating temperatures. This will require changes in engine oil composition, so they can withstand more heat without sacrificing engine protection. It will also mean that instead of one category of engine oils, we’ll have two—CK-4 and FA-4.

CK-4 engine oils will be a direct replacement for the engine oils you’re using now.

You’ll be able to buy the same viscosity grades and oil types (conventional, full synthetic, synthetic blend) you’re using now, and they’ll be “backwards compatible” to ALL current vehicles. They’ll just also conform to the new PC-11 standards.

The new FA-4 engine oils will be offered in lower viscosity grades and are designed primarily for next-generation engines to help maximize fuel economy without sacrificing engine protection. These FA-4 oils may have limited backwards compatibility, and would be labeled as such.

If you feel the need to spend seven or eight minutes on this, Chevron has prepared a series of short videos at www.deloperformance. com debunking myths about PC-11 and the like. The point for this article is to let you know that you’ll find new oil specified for your Tier 4 compliant engine. If you pick up the API CK-4, it is designed to work optimally with older and newer engines. If you pick up the FA-4, it is designed to work optimally for the 2017 engines.

keep it up

All trucks must have a clean and visible “Construction Vehicle—Do Not Follow” sign.

It’s the law. Part of your daily, pre-shift walkaround should include looking at this sign to ensure it is clean, legible and in good repair.

Photo courtesy John Ball of Top Quality Paving & Training, Manchester, New Hampshire.

Maintenance Matters For the Quality of the Job

Keeping the haul truck in top notch condition does more than keep you in compliance with the DOT. If you’re an independent driver, you want contractors to hire you again, thus having a truck that contributes to bonus-worthy quality works in your favor. If you’re part of a company that maintains its own trucking fleet, each vehicle is a piece of the paving puzzle. Each piece requires maintenance for optimum performance. Start at the top.

You want to inspect the tarp—or canopy— each day to ensure it has no rips or tears. Look at the mechanism that lowers and raises the canvas to ensure it moves smoothly and completely. In other words, you don’t want the device to stop short, leaving the tarp to hover a foot or two above the HMA in the bed.

This leaves room for wind to whip in and cool the top of the material into a segregated shell while you drive from the plant to the job site.

Independent driver Steve Murray Trucking’s Murray installed a Slide-n-Go cover system from Cramaro of Stuart, Florida. This system runs on two cables that unroll and retract the canvas along rails, forming a lid on the truck body when closed. “If you have arms on the cover, you have to watch those don’t hit wires,” Murray cautioned.

“With the system Murray has, it holds the heat in the body,” John Ball of Top Quality Paving & Training, Manchester, New Hampshire, said. “You don’t want the tarp flapping like a sail as you drive down the road. You’ll lose heat from your perishable material.”

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Telematics is, at its core, machines talking to machines. The Guardian system from Roadtec, an Astec Industries company, allows machines to notify mechanics, operators or even personnel back at the OEM headquarters when it’s time for routine maintenance or when a system has “moved” out of its optimum settings. Depending on the type of package—or subscription—the contactor has opted into, a technician in the home office or OEM’s office can troubleshoot remotely or send a mechanic to perform maintenance in a timely fashion. Photo courtesy Roadtec, Chattanooga.

While inspecting the tarp before your shift begins, look into the truck bed. You’ll want to make sure it’s clear of clumps of yesterday’s mix, of course, but look for debris that may have blown in overnight. Take the time to pick out plastic wrappers, soda cans and anything else that has gotten in. Anything you see in the bed of the haul truck will get covered with mix and then will get carried into the hopper of the paver. Once it’s in the hopper, it will likely go into the mat, creating a quality control problem that spells deducts later. As the haul truck driver, you can stop that financial loss with just a few minutes of cleanup during your preshift walk-around.

Another way you can make your vehicle appealing to the paving crew is to make it com-

patible with paving equipment. For example, does your haul truck have a trailer hitch at just the right height to “grab” and tear the rubber on the front of the hopper? That leads to a potential mess each time trucks charge the hopper—giving laborers extra shoveling to do and an extra repair for the mechanic. The crew won’t be excited to re-hire you if you tear up the equipment. Instead, remove the trailer hitch on those weeks when you’ll be hauling asphalt.

Your truck will be more compatible with the paver if you can get the mud flaps out of the way, as well. Each individual state department of transportation (DOT) has different requirements of haul truck mud flaps— splash guards. You won’t find guidance on the

keep it up

Keep Paperwork on the Daily Walk-Around There’s more than a backup alarm to check before each shift to ensure your haul truck meets your state’s department of transportation (DOT) requirements for legal operation. With electronic data logging regulations in legal flux, you’ll want to err on the side of caution and keep a paper trail whether you’ve started using electronic logging devices or not. Starting under the hood, make sure these items are included on your daily pre-shift walk-around list: Good Not Good Motor/Engine ❒ ❒ Check Oil/Oil Pressure ❒ ❒ Other Fluid Levels ❒ ❒ Transmission ❒ ❒ Radiator ❒ ❒ Belts & Hoses ❒ ❒ Air Lines ❒ ❒ Battery ❒ ❒ Horn ❒ ❒ Headlights ❒ ❒ Direction Lights ❒ ❒ Strobe Lights ❒ ❒ Marking Lights ❒ ❒ Windshield Wipers ❒ ❒ Windows ❒ ❒ Mirrors & Side Mirrors ❒ ❒ Fire Extinguisher ❒ ❒ Flags, Flares, Fuses ❒ ❒ Spare Bulbs & Fuses in the Glove Box ❒ ❒ Starter ❒ ❒ Defroster/Heater ❒ ❒ Clutch (or automatic transmission) ❒ ❒ Backup Alarm ❒ ❒ Foot Brake ❒ ❒ Air Compressor & Gauge ❒ ❒ Parking Brake ❒ ❒ Steering ❒ ❒ Trip Recorder ❒ ❒ Frame ❒ ❒ Tarp/Canopy ❒ ❒ Fuel Tanks ❒ ❒ Front Axle ❒ ❒ Suspension System ❒ ❒ Wheels & Rims ❒ ❒ Tires ❒ ❒ Reflectors ❒ ❒ Safety Decals ❒ ❒ Muffler/Exhaust ❒ ❒ Mud Flaps ❒ ❒ Tailgate ❒ ❒ Direction Lights ❒ ❒ Taillights ❒ ❒ Source: John Ball of Top Quality Paving & Training, Manchester, New Hampshire

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FMCSA site because it doesn’t dictate policy on this item, but your state DOT will have regulations for the height the flap can hang from the ground, how much of the back tire it must cover, and the angle of flying debris it is to block. Check with your DOT’s website to make sure you start out in compliance. Then look into systems for easily lifting the flaps out of the way.

When you back the truck to the paver, you stop before making contact. When the paver operator moves the paver forward and brings the push rollers into contact with your vehicle, the push rollers are to touch the back wheels of the haul truck. If the mud flap is in the way, the push rollers now have the opportunity to deliver a jerking motion as the tractor moves forward. This will cause segregation in the mat. The push rollers also have the opportunity to tear the mud flaps. This means a repair for you later and possibly a chunk of polyurethane in the mat, which is another quality control problem. The push rollers also have the opportunity to leave asphalt mix on the mud flaps, which means more cleaning for you at the end of your shift. None of those scenarios is an efficient use of time or materials.

Instead, look for a system that will let you press a button in the cab to hydraulically lift the mud flaps when you enter the paving work zone. Or use this idea from Murray. He has extended the outer flaps of his rig from heavy duty chain. The chains keep the flaps hanging at the proper height for his DOT regs, and allow him to physically place the flaps on the fenders to keep them out of the way while he discharges the load. Check out Part 4 of this series, Move the Mud Flaps Out of the Way, next month for a full explanation.

As you can see, haul truck maintenance goes beyond changing fluids and filters on a regular basis. It goes beyond handling the big emergency repairs that crop up. By performing daily inspections and regular maintenance, you keep your vehicle in compliance and enhance your ability to contribute to a quality paving team.

– By Sandy Lender

The Owner Operator Independent Driver’s Association (OOIDA) has tips regarding hours of service regs and more at http://www.ooida.com/.

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Coastal Bridge Hits the Right Blend Ever since its formation in the 1950s, Coastal Bridge has focused on expansion and improvement.

As the name would imply, Coastal Bridge got its start building bridges in the 1950s before expanding to soil work in the ’70s and asphalt in the late ’80s.

Today, Coastal Bridge employs between 350 and 400 people in the asphalt division of the company, which also has bridge, industrial and commercial divisions.

Its four asphalt plants—all Astec double drums running 350 tons per hour—are located in Baton Rouge, Convent and Lafayette, Louisiana, and in Tampa, Florida.

Roughly 70 percent of the 400,000 tons of mix it makes annually gets laid by its four laydown crews on projects ranging from parking lots to interstate highways.

In the spirit of expansion, Coastal Bridge bought the Tampa plant just two and a half years ago, hoping to add another 150,000 to its annual tonnage. And, in the near future,

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Coastal Bridge also expects to add a fifth crew, based in Tampa.

