Lab & Binder Issue
asphaltPRO PRODUCTION – PROFESSIONALS – PRODUCTS
• How to Use DPS • Additive Matters • Comply with NEP • Trees Enter the Mix • Stop Suicide Epidemic
JM Fahey Tops 50th Anniversary with New Plant
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CONTENTS
asphaltPRO June 2022
DEPARTMENTS
8
EDITOR’S LETTER 6 – Is This Still Asphalt?
SAFETY SPOTLIGHT 8 – Comply with NEP Tips to Keep Workers Cool, Safe and Your Company in Compliance By Sandy Lender
MIX IT UP 14 – Raise the Resilient RAP Bar A discussion of one plant-based rejuvenator to facilitate higher RAP in the BMD paradigm By Sandy Lender
TRAINING 16 – How to Use DPS for QC in Paving By Bryce Wuori
WOMEN OF ASPHALT
44
20
20 – Meet a Woman of Asphalt: Tri-State Emulsions’ Jodi Loud By Sandy Lender
INTERNATIONAL SNAPSHOT 26 – International Tree Mix Stora Enso of Finland offers a biomaterial for the scope 3 emissions discussion By Sandy Lender
Lab & Binder Issue
asphaltPRO PRODUCTION – PROFESSIONALS – PRODUCTS
PRODUCT GALLERY 38 – Paver Roundup from World of Asphalt By AsphaltPro Staff
NEW TECH 44 – PaveScan MDM Offers Real-Time Density Data By Sarah Redohl
HHIW 50 – Eagle Crusher’s RapiDeploy 1000
FEATURE ARTICLES 28 – Family Connections JM Fahey celebrates 50 years with CWMF’s stationary full plant build By Sandy Lender 34 – Before It’s Too Late: Talk About It The asphalt industry prepares to stem the tide of construction industry suicide By Vince Hafeli and Sandy Lender
• How to Use DPS • Additive Matters • Comply with NEP • Trees Enter the Mix • Stop Suicide Epidemic
JM Fahey Tops 50th Anniversary with New Plant
JUNE 2022 WWW.THEASPHALTPRO.COM
ON THE COVER
When JM Fahey wished to replace an older facility, the family business turned to CMWF for a custom build. See related article on page 28. Photo courtesy of CWMF
E D I TO R ' S L E T T E R
Is This Still Asphalt?
June 2022 • Vol. 15 No. 8
T
he preface for this month’s note is that I do in fact understand the need to placate climate change advocates to continue doing business in today’s world. One example out of the multitude I can offer is that of shareholder advocacy group Majority Action filing an exempt solicitation mid-March for the board to remove Lead Director Ronald Sugar and CEO Michael Wirth from Chevron for failing to do “enough” to curb Scope 3 emissions. This issue will go to press before the vote in late May, but information is archived here: https:// www.sec.gov/Archives/edgar/data/000 0093410/000138713122003291/cvx-px14a6g_030822.htm An example that may hit closer to home for readers is the spate of state legislative actions introducing “buy clean” language that attempts to set unattainable benchmarks for construction materials. Luckily, the asphalt industry has a history of encouraging environmental stewardship and, as an industry, now has a mission of The Road Forward, launched at the National Asphalt Pavement Association (NAPA) annual meeting January 2022. As part of The Road Forward climate stewardship mission toward net zero carbon emissions, NAPA listed the third industry goal would involve developing a net zero materials supply chain by 2050, putting an emphasis on upstream Scope 3 emissions, such as those created or emitted by vendors who supply liquid asphalt binder or asphalt binder replacements. One of the companies offering to replace a portion of liquid binder in asphalt mix designs is Stora Enso, a provider of renewable products in packaging, biomaterials, wooden construction and paper, headquartered in Helsinki. Its biomaterial offering comes from lignin—one of the main building blocks of a tree. It’s an intriguing concept, complete with data to fit into your environmental product declaration (EPD) to support your mix for buy-clean parameters. See the article on page 38. Separate from the kraft lignin discussion, I’d like to posit: At what percentage of binder replacement does a mix design 6 | JUNE 2022
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
Ted Christian and Sandy Lender talk about WEM Automation controls for asphalt plants at WOA 2022. Photo courtesy of WEM