And, in 2012, Coastal Bridge purchased its first Stansteel Accu-Shear Blending System to continue its history of continuous growth and improvement. After experiencing a slew of unexpected benefits, in addition to the ability to foam its mixes, Coastal Bridge purchased a second Accu-Shear for one of its other plants.

But, the road to this point was paved with plenty of issues—no pun intended.

Coastal Bridge Blends for Better Mix

When Coastal Bridge first began foaming its material eight or nine years ago, their foaming gun was a pain. The AC going through would often clog the water ports.

That’s when Coastal Bridge Manager Kent Langley first started conversing with Rick Rees from Stansteel about the Accu-Shear.

“We could see the benefits of the Accu-Shear would outweigh what we had at the plant already,” Langley said. These conversations just so happened to occur around the time Louisiana agreed to allow latex-modified asphalt cement (AC) to replace PG70-22 polymer modified AC. But, it would still be a while before Langley would get the equipment he now knew he wanted. Instead, Coastal Bridge purchased an inline blender.

“Some samples would pass and some would fail, because the latex was floating on top of the tube system, so it wasn’t totally blended in,” Langley said. So, the company tried a different, fluted blender and placed it on its Lafayette plant. Although it worked much better, it would use more latex to obtain the same values—1.7 percent through the Accu-Shear versus 1.8 to 1.9 percent through the fluted blender.

So, finally, the company purchased the Accu-Shear. “We put it on the Baton Rouge

Left: This Coastal Bridge plant is located in Port Allen, just west of Baton Rouge. Above: Coastal Bridge’s plant in Port Allen is an Astec double drum plant and produces 350 tons per hour. ed than without foaming or with our other foaming devices.”

“Think about flour—we have dust in this hot mix that’s that fine or finer,” Langley said. “Trying to coat that in a mass of 350 tons an hour gets to be a problem, but with foaming and expanding that liquid and changing its viscosity, that material gets coated better and we see that coming out of our drum. They’re coated better, from big to little.”

Now, Coastal Bridge foams every mix it makes, unless the specs forbid the practice.

Benefits Well Beyond Warm Mix Coastal Bridge’s asphalt plant in Convent is equipped with an Accu-Shear Blending System from Stansteel. plant and ran another job, and it was a piece of cake. The tests were consistent, the whole nine yards. It was great.”

Now, both its Convent and Baton Rouge plants have Accu-Shears, and the Lafayette plant continues to run the fluted blender.

Its Tampa plant uses the foaming system that came with its Astec plant.

“You didn’t see that volume increase with other foamers,” Langley remembered.

“We found with the Accu-Shear, because of the volume expansion it can create in the liquid, we have more fines being coat-

Langley estimates that foaming has saved Coastal Bridge between 8 and 10 percent a year in fuel costs and has substantially reduced its carbon footprint.

By using the Accu-Shear, Coastal Bridge also saw the amperage draw on its slat conveyors decrease when running a dynamically foamed mix. Langley also discovered he could keep foamed mixes in the silo longer and that the material released and flowed better.

“It’s funny that you can run the same amount of material foamed and still see a 10 percent or so drop in amperage,” he said. “It just generally seems that the foamed mixture doesn’t stick as bad or doesn’t have as much resistance as it’s sliding up that steep plate.”

Consequently, the machine’s motor doesn’t have to work as hard.

Although foamed mix can stay in the silo longer, Langley said it’s hard to expand your silo time, even if you hit the right numbers. Langley said the contractor picks the time he or she wants to hold mix in the silo, where it’s tested at certain time intervals.

“It’s the long-term testing that makes it impractical because the contractor and technician must both be present to test the mix—and you can’t use that one silo for anything else during this time,” Langley said. “Therefore, it makes it hard to increase silo storage time.”

But, he adds, after foaming the mix, it does stay up a little longer and comes out of those silo doors easier.

Generally, Coastal Bridge limits the range it hauls mix to 80 to 100 miles away from the plant. But, with properly foamed mix allowed to be made at a lower temperature, Langley reports they can go up to 30 percent further without reductions in temperature.

“If you put two trucks on the same road,” he said, “one full of mix at 330 degrees and one at 290, they’ll probably be the same temperature by the time they arrive on the job.”

Another place the foamed mix makes a big difference is for Coastal Bridge’s four laydown crews. Langley reports seeing increased compaction on foamed mix, even when the crew uses the same roller, in the same manner, with the same number of passes.

That means the crew can reduce its compaction effort by up to three passes, in some cases.

“That saves them 15 minutes, which means they’re 15 minutes further down the road,” Langley said. That means the crew is moving faster with fewer passes, an increased paver speed, and is laying more in terms of total tons by the end of the day.

“We used to think with rolling it was the hotter the better, but that’s not always true,” Langley said. “Working with mix at a lower temp might actually put it in a better temperature zone for compaction. If it’s too hot, the mat won’t react right. It’ll want to move and you could choke or push it.”

Langley also said it’s easier for the crew to work with a 300-degree mix than one that’s 325 degrees or higher.

Coastal Bridge is one of only a few companies using liquids modified with ground tire rubber (GTR).

www.THeAsphaltpro.com // 29

producer profile “What’s funny is if it drops to 300 degrees, it doesn’t get any stiffer,” Langley said. “It still works as good at 300 for handwork as it did at 325 or 340 because of foaming.”

Overall, Langley said, the crews like working with the foamed mix.

“When we first started experimenting with shingles, they complained,” he recalled. “But they’ve never complained about this.”

What Makes a Mix “Warm”

Coastal Bridge acquired the plant in Tampa, seen here, only two years ago. It plans to significantly ramp up production at the plant and establish a fifth paving crew in Tampa.

Coastal Bridge purchased its first Stansteel Accu-Shear Blending System in 2012. After noticing its many benefits, the company purchased a second Accu-Shear for another of its plants.

30 // july 2017

In Louisiana, Langley said, the state wants to see a reduction in temperature if a plant is foaming its mix. However, the lower limit is typically 275 degrees.

Coastal Bridge runs at 290 degrees, for a bit of added flexibility.

“If it gets lower than 275, the inspector has a reason to throw it away,” Langley said. “We wanted to make sure that doesn’t happen, so we bumped it up to between 290 and 300 degrees.”

That means if they hit a wet spot in the stockpile and the temperature drops 10 or 15 degrees, the load is still acceptable. That extra bit of heat also had a positive impact on the mix quality.

“When we first started foaming, we were looking at mix coming out at 275 and thought, ‘Okay, it looks pretty good—better than it did without foaming,’” Langley said. “Then we kicked it up 10 degrees and thought, ‘That looks pretty dang good.’ So we went up a bit more to 290, and saw that it was way better than the first and somewhat better than the second.”

Producers can go below 275 degrees if the producer can provide substantial proof that the liquid can achieve the same standards at lower temperatures. That requires suppliers to write a letter confirming their materials can achieve those standards, but Langley said suppliers are often hesitant to do so.

“If [the supplier] says I can do it, but I have to run it a lot hotter and spend more fuel to get it where it needs to be, they know they’re going to be locked into an arbitration matter because the chemical didn’t do what it said it would,” Langley said.

Instead, most of Coastal Bridge’s mixes are Superpave. Around 70 percent of Coastal Bridge’s paving jobs are state work and 30 percent, private sales.

and get the state to do a study to allow RAS in specifications.”

Coastal Bridge Experiments with the Accu-Shear Coastal Bridge also uses its Accu-Shear to make its cold mix, produced at its Baton

Rouge plant. “We run our cold mix liquids through the Accu-Shear to enhance our cold mix—one of them being latex to turn our cold mix into polymerized cold mix. It’s SBR, not SBS.” That’s also the plant where Langley has done his experiments with RAS, as well as experiments with various chemicals for

Coastal Bridge performs nearly every type of test for virtually any specification, Langley said. The only thing Coastal Bridge doesn’t test for itself is liquid AC, instead buying certified liquid from refineries in the area.

“In Louisiana, state work is predominantly a form of Superpave consisting of two sections—a true Superpave mix and thin lifts, which covers OGFC and other mixes as thin as ¾ of an inch,” Langley said. “We also do Marshall Method mixes for older regimes in cities and parishes.”

Coastal Bridge also makes airport mixes.

It has labs in each of its plants, but its main lab is in the Baton Rouge plant.

“We can run all the tests we need for virtually any specification,” Langley said. The only thing Coastal Bridge doesn’t test for itself is liquid AC, instead buying certified liquid from refineries in the area. “The only AC we test is DSR, dynamic shear rheometer, which the state requires we run daily.

The fancier tests we ship out to private testing labs.”

Langley estimates that the percentage of RAP Coastal Bridge runs is anywhere from 15 to 30 percent, depending on the job specifications. They’ve toyed with recycled asphalt shingles (RAS), he adds, but he says he’s still learning.

“Most mix we’ve run with RAS has been on a purely experimental basis,” he said.

“The owner of Coastal Bridge develops subdivisions, so we’ll pave a street as we try to learn how to handle RAS, find the right rejuvenators and compile data in the hope that one day we can have the process right

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producer profile rejuvenation, and rejuvenating and foaming at the same time.

With the Accu-Shear, users can buy them with a handful of ports to inject several different liquids at the same time, or simply as a water foamer.

Langley is even thinking about getting a second Accu-Shear for the Baton Rouge

plant, for a number of reasons. First, he wants to better integrate antistrip into his mix.

Louisiana requires plants to use a minimum of .5 percent antistrip of any brand the plant chooses. Langley said most plants use an amino-based antistrip. However, Coastal Bridge can’t use the Accu-Shear system for this particular mix design process because

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The Accu-Shear comes with a 275-gallon water tote with a fill valve with auto shutoff, mounted water and electrical enclosures, and lifting eyes and forklift pads. the specs require it to be injected after the sampling point when blending latex or some other type of product into the liquid.

“They want to test that the latex is doing what it’s supposed to be doing, and some antistrips when mixed with liquid can cause it not to meet the particular grade qualities,” Langley said.

Second, he wants to do some experiments with rejuvenators and expand the variety of products he may want to add, especially as he continues his RAS and RAP experiments.

“I feel we need to rejuvenate the liquid before we foam it, especially if I get big into the use of rejuvenators or other chemicals,” Langley said, which is a possibility if he continues his work with RAP and RAS. “If I’m running 50 percent RAP or 5 percent RAS, I may not want to do everything all in one Accu-Shear.”

Having two Accu-Shears at one plant also means that Langley can test the mix after adding a rejuvenator, but before its foamed, and then test a second time on the blended modified liquid. “I think foaming needs to be in the last section,” he said. “At the price of an Accu-Shear, I’d rather have two and be prepared for the future.”

“When we want to do something with our Accu-Shear,” Langley said, “Stansteel can normally come up with an answer for us. It’s been a great relationship for us, to be able to try out so many new things.”

– By Sarah Redohl

32 // july 2017

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that’s a good idea

Here Steve Murray of Steve Murray Trucking, Hooksett, New Hampshire, points to the sunroof he had installed for safety on his truck. All photos courtesy John Ball, Top Quality Paving & Training, Manchester, New Hampshire.

Save on Costs with Your Professional Guide to Asphalt Mix Delivery Part 2—Put in an Eye to Safety For the 2017 paving season, we dive into an essential area of project management for asphalt professionals: safe and timely delivery of hotmix or warm-mix asphalt (HMA/WMA) to the paving site. During this eight-part series, you’ll get some back-to-basics best practices to share with veteran and new haul truck drivers, in addition to new tips, ideas, and case studies with logistics and technology that will enhance your bottom line. Producers have streamlined processes

F

36 // july 2017

at the plant; contractors have nailed down best practices in the work zone. Now it’s time to harness the potential you’ve been missing when it comes to mix delivery and haul truck fleet management.

This installment looks at the roof of the haul truck cab. That might sound odd at first, but think about the dangers overhead that the haul truck driver doesn’t see when he’s sitting behind the wheel.

The paver operator, dump man and screed operators are tasked with watch-

ing the hopper, the head of material, the movement of mix out of the truck body, the mat behind the screed and much more.

Their attention is typically focused downward, not up. If the paving train moves forward at 20 feet per minute, the paver may push the truck, with its body in the air, right into a mature tree branch or—worse—into live wires. The downtime involved when a truck gets tangled up in wires amounts to thousands of dollars at best, serious injuries at worst.

If your haul truck gets tangled up in wires, the National Institute for Occupational Safety and Health (NIOSH) best practices recommend that you do not exit the truck. Stay inside and don’t reach out.

Other crew members should not approach the truck and should not attempt to untangle wires.

A member of the crew will contact the utility company, of course, but will also contact emergency responders to assist.

Trying to exit the cab before the utility company has ensured power has been cut off to the affected wires can result in serious injury or even death.

Some companies have wisely implemented the use of fluorescent-green colored safety cones with the word “danger” painted on them to designate utility poles with overhead hazards and the like. This doesn’t mean a dangerous situation is resolved. Truck drivers still need to be on the lookout for dangers overhead.

When independent haul truck driver Steve Murray wanted extra safety, he in-

The sunroof Steve Murray had installed for safety on his truck’s cab allows him to see overhead wires and tree branches from the safety of the driver’s seat. He said the $750 it cost to have the sunroof installed is the best investment he’s made. stalled a sunroof in the cab of his truck. For the reasonable cost of about $750, Murray made it possible to see overhead obstructions and hazards from the driver’s seat.

“I can see wires, trees, branches,” Murray said. “It’s the best investment I ever made.”

When he’s on a job, he doesn’t have to rely on overworked and overwhelmed ground personnel to watch out for him; he

can see what’s above his truck and act accordingly to prevent mishaps. While he stated that each job “needs a guy on the ground watching the overheads,” he has peace of mind now that he can see above the cab for himself.

“Now I don’t have to worry about whether the guy on the paver is distracted.”

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Raise Funds for Industry’s Fallen

C

Construction Angels Inc., Pompano Beach, Florida, is a national non-profit organization that was created to provide immediate financial assistance and grief counseling to the families of construction workers who have lost their lives while working on the jobsite. The organization’s vision is to be there for those families.

Its website states: “We support their surviving family members when such an incident occurs, and facilitate aid during their time of immediate need. Our goal is to assist the family at the beginning of their grieving process with hopes to provide them with a sense of comfort, both financially and emotionally. Construction Angels wants to make an everlasting impression and impact within the industry, one family at a time.”

Founder Kristi Ronyak met with AsphaltPro staff during CONEXPO-CON/ AGG 2017 to share updates on the organization’s goals. She was deep in the planning stages of the Alligator Ron’s WingsFest 2017, which is an important fundraising event for Construction Angels.

The third annual event was held at the Bergeron Rodeo Grounds in Davie, Florida, April 15, and featured an all-day battle of the best chicken wings and sauces from at least 14 of the best restaurants in the area with celebrity judging. Live rock and country bands entertained a record-setting audience. Alligator Ron’s WingsFest is designed to bring beer and chicken wing fans together each spring for an unforgettable experience that pairs music with meaning—all to raise awareness and funds for construction fatalities in the state of Florida.

Because Construction Angels is a national organization, Ronyak seeks ways to expand its good work beyond the headquarters of Florida. Currently, Construction Angels operates in Florida, Georgia and Ohio; and expanded operations to Mich-

By AsphaltPro Staff

igan in early 2017. A Michigan contractor, Giannetti Contracting Corporation in Sterling Heights, is fundamental to that recent piece of success.

Giannetti’s President Richie Gibbs III has accepted the position of director of Construction Angels Inc., and he wrote: “This is an organization I am very passionate about. Construction Angels is a South Florida-based, non-profit organization, created to facilitate access to financial assistance immediately to the surviving children and/or surviving spouse of construction workers who have lost their life while working on the jobsite. Construction Angels also provides grief counseling to those families who have lost loved ones in our industry. We have partnered with various organizations and charities to ensure Construction Angels is able to assist these families during tragic times. Our goal is to operate in every state and to assist these families around the United States.”

“Our goal is to operate in every state and to assist these families around the United States.”—Richie Gibbs III, Director of Construction Angels Inc. To help the organization help more families in their most dire time, everyday workers can get involved without traveling to Davie, Florida, for the annual WingsFest.

Construction Angels hosts a number of golf tournaments, clay shoots, comedy nights and other events throughout the year to give the community at large opportunities to pay it forward to help our construction workers’ families. A listing of events in the four regions resides on the Construction Angels website at http://constructionangels.us/.

Ronyak has another, easy way workers can pay it forward to help one another. There’s a “donate” tab on the website where anyone can select from a host of tax-deductible methods for giving to the cause. Then, on the back of this article, you’ll find an employee payroll contribution form that makes sustained giving easy to do. By providing the form to your human resources department, you authorize the payroll department to deduct a dollar or two—or whatever you are comfortable donating—from each of your paychecks. This makes your donation a recurring tax-deductible event that you don’t have to physically perform.

The way Ronyak explained it makes perfect sense. Not everyone can afford to donate $50 or $100 to a charity in one lump sum. But most people can afford to donate $1 or $2 each pay period. That may not seem like much to the person doing the donating, but it adds up for the Construction Angels and for the families who suffer a tragedy down the road.

At press time, Construction Angels was hard at work preparing for the next fundraising events in the four regions in which it operates, and working to incorporate offices in additional states. With time and industry support, Ronyak’s excellent organization has already helped families find calm and peace; with time and industry support, this organization will be able to expand its good work. AsphaltPro magazine is honored to bring attention to this good work and to increase awareness of construction safety.

www.THeAsphaltpro.com // 39

Your tax deductible donations help support families that have lost a loved one, working on a construction site

Construction Angels, Inc. 501(c)3 Payroll Deduction Form Dear Construction Employee,

Construction Angels, Inc. provides immediate financial assistance to surviving children and spouse of a construction worker’s family when they lose a loved one to an onsite construction fatality. Your decision is yours alone to make, but Construction Angels will be there to help you or your friend’s family, pick up the pieces, if a tragedy such as this should occur.

Is your family prepared? Everyone expects to return home at the end of the day to our families, but for unforeseen accidents, the loss of a family member or friend is heartbreaking.

Construction Angels hopes you and your family will consider the option to support “One of our Own” in the construction industry.

Instructions • Use this form to file for deductions from your payroll.

• You can obtain additional copies of this form, by asking your HR department.

• Print in capital letters with blue or black ink. Give a copy of this form to your Employer.

• Note: Your deductions will be automatic every pay period.

• Visit www.constructionangels.us for more information about this charity you are donating to.

1. What would you like to do? (Check only one box, and then complete all sections of this form.) ❒ Establish Payroll Deduction (Check this box to establish payroll deduction for the first time.) ❒ Increase or Decrease Amount (Use this form to increase or decrease your deductions. To stop payroll deduction speak with your employer.)

2. Contribution Instructions (You must complete all applicable parts of this section.) ✓ Tell your employer how much to deduct from your pay each pay period.

The minimum contribution is $1 per week option, per pay period.

Please Circle Contribution Amount per pay period: $1 $2 $3

$4

$5

$10

✓ Tell your employer when to begin these deductions.

Unless otherwise indicated, your deductions will begin as soon as possible following receipt of all paperwork in good order.

Effective Date (MM/YY): ______________________________________ 3.Employee Authorization and Signature By signing below, I authorize my employer to process periodic deductions from my paycheck for contribution into the Construction Angels, Inc. Fund.

This authorization will remain in effect until canceled by me or by the Employer, Charity, or upon termination of my employment with my employer.

Employee Signature_______________________________________________________ Date___________________________________ Construction Angels, Inc. • 3640-B3 N. Federal Hwy, Suite 132 • Lighthouse Point, FL 33064 754-300-7220 Office • www.constructionangels.us

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WMA Use Increases Gently

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By Kent Hansen, Audrey Copeland, T. Carter Ross

In 2007, a group of asphalt pavement experts from the United States travelled to Belgium, France, Germany and Norway to learn about various warm-mix asphalt (WMA) technologies as part of a Federal Highway Administration (FHWA) technology scanning tour.

Eight years later, what was once an interesting idea is now a standard practice across most of the nation. In 2015, about a third of total asphalt mix produced in the United States was produced as WMA with a temperature reduction of at least 10°F compared to hot-mix asphalt mixes.

For each construction season since 2009, the National Asphalt Pavement Association (NAPA), working cooperatively with FHWA, has surveyed the industry on the use of WMA, as well as the use of recycled materials. The 2015 construction season survey results were released in March 2017, and NAPA is currently surveying the industry about use of these technologies and materials during 2016.

The first survey found that barely 43 percent of U.S. mix producers used WMA technologies in 2009 and only about 16.8 million tons of WMA (4.7 percent of total tonnage for the year) was produced. Since that time, growth in warm-mix production has increased dramatically, although the adoption curve has begun to plateau (See Figure 1).

During the 2015 construction season, some 119.8 million tons of WMA was produced, making up 32.8 percent of total production during the year. Seventy-eight per-

42 // July 2017

IS-138 is now available. To download a full copy of the survey, visit www.AsphaltPavement.org/ recycling. cent of producers reported using WMA to reduce production temperatures, and about 60 percent of respondents noted they also use WMA technologies at hot-mix asphalt temperatures to gain construction benefits.

The 2015 numbers are a dramatic 613 percent increase in WMA tonnage and a 600 percent increase in the use of WMA when considered as a percent of total tons since 2009. It is also a greater than 5 percent increase in tonnage over the 2014 construction season and a 1.6 percent increase when considered as a percent of total tons.

State departments of transportation remain the biggest customers for WMA. Nearly 37.4 percent of tons produced for DOTs was produced as WMA. For other public agencies, such as cities and counties, 34 percent of the tonnage was WMA. For commercial and residential customers, the percentage was slightly higher at 34.3 percent.

Figure 2 shows WMA use as a percent of total asphalt mixture production in each state. WMA makes up over half of the total asphalt mix production in 14 states, and four of them—Kansas, Louisiana, Virginia

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Figure 1. Percent of Total Tonnage Produced as WMA from 2009 to 2015

Figure 2. State-by-State Percent of Total Tonnage Produced as WMA in 2015 and Wyoming—reported WMA as 75 percent or more of total production in 2015. Nevada, West Virginia and Rhode Island did not report the production of WMA in 2015.

As states continue to update specifications and approve WMA technologies, room for growth in WMA production remains.

Of the available WMA technologies, plant foaming remains the most common, being used for 72 percent of the WMA produced in 2015. The use of chemical additive technologies reached an all-time high

44 // july 2017

in 2015, accounting for a little more than 25 percent of the WMA produced. Additive foaming and organic additives make up the remainder of the market. The percent of WMA produced with additive technologies has grown significantly since 2011 when they made up less than 5 percent of the WMA technologies used.

In total, 214 companies representing 1,119 plants participated in the survey. Responses came from 48 U.S. states plus Puerto Rico.

Kent Hansen, P.E., is director of engineering for NAPA and manages the annual survey.

Audrey Copeland, Ph.D., P.E., is vice president for engineering, research and technology at NAPA. T. Carter Ross handles communications for the association.

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Nearmap Aerial Imagery Helps Lindy Paving Improve Processes

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Innovative employees know how to make a job flow more smoothly for a company.

For Lindy Paving Inc., based in New Galilee, Pennsylvania, employees took on a collaborative effort between operations and IT to develop a field data collection app that helps the company manage increasing numbers of paving projects. Project Engineer Kyle Monceaux and Senior IT Business Analyst Steve van Vliet reached out to Robert Carroll, the vice president of commercial initiatives for Nearmap, a location content provider specializing in high-resolution, aerial imagery, to set up a mapping technology within the app. Now the new app helps Lindy Paving lower expenses while increasing revenue.

The field data collection app is browser-based and designed to increase efficiencies in communication and project management of its 400 plus paving projects conducted each season. Created for both field and office use, the browser app replaces reams of paper maps, spreadsheets and PDF files, while allowing planners and estimators to prepare for projects without physically going to the site.

“We needed a simple, mobile map to relay project progress and provide communications between Lindy field staff, estimators, project managers and executives,” Monceaux said. “It also helps provide the planning information we need for next year’s projects.”

Monceaux explained that Lindy Paving crews operate in urban environments where it is often difficult to get to the project site to assess each parking stall or piece of pavement. In the past, the company had to send a field engineer to walk the site and take pictures of problem areas.

General consumer grade technology such as Google Earth could not provide them the detail that project managers need-

46 // july 2017

From Nearmap and AsphaltPro Staff

ed, but Monceaux spoke directly about the quality he can get from the Nearmap professional grade technology. “The imagery is so clear we can see cracks that need to be addressed.”

Carroll explained how the images are collected. “We use manned aircraft flying at high altitudes to get over the noise of air traffic, yet can get the high resolution clients need. We developed our own camera and data collection system.” The Nearmap photography takes tens of thousands of high-resolution pictures over an area, and then technicians use cloud-based processing to stitch the images together seamlessly to reveal pictures of sites with clarity down to three ground inches or better.

In future versions of the app, Lindy plans to build in tools allowing calculations and drawing directly on the Nearmap imagery to determine exactly where objects will go on any given project.

Lindy’s custom app shows active and archived projects on a map merged with Nearmap aerial imagery that can be zoomed in and out as needed by the user. For example, one of their clients – a large utility company – works with Lindy to repave roads and sidewalks of the hundreds of infrastructure repair locations they work on each year. The aerial images show Lindy crews the exact locations of their projects. “It makes it very easy for us to look and see where our projects are located for planning and execution purposes,” Monceaux said.

Planning is something Nearmap can assist clients with thanks to the regularity and frequency of flights and image collection. Carroll said the flights take place several times a year, which means pictures are updated on a regular basis, keeping images current.

“We’ve been collecting since 2014, so some of these areas have six or seven refreshes.

So we can see and track changes over time.

We can see erosion or construction changes or other contributing factors” to an area’s change, and give that additional data to an agency for pavement maintenance planning.

Lindy Paving Inc. is the largest asphalt paving contractor in Pennsylvania. Lindy has consistently delivered award-winning asphalt paving and product manufacturing. By 2009, the company had garnered three of the National Asphalt Pavement Association’s Sheldon G. Hayes awards and has continued to attain Quality in Construction awards since then. The company boasts five asphalt plants and a terminal in the state to serve its own paving crews as well as customers. The drum mix plants are set up to produce any mix design for commercial, municipal or state projects, including warm-mix asphalt when needed.

Monceaux said he couldn’t speak highly enough about the encouraging culture at Lindy Paving where award-winning work and ideas can flourish. The collaborative team had leadership’s full support in developing the field data collection app. “Lindy Paving is family oriented and they give freedom to develop ideas. If you bring an idea forward and they like it, they’ll let you go the distance with it. You can approach any one of their executives and sit down to discuss an idea.” He explained that even an idea that isn’t fully “attainable” may have a part that someone will help you expand. It’s a culture of encouragement and innovation for the end result of growing an entire business.

Left: Kyle Monceaux, project engineer at Lindy Paving who worked with the team on the field data collection app. Middle: Steve van Vliet, senior IT business analyst in the Lindy family of companies who worked with the team on the field data collection app. Right: Robert Carroll, vice president of commercial initiatives for Nearmap, a location content provider specializing in highresolution, aerial imagery.

Nearmap’s aerial imagery allows all the players to come to the table through the app. In future versions of the app, Lindy plans to build in tools allowing calculations and drawing directly on the Nearmap imagery to determine exactly where objects will go on any given project, which will help in developing estimates.

Lindy built the storage and retrieval system using SQL, ArcSDE, ArcGIS Server,

Amazon S3 media storage, and aerial map services provided by Nearmap.

Lindy Paving’s field data collection app is proving to be a big hit among the company’s project managers, estimators and planners by providing: Better planning and estimates—Nearmap aerial imagery allows Lindy to view new projects and better plan without onsite visits, resulting in cost savings and faster estimates.

More efficient crew management—The Nearmap imagery allows crews to see the project site before they physically go there. It does not require a lot of clicks and steps to get to the information they need.

Pre- and post-construction information— Nearmap within the app provides all the key data points and a whole view of the project lifecycle. Visibility and access to all key data points allows Lindy to better plan and prioritize projects, which leads to increased projects and revenue.

Reduced staffing—The increased effectiveness of all parties involved has eliminated the need to add additional staff to manage the more than 400 projects completed in a single paving season.

“We are grateful for our partnership with Lindy Paving,” Patrick Quigley said. He’s the senior vice president and general manager, North America at Nearmap. “They are utilizing Nearmap aerial imagery in a unique way to improve their business processes and strengthen their bottom line. This type of innovation allows Lindy Paving to make informed decisions rapidly. They plan and deploy resources in a highly efficient manner.”

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www.THeAsphaltpro.com // 47

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Asphalt Drum Mixers

Innovation in the Asphalt Industry

Part 1—How to Take Your Idea to the Next Level

By Brian Mack and Anna Quinn

rels are collected and moved on or off of the road, without knocking the barrels over. “I was just trying to come up with something to keep the guys safer,” Ruby said.

Ruby formed his own company, BarrelMover 5000 LLC, and filed for patent protection for his system. “I wasn’t planning on doing anything else with it, but my supervisor encouraged me to obtain patent coverage Advancements in the asphalt industry make paving America’s roads safso no one else would take and copy my equipment,” Ruby said. er and more efficient, and result in more robust pavements. EnhanceWhat you can do with your invention depends on the circumstancments and improvements come from a variety of sources—original equipment manufacturers (OEMs), plant operators, and other industry es surrounding how you conceived it, and your employment situation workers. So what do you do if you’ve come up with a great idea, making at the time of the invention. First, regarding the circumstances of your your asphalt work easier, quicker, safer, or better? What should you do invention, did you create the invention on your own or did someone with your idea? Who do you tell? What steps can you take to protect your else help you create the invention? Believe it or not, this simple quesidea? Is your idea patentable and should you consider filing for a patent? tion has been the subject of much litigation and conflict over the years.

What things can you do for prototyping and developing your invention?

If you created the idea on your own and on your own time and with How does the process of obtaining a patent work? What do you do with your own resources, then you can generally control what you can do a patent once it is awarded? These questions and many more will be anwith the idea. For Ruby and his BarrelMover, he developed the prodswered as part of this three-part series written to provide you with some uct at home, on his own time, and then tested it in the field. Howevimportant information about the role intellecer, if you jointly created the idea with another person, then you are each considered to be an tual property, such as patents and trademarks, inventor, and, absent an agreement otherwise, plays in road construction, and specifically the Although there may be a each has a right to the invention. asphalt plant and paving industry. desire to prototype and/ Second, your employment situation will also Asphalt equipment OEMs have developed or test out your idea, it impact what you can or cannot do with your many improved systems and technologies new invention. If you are employed by a comover the years to make paving safer and quickmay be better to keep any er, and ultimately deliver a better finished road pany or work as an independent contractor for such plans secret until surface. However, many of the best ideas come a company, often times, many employers have after a patent application from those who are trying to improve the way an intellectual property clause included in an has been filed. they perform their day-to-day jobs. For examemployment contract. Under a typical intellecple, many industry professionals will often rectual property clause, an idea, if created on comognize and implement a safety improvement or pany time with company resources, is considan improvement to a piece of paving equipment or asphalt plant comered property of the company/employer. Often times, such employment clauses require the employee to assign his or her rights in the invention ponent. Chances are, if you haven’t already had an idea or two over the to the company. If you work for a company and have created a new inyears to improve how you do your job, you will at some point.

Kyle Ruby of BarrelMover 5000 LLC, Dry Ridge, Kentucky, is an vention, consider contacting your supervisor or an in-house attorney, if example of an individual who came up with a better and safer way of there is one on staff, to determine what corporate procedures, if any, are performing road work and turned it into a successful business. When in place for inventors and their ideas. Although your invention may be lanes are closed for paving or other roadwork, cones or barrels are ofcompany property, a number of companies often have an inventor proten moved on and off of the road manually by the road crew. This takes gram to award inventors for their creativity, as your creativity helps to considerable time and also puts workers in harm’s way by having the improve the company’s overall value. road crew near moving traffic. Ruby developed a system that connects It is imperative for an inventor to thoroughly document his invento a vehicle such that when the vehicle is driven down the lane, the bartion. For example, notes outlining details of the invention, such as how Editor’s Note: The information contained in this article is provided for educational purposes only and does not constitute legal advice nor result in an attorney-client relationship with the reader. Any questions about how this information might affect your particular situation should be addressed to an attorney.

A

50 // july 2017

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

Kyle Ruby of BarrelMover 5000 LLC, Dry Ridge, Kentucky, developed the product at home, on his own time, and then tested it in the field. Ruby’s supervisor at the time encouraged him to obtain patent coverage so no one else would take and copy his equipment. AsphaltPro featured the safety product in the Here’s How it Works department at http://theasphaltpro.com/the-barrelmover-5000/. ever, a public disclosure of your invention, such as a commercial offering for sale, prior to filing your patent application, can bar you from obtaining patent protection. Therefore, although there may be a desire to prototype and/or test out your idea, it may be better to keep any such plans secret until after a patent application has been filed.

In part two of this series, we will look at some important things to consider when bringing your new idea to market, including non-disclosure agreements, business formation, obtaining investor support, and some important business aspects such as operating as an individual versus as a corporation. Finally, part three of this series will provide you with some guidance regarding the patent process, including parts of a patent application, performing a patent search, the rights conferred by a patent, and the limitations of patent coverage.

A.J. Ronyak of Odor Solutions Group, Arizona, developed his product while a plant operator back in the 1990s. He applied for the U.S. patent of his odor eliminating additives in March 2000, received the patent in October 2002, and also patented the additives in Europe and Canada. it operates and what it looks like, the date of conception, the parties involved and their respective contributions, are all important details to be recorded. These details will be helpful to the patent attorney who prepares your patent application, but can also be used in the event there is a dispute over inventorship or ownership of the patent.

While it may be necessary to prove your idea commercially through a working prototype, no such working prototype is required to prove patentability of your invention at the U.S. Patent & Trademark Office. How-

52 // july 2017

Brian Mack and Anna Quinn are registered patent attorneys with Lathrop & Gage LLP in Overland Park, Kansas.

Their work includes counseling clients on various intellectual property issues including drafting and prosecuting patent applications, trademark applications, licensing patents, enforcing patents, and avoiding patent infringement. Their client base spans different technologies and industries including general mechanical, construction equipment, power generation, aerospace, energy, biological, and chemical industries. For further information, contact Mack at bmack@ lathropgage.com or Quinn at aquinn@lathropgage.com, or visit www.lathropgage.com.

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

This is What’s New for Paving and Pavement Maintenance This Season While many original equipment manufacturers (OEMs) launched new equipment models during CONEXPO-CON/AGG 2017 in Las Vegas March 7 through 11, some companies still have new components, upgrades, tech packages and even new iron coming to market now that we’re into the heart of construction season. For example, if you’re looking for a puncture-proof radial tire specifically for compact loaders, the research and development team at Magna Tyres Group out of The Netherlands, introduced its new Magna MA11 Tyre with an E2/L2 tread pattern for road, residential, commercial and landscaping applications April 6. The manufacturer says its high-tech casing reduces heat buildup inside the tire, which offers lower fuel consumption and prolonged service life. To contact someone about the Magna MA11, you email info@magnatyres.com.

Another example of post-CONEXPO launches is the commercial cold planer series from Caterpillar—the PM300s. The series will be available in September.

Even the peripheral equipment you must have on every job has some news. Schwarze Industries out of Huntsville, Alabama, for instance, announced in early April a free 5-year/5,000-hour extended warranty program on its A7 Tornado, A8 Twister and A9 Monsoon sweeper engines. The company says the extended warranty is portable and transferable, and covers “reasonable” travel expenses for John Deere service dealers so you can get help virtually anywhere in the United States and Canada. For more information on that, you have to contact your local Schwarze dealer or call Schwarze direct at (800) 879-7934.

Check out some other paving and pavement maintenance related products and services that have hit the marketplace this year to enhance your bottom line.

W

ALLMAND BROS.

Allmand Bros. Inc., Holdrege, Nebraska, a subsidiary of Briggs & Stratton Corporation, ex-

54 // july 2017

The smallest unit in the new Maxi-Power line from Allmand Bros., the MP25, pictured here, uses a 33.3-horsepower engine and provides 20 kilowatts of prime power. pands its product offerings with the introduction of Maxi-Power™ mobile generators.

The line includes seven maneuverable generators ranging in output from 25 to 50 kilovolt amps. The generators feature a heavy-duty, oversized alternator with separate excitation winding to handle large motors and variable loads. The automatic voltage regulator is designed to adjust quickly to provide stable and consistent voltage for powering sensitive equipment. Maxi-Power generators switch between 50- and 60-Hertz frequencies. All models adjust between 120, 240 and 277 volts in single-phase power, and 208, 240, 415 or 480 volts in three-phase. An electronic governor maintains engine speed independent of the load. The Maxi-Power series features programmable start and stop capabilities for use as a standby system.

Features include a large-capacity fuel tank, external fuel connections, a high-capacity cold start battery, a dual filtration system, durable 15-inch tires and an adjustable couple channel for towing ease.

For more information, contact (800) 5621373 or info@allmandcom.

of the screening blades that spin between the screening combs. The end product size is defined by the space between the combs. Because the screening combs carry most of the material weight, the drums and bearings experience less impact and load.

The TS drums are available with two different blade types: standard for screening applications; axe for crushing or shredding.

Available blade sizes include: 0.63/1.26 inch, 0.98/1.97 inch and 1.38 inch. The TS assembly is available in seven different models for 17.6- to 49.6-ton excavators and 7.7- to 33ton wheel loaders.

For more information, contact ALLU Group at (800) 939-2558 or visit www.allu.net.

BOMAG AMERICAS

BOMAG Americas, Ridgeway, South Carolina, has released the RS500 reclaimer with FLEXMIX. The extra breaker bar assemblies and an additional variable-position mixing door within the rotor chamber of reclaimer/stabilizer are designed to allow contractors to achieve consistent and controllable gradation with a simple toggle switch. The optional FLEXMIX, adjustable door is located above the rear discharge door to provide flexible mixing of material inside the rotor chamber. Check out the Here’s How it Works feature on page 66 for a full description.

For more information, contact Tim Hoover at (660) 580-0350 or tim.hoover@bomag.com.

ALLU

ALLU Group of Teterboro, New Jersey, has introduced the patented ALLU TS® drum assembly construction, which lets customers reposition standard screening blades to perform multiple jobs with one unit. The core of the ALLU TS technology is the configuration

The RS500 from BOMAG Americas has a forward operating speed of up to 164 feet per minute, and uses variable rotor speeds from 100 to 180 rpm to match rotor speed to the application.

ASTEC Parts. We’re Here. Always.

Combine the world’s largest inventory of in stock parts for asphalt plants, the ability to build and machine custom parts and a fully staffed department of salesmen, technicians and engineers and you have ASTEC parts.

• Over 100,000 parts in stock • OEM for ASTEC, DILLMAN, Barber-Green, EssTee & McCarter • In-house parts techs and engineers available 24/7 • Over 406 combined years of experience ready to help you

800.251.6042 • www.astecparts.com

product gallery

The new DV45CC asphalt compactor from CASE is designed for groundline serviceability.

CASE CONSTRUCTION EQUIPMENT

CASE Construction Equipment, Racine, Wisconsin, launched the new DV45CC combination vibratory roller in March. The new vibratory roller is designed to compact with the front drum and deliver a smooth finish with the rear pneumatic tires. An offset drum with tapered edge and high curb clearance is designed for tight spaces; adjustable scrapers, an automatic vibration control system and a pressurized water system offer smoothness for asphalt applications. It features an operating weight of 10.296 pounds and a drum width of 54 inches.

The DV45CC has a 40.8 horsepower Tier 4 Interim engine. It features standard dual amplitudes of 0.01/0.21 inches and dual frequencies of 2,700/3,420 vpm. The automatic vibration control system provides automatic or operator-controlled start and stop to the drum.

For more information, visit CaseCE.com.

HAMM

At CONEXPO-CON/AGG 2017, Hamm, a Wirtgen Group company, Antioch, Tennessee, showcased new asphalt and soil compactors to boost contractor productivity via unique

The Easy Drive operating concept is available from Hamm.

56 // july 2017

product innovations and intelligent operation. A highlight for asphalt construction is the DV+ series of pivot-steered tandem rollers, which feature the new Easy Drive operating concept.

The DV+ series tandem asphalt rollers feature vibration with split drum and exclusive Hamm Oscillation compaction. The DV+ series is available in three models: with double vibration (VV), with one vibration and one oscillation drum (VO), and as a combi roller (VT). All models are available in a ROPS version or with a fully tinted panoramic cab.

With both versions, the driver has a view of the drum edges, the edge pressing and cutting equipment, as well as the construction site. Viewing panes in the cab floor ensure the driver can always see the rollers or wheels.

The Easy Drive operating concept provides top-class ergonomics and comfort in the cab, according to the manufacturer.

• Tier 4 engines with high-efficiency diesel particulate filters • Large water and diesel tanks • DV+ operates with split vibration drums are standard • Pivot steering with large turning angles in four different steering modes • Easy Drive operating concept For more information, contact Brodie Hutchins at (615) 501-8105 or Brodie. hutchins@wirtgen-group.com.

ROADTEC

The Roadtec MTV-1100e from Roadtec, an Astec Industries company, Chattanooga, was introduced at CONEXPO 2017 and offers a low, machine-height profile. The 9-foot, 10.5-inch machine height with a deck height of 6-foot, 2-inches is designed to provide the machine operator with a clearer view of the surroundings and the ability to more easily communicate with ground crew. A dual staircase with handrails flanks the machine, allowing workers to cross the paving train without risk of being on the ground between machines.

The MTC-1100e is 47,890 pounds and powered by a 250-hp Cummins QSB 6.7 Tier 4 Final engine. It features a dump hopper with 22-inch triple-pitch segmented auger for mild re-blending before material moves toward the paver, and offers a 500-tph capacity. Sized for mass discharge from standard haul trucks, the front hopper is de-

The MTV-1100e features a frame fabricated, welded and assembled by Roadtec using American steel. The machines are built by American workers in Chattanooga, Tennessee. signed to allow trucks to unload quickly. A vibrating bottom plate in the hopper is designed to prevent material build-up. Heavy duty, swiveling support casters under the hopper are designed to provide smooth movement. The dump hopper is controlled from the main operator platform.

For more information, contact Eric Baker at (423) 265-0600 or ebaker@roadtec.com.

SAKAI AMERICA

Sakai America, Adairsville, Georgia, launched a cabbed version of its 84-inch Sakai SW994 vibratory double-drum roller in March. The roller’s comfortable, spacious cab allows operators ample room to move about. The rig’s trim sightlines and wide windows offer the operator excellent visibility. The seat offers five positions to choose from ranging from front facing to plus or minus 45 degrees and plus or minus 90 degrees, depending on

The cabbed version of the 84-inch Sakai SW994 vibratory double-drum roller is designed with operators in extreme climates.

However, operators throughout the industry can benefit from a quieter, dust-free environment that an enclosed cab provides.

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product gallery working lane. To swivel the seat, operators simply depress the pedal at the lower right side to release the lock while sitting.

The Sakai SW994 with cab has a maximum operating weight of 31,401 pounds (14,090 kg) with load on front axle at 14,528 pounds (6,590 kg) and load on rear axle of 14,903 pounds (6,760 kg).

High-frequency, low-profile vibratory rollers offer low-profile vibration at 4,000 vpm.

Operators simply flip a switch to choose frequency and amplitude or no vibration from front or rear drum, independent of each other.

A cross-mounted drive and vibration motor help to minimize drum edge marking. The rig is powered by a Cummins QSF3.8 Tier 4 Final engine. Range of speed for the SW994, reverse/ forward, is 0-4.5 / 0-6.8 mph (0-7.2 / 0-11 km/h).

For more information, visit www.sakai.com.

SANDVIK

Sandvik Mining and Rock Technology, Bristol, Virginia, introduced its new Double TriSpec® tool, which is intended for use in extremely abrasive asphalt milling conditions. In road milling, one of the greatest causes of tool failure is known as body wash—the premature wearing away of the steel body that surrounds and supports the vital brazed-carbide insert in each of the tools on the milling drum.

When body wash occurs, the tool’s steel body becomes vulnerable to failure, and the tool must be changed before the carbide tip has been fully used—resulting in downtime, lost production and higher labor costs.

The Double TriSpec tool features an additional carbide ring strategically located at the shoulder of the tool to prevent body wash and extend the life of the tool’s steel body.

The manufacturer states there is no compromise on cutting speed, and the design allows

for maximum use of the carbide tip, which in turn allows even wear in proportion to the tools located across the drum. The new dual carbide ring design maintains puller groove performance throughout the life of the tool for easy removal, as it reduces wear on the washer and block, according to the manufacturer. Sandvik states the Double TriSpec tools will fit any milling machine.

For more information, contact (800) 8686657 or constr.tools@sandvik.com.

TALBERT

In April, Talbert Manufacturing of Rensselaer, Indiana, introduced its 55SA-TELE heavy haul trailer. The deck length of the unit is 54 feet when open, which allows users to haul a wide range of large equipment, plus generators, air compressors, tanks, etc. Operators can then retract the trailer to 32 feet, 6 inches to shorten the overall trailer length to 53 feet, which the manufacturer states eliminates the need for permits.

Talbert designed the 55SA-TELE with a 90-inch swing radius that can be extended to 114 inches with the use of a gooseneck extension. The unit features a 29-foot wood deck in the front and a 3-foot Apitong platform in the rear with beams stretching between. The trailer expands and locks in 4-foot increments.

The 55SA-TELE features one of the lowest deck heights in the industry—20 inches, which optimizes headspace for taller equipment.

For more information, ask about ENitro at sales@talbertmfg.com.

58 // july 2017

company, Antioch, Tennessee, are 8-foot pavers that combine the paver and screed in a single system with the front-mounted VF 500 extending screed. With the ErgoPlus 3 screed console, the screed can be adjusted for infinite variability in a range from 8 feet to 15 feet, 6 inches; or with bolt-on extensions to 19 feet, 6 inches. The entire material handling system of the Super 1700-31 and Super 1703-3i is designed for high output, starting with a receiving hopper with a capacity of 14.3 tons. The high-powered, separate hydraulic drives on the conveyor and auger support laydown rates of up to 770 tons per hour.

• Liquid-cooled, 4-cylinder Cummins diesel engine • Engine output of 173 hp at 2,000 rpm • Hardtop with extendable sunshade and comfort seats that swing out For more information, contact Brodie Hutchins at (615) 501-8105 or Brodie. hutchins@wirtgen-group.com.

XL SPECIALIZED TRAILERS

Talbert Manufacturing’s new 55-ton extendible trailer, the 55SA-TELE, can be retracted from 53 feet to 32 feet, 6 inches.

Strategically placed dual carbide rings on the new Double TriSpec tool from Sandvik are designed to prevent body wear and maximize carbide tip use.

The front-mounted Vogele VF 500 extending screed features high stability for maximum evenness, according to the manufacturer.

VOGELE

The new Super 1700 3i and Super 1700-3i and Super 1703-3i from Vogele, a Wirtgen Group

XL Specialized Trailers has introduced the XL 80 Power Tail trailer in 48- or 53-foot lengths for transporting medium-duty construction equipment. The trailer features a hydraulic fold-under flip tail ramp and a load angle of 10 degrees.

The XL Power Tail is rated at 80,000 pounds overall and 50,000 pounds concentrated in 10 feet. The tail has a lifting capacity of 25,000 pounds for loads centered on the main platform. The tail is comprised of two sections—an 8-foot, 8-inch platform ramp and a 60-inch flip tail.

For more information, contact Erin Pilcher at (319) 361-3803 or visit www. xlspecializedtrailer.com.

TIER3 TODAY, GONE TOMORROW Eagle Crusher still has Tier 3 diesel engines available. Save on equipment costs and experience less complex maintenance than with the higher priced and more complex Tier 4 diesel engines.

Get a Tier 3 before they’re gone.

TM

TM

800-25-EAGLE www.EagleCrusher.com

off the mat

DOJ’s Fraud Section Issues New Guidance on the Evaluation of Corporate Compliance Programs Corporate compliance programs are an integral part of a company’s efforts to avoid a federal investigation or prosecution for violation of regulatory laws that affect its business. When federal prosecutors are trying to determine whether to conduct an investigation of a company or to bring charges against a company for fraudulent conduct, they look to a series of 10 factors, known as “Filip Factors,” found in The Principles of Federal Prosecution of Business Organizations in the U.S. Attorney’s Manual (USAM).

Only two of these factors involve a corporation’s compliance program. The first is “the existence and effectiveness of the corporation’s pre-existing compliance program” and the second is the corporation’s remedial efforts to “implement an effective corporate compliance program or to improve an existing one.” However, until recently, the question that remained open was exactly how the compliance program could be effectively designed and implemented to satisfy these two factors.

On Feb. 8, 2017, the Fraud Section of the U.S. Department of Justice (DOJ) published a new compliance guidance called “Evaluation of Corporate Compliance Programs,” on its website. It provides valuable insight on how the Fraud Section evaluates corporate compliance programs during an investigation by providing important topics and sample questions the DOJ may ask in specific cases. The Evaluation of Corporate Compliance Program offers a company practical examples of how federal prosecutors can evaluate a company’s compliance program under the Filip Factors. Below are the 11 topics that the DOJ considers in its evaluation: • Analysis and Remediation of Underlying Misconduct • Senior and Middle Management • Autonomy and Resources • Policies and Procedures

C

60 // july 2017

• Risk Assessment • Training and Communications • Confidential Reporting and Investigation • Incentives and Disciplinary Measures • Continuous Improvement, Periodic Testing and Review • Third Party Management • Mergers and Acquisitions (M&A) Under each of these topics, the DOJ lists several sample questions the Fraud Section can consider when evaluating the effectiveness of a company’s compliance program. One of the common themes running through the sample questions is the ability of the compliance program and personnel to have prevented the misconduct and to have adequately addressed the conduct to avoid similar incidents from reoccurring.

Another example of a key theme is the role and responsibility undertaken by management and corporate compliance personnel in monitoring the company’s conduct and in creating an atmosphere of corporate responsibility. Notwithstanding, one thing made clear from the guidance is that there is no rigid formula used by the Fraud Section to assess the effectiveness of a corporate compliance program. The Fraud Section recognizes that no two companies view their corporate risk the same; therefore, it evaluates each company’s program on an individual basis in the specific context of a compliance failure. Specifically, it noted that the topics and questions should be used as “neither a checklist nor a formula.” Some of the topics and questions may not be relevant at all while others may be more salient based on the facts of the case.

The DOJ has made it clear that fraud investigations are still a priority under the new administration. Many of the topics and questions are intuitive and should not be a surprise to compliance personnel or senior management. However, they provide valuable insight into the Fraud Section’s con-

siderations in determining whether the corporate compliance components of the Filip Factors have been satisfied, and are sufficient to possibly avert a fraud investigation or prosecution of a company’s actions. Based on the guidance issued by the DOJ, companies will now have a clearer set of guidelines to use in designing, evaluating and defending their corporate compliance programs. With this guidance in hand, companies are in a position to effectively reexamine their current programs and structures to ensure that they address the various considerations raised by the DOJ. A copy of the DOJ’s Evaluation of Corporate Compliance Programs, which includes all the questions, can be found at https:// www.justice.gov/criminal-fraud/page/ file/937501/download.

–By Lorraine D’Angelo & Silvia Zicherman

Lorraine D’Angelo, a nationally recognized expert on legal and regulatory risk management, is the president of LDA Compliance Consulting Inc. She has more than 25 years of experience in the construction industry, including a recent tenure as senior vice president for ethics and compliance at a global construction company. D’Angelo is an accredited ethics and compliance professional and a leading expert on small, women-owned, minority and DBE matters, programs and policy implementation. For more information, contact her at (914) 548-6369 or Lorraine@ldacomplianceconsulting.com.

Silvia Zicherman is a consultant at LDA Compliance Consulting Inc. She is an attorney and has 12 years of experience in the construction industry as a former marketing director at a national construction law firm.

Teach Your Crew What it Takes to Pave a Bonus-Worthy Mat

AsphaltPro magazine joined forces with hall-of-fame paving consultant John S. Ball III of Top Quality Paving & Training to bring you the newest online training resource for your crew: Asphalt Paving 101.

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Asphalt Paving 101

In this course, your crew will learn: • How to stay safe on the job site • How to build a takeoff ramp • How to determine fluff factor • How to determine yield • How to prep for real paving in the real world • How to maintain equipment the right way • Job responsibilities for each paving crew member • and so much more…

Purchase your access to the course at: training.theasphaltpro.com

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Italian Painters Check the VFD If you run variable frequency drives (VFDs) on plant components, you may relate to a paint production facility’s recent emergency.

Easy Tool, a condition monitoring solutions provider in Italy, works with a paint production facility in Ancona, a city along Italy’s Adriatic coast.

This paint producer has worked with Easy Tool since 2013, relying on their field engineers to perform regular monitoring services for the motors, fans, pumps and mixers operating in the facility.

Every six months, field engineers from Easy Tool spend six days at the facility, using a variety of technologies to test things out, perform vibration analysis and the like. In January, Field Engineer Ettore Di Pasquale was performing a dynamic test on a 55-kilowatt, 4-pole motor at the facility when he discovered a significant current imbalance.

The motor was driving a fan that sucks solvents from the air.

It’s critical for ensuring worker safety. If the fan stops running, the paint producer must stop the production process. The fan is comprised of an impeller keyed directly to the motor shaft, which is controlled by a VFD. Di Pasquale used the ALL-TEST PRO On-Line II™ energized motor testing instrument to test the fan motor and discovered the current imbalance at the VFD input and output.

“Testing showed a current imbalance of 12.4 percent at the input of the VFD that became 74.8 percent at the output of the VFD,” Di Pasquale explained. “This is not good for the motor—the VFD should supply the fan motor with balanced current. Given such high levels of current imbalance and the absence of several input half-waves, it became clear to me that the motor and fan were fine, but that the VFD needed to be replaced.”

Of course Di Pasquale discussed the issue with the facility owner. Trusting Di Pasquale’s recommendation, the producer had the VFD removed and confirmed there had been serious damage to the VFD’s internal diodes. After a new VFD was installed, Di Pasquale went back to test the fan motor. The second round of energized motor testing with the ATPOL II™ showed healthy waveforms.

Whether a VFD is in the mechanic’s shop or on a slat conveyor, it needs to be checked regularly. There are easy-to-use, portable instruments domestically and internationally, that can help you check the condition of your motors. When you know what is really happening with your equipment, you can make smart decisions to keep people safe and to keep your operation running smoothly.

For more information, visit www.alltestpro.com. Let them know you saw it in AsphaltPro Magazine.

I

– From ALL-TEST PRO

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new tech

Volvo Displays World’s First Fully Electric Compact Excavator

The EX2 prototype is a fully electric compact excavator, and is believed to be the world’s first 100 percent electric machine of its kind.

On May 16, Volvo Construction Equipment showed off a prototype of the EX2, a 100 percent electric compact excavator, at the Volvo Group Innovation Summit in London.

The EX2 is Volvo CE’s latest concept machine and, according to Volvo, the world’s first fully electric compact excavator prototype. It’s important to note that the EX2 is “purely a research project,” according to Volvo CE, with “no plans for industrialization.” However, it offers an interesting glimpse into a cleaner, more efficient future.

O

The Current State of Electric Construction Vehicles

A recent report from emerging technologies market research firm IDTechEx estimates that more than 165,000 fully electric machines will be operating in the construction, maintenance, agriculture and mining industries by 2027, as manufacturers like Komatsu, John Deere, Caterpillar, Volvo and others continue to push the limits of electric-powered heavy equipment.

As the world continues to urbanize and legislative pressures continue to mount, the report outlines, demand for machines that can operate with limited emissions and less noise will continue to increase.

The report, originally published in May 2015 and updated in May of this year, originally estimated the market would reach $30 billion by 2025. Its latest prediction estimates

64 // july 2017

the market will reach $81 billion by 2027. This vast estimated increase is a clear indication that the industry is moving towards hybrid and fully electric heavy machinery more rapidly than previously expected.

It’s estimated that there are between 664,000 and 649,000 machines active in the construction market worldwide, with a significant portion of those being electric drive machines. But, this isn’t the same thing as a true electric vehicle, which is the direction the industry continues to inch towards.

According to a report entitled “A Comprehensive Overview of Hybrid Construction Machinery” published in Advances in Mechanical Engineering in March of 2016, hybrid wheel loaders and excavators are among the most successful categories for the application of electric technology based on current market share.

Hitachi launched the world’s first hybrid excavator back in 2003, and by 2008, Volvo had showed a preproduction prototype of its L220F hybrid wheel loader and Komatsu had developed the world’s first commercial hybrid excavator.

And, last September, Volvo CE unveiled its hybrid electric loader prototype, the LX1, which was capable of doing the same level of work of a wheel loader one size larger.

Now, Volvo Construction Equipment can claim the world’s first known fully electric compact excavator prototype.

How to Make an Excavator Fully Electric

As a fully electric piece of machinery, the excavator can perform all of its regular tasks while delivering zero emissions.

To achieve this, the combustion engine was replaced with two lithium ion batteries, offering a total of 38KWh. To give perspective, those batteries store enough energy to operate the machine for eight hours a day at what Volvo CE considers an “intense application, such as digging compact ground.”

To make the machine fully electric, Volvo CE also had to replace the hydraulic system

with an electric system using electromechanical linear actuators.

Making those two changes—replacing the combustion engine and hydraulic system—has reduced the machine’s cooling needs and noise levels by a factor of 10.

According to EX2 Project Leader Ahcène Nedjimi, the prototype delivers the same power and force as its conventional counterpart, but also offers faster speeds in combined movements.

Powering the EX2 Prototype This prototype in particular offers modular power solutions, including a mix of at least one 600V 19kWh lithium ion battery paired with either a second identical lithium ion battery, a diesel range extender, or a fuel cell system. Or, it can be plugged into the grid for its power or to recharge.

“A diesel range extender would be ideal on a site that doesn’t have a charging infrastructure in place,” Nedjimi said. The time it would take to recharge the batteries depends on the available infrastructure, he adds.

“On a 16 amp domestic grid it will take between eight and ten hours to fully recharge both batteries,” Nedjimi said. “However, the batteries can take more power than this, so with a dedicated grid, which could draw more current, and a slightly adapted charger, you would be able to recharge the batteries within one hour.”

Although electric machines are pricier compared to traditional machines, as the cost of energy storage systems like lithium ion batteries steadily decreases over time, one can only assume we’ll see more prototypes, more research on these machines’ efficiency and durability, and—eventually— more electric options in the marketplace.

Although Volvo CE has made it clear that these machines won’t be available commercially anytime soon, some elements of their designs could make their way into existing product lineups.

– By Sarah Redohl

advertiser index Ammann....................................................................................43 ArrMaz.........................................................................................41 Asphalt Drum Mixers................................................................48 Astec, Inc..................................................................... 34, 51, 55 B & S Light.................................................................................17 CEI................................................................................................ 4 ClearSpan.................................................................................. 37 CWMF Corporation.................................................................. 57 Dillman Equipment....................................................................18 Eagle Crusher............................................................................59 E.D. Etnyre..................................................................................21 Fast-Measure............................................................................ 37 Gencor Industries...................................................................... 11 Heatec, Inc............................................... Inside Front Cover, 53 Hot-Mix Parts...........................................................................45

Ingevity...................................................................................... 27 KPI-JCI-AMS..................................................Inside Back Cover LDA Compliance Consulting...................................................65 Libra Systems...........................................................................32 Meeker.......................................................................................23 Process Heating........................................................................31 Reliable Asphalt Products........................................ Back Cover Roadtec.....................................................................................7, 8 Stansteel AsphaltPlant Products..........................................63 Systems Equipment.................................................................33 Tarmac International, Inc.........................................................13 Top Quality Paving....................................................................38 Willow Designs.........................................................................65 Wirtgen......................................................................................25

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www.THeAsphaltpro.com // 65

Here’s how it works

Step 1 The RS500 moves forward at an operating speed of up to 164 feet per minute.

Step 4 The rotor teeth turn in close proximity to the breaker bar teeth on four optional breaker bar assemblies.

Step 5

Step 2

The operator moves a toggle switch to position the FLEXMIX door, which channels material back into the rotor for additional mixing and blending.

The rotor speed will be adjusted from 100 to 180 rpm to match the application.

Step 3

Step 6

As the rotor turns, the teeth cut material and pull it into the rotor chamber.

The RS500 leaves consistently graded material in its wake.

BOMAG’s RS500 with FLEXMIX Sometimes an owner/agency requires full depth reclamation of a pavement. Sometimes the pavement—and the budget—needs a repair of lesser depth. In all applications, however, the desired end result is to have consistent material gradation behind the machine.

The team at BOMAG Americas, Ridgeway, South Carolina, has incorporated extra breaker bar assemblies and an additional variable-position mixing door within the rotor chamber of its RS500 reclaimer/stabilizer designed to allow contractors to achieve consistent and controllable gradation with a simple toggle switch. Here’s how it works.

First, the operator will ensure the machine is ready for operation, following best practices and performing his pre-shift

S

66 // july 2017

walk-around. He will ensure the 230-gallon fuel tank is full.

Moving forward at an operating speed of up to 164 feet per minute, the RS500 uses variable rotor speeds from 100 to 180 rpm to match rotor speed to the application.

Four optional breaker bar assemblies— each containing seven cutting teeth positioned in the opposite direction of material flow—mounted above the front rotor door offer additional crushing and gradation of asphalt material. The rotor teeth turn in close proximity to the breaker bar teeth to break up material.

Above the rear discharge door, an adjustable door—the FLEXMIX—moves at the operator’s command to provide flexible mixing of material inside the rotor chamber. The operator moves a toggle ro-

tary switch to effect the positioning of this third, FLEXMIX door. As the door is moved closer to the rotor—beneficial when working with thinner lifts and when mixing in additives—material is channeled back into the rotor for additional mixing and blending. For full depth reclamation, the operator will position the door further away from the rotor.

When the operator comes to a flare, tiein or road’s edge where ground conditions are marginal, the side-shifting capabilities of the 88.58-inch rotor come into play. The entire rotor housing can offset up to 11.8 inches beyond the wheel track, offering full depth cutting while the machine remains stable.

For more information, contact Tim Hoover at (660) 580-0350 or tim.hoover@bomag.com.

ProSizer Series

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ProSizer® 3100 This unit is the ideal mobile solution for milled RAP processing. The compact 31x36 horizontal shaft impactor and double deck high frequency screen make this unit the best investment for asphalt producers. The new swing-out return conveyor allows producers to run closed-circuit or stockpile a third finished product.

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