become a lignin pavement with asphalt additive, rather than an asphalt pavement? Imagine my horror at hearing an asphalt industry member suggesting to a group that we might meet high standards with full binder replacement. Lately, well-meaning conservationists have suggested any number of additives to “turn roads into the new landfills.” I shudder at that language. But at what percentage of replacement does a mix design become a plastic road merely with asphalt binder additive? I fully agree that ignoring plastic pollution in our world would be irresponsible, but I’m not yet sold on the idea of putting that pollution into mix designs. I’m not a scientist, thus I will reserve judgment and offer a more educated and informed opinion when science is further along in that arena. For now, I ask if we are, under the guise of lowering the construct of “carbon footprint,” removing asphalt roads in favor of tree, plastic or fad-of-the-moment roads? And should replacing asphalt be the mission the Asphalt Industry undertakes? Stay Safe,
Sandy Lender
EDITOR Sandy Lender sandy@theasphaltpro.com (239) 272-8613 DIGITAL EDITOR Sarah Redohl sarah@theasphaltpro.com (573) 355-9775 MEDIA SALES Cara Owings cara@theasphaltpro.com (660) 537-0778 ART DIRECTOR Kristin Branscom BUSINESS MANAGER Susan Campbell (660) 728-5007
AsphaltPro is published 11 times per year. Writers expressing views in AsphaltPro Magazine or on the AsphaltPro website are professionals with sound, professional advice. Views expressed herein are not necessarily the same as the views of AsphaltPro, thus producers/contractors are still encouraged to use best practices when implementing new advice. SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the United Sates, Canada and Mexico to qualified individuals. One year subscription to non-qualifying Individuals: United States $90, Canada and Mexico $125.00. For the international digital edition, visit theasphaltpro.com/subscribe/.
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S A F E T Y S P OT L I G H T
Comply with NEP Tips to Keep Workers Cool, Safe and Your Company in Compliance BY SANDY LENDER
Steve Schayer of OSHA shared that the agency hasn’t set a date for publishing the federal standard on heat-illness prevention.
ESTABLISH HEAT PROGRAM
Effective April 8, 2022, the NEP created “a nationwide enforcement mechanism for OSHA to proactively inspect workplaces for heat-related hazards in general industry, maritime, construction, or agriculture operations alleging hazardous exposures to heat (outdoors and/or indoors),” according to an agency fact sheet. “This means that OSHA can now launch heat-related inspections on high-risk worksites before workers suffer preventable injuries, illnesses, or fatalities.” If that list of industries looks wide of scope, it is. But it does target roadbuilding. During an online “Stakeholder Meeting on OSHA Initiatives to Protect Workers from Heat-Related Hazards” May 3, OSHA Presenter Jennifer Kim showed the three tables of high heat hazard industries identified in its NEP Appendix A. Table 2—Examples of construction industries, includes “Highway, Street, and Bridge Construction” and “Other Heavy and Civil Engineering Construction.” There are at least 70 industries targeted by OSHA for inspections and citations, and the words “target” and “targeted” have been used multiple times when discussing how OSHA inspectors and the NEP will approach employers or companies. “The NEP encourages employers to protect workers from heat hazards by providing employee access to water, rest, shade, adequate training, and implementing acclimatization procedures for new or returning employees. It contains both enforcement and outreach/compliance assistance components.” 8 | JUNE 2022
Outdoor and indoor heat exposure can be dangerous.
Ways to Protect Yourself and Others Ease into Work. Nearly 3 out of 4 fatalities from heat illness happen during the first week of work. 100% 20% MON TUE WED THU FRI
New and returning workers need to build tolerance to heat (acclimatize) and take frequent breaks. Follow the 20% Rule. On the first day, work no more than 20% of the shift’s duration at full intensity in the heat. Increase the duration of time at full intensity by no more than 20% a day until workers are used to working in the heat.
Drink Cool Water Drink cool water even if you are not thirsty — at least 1 cup every 20 minutes.
Dress for the Heat Wear a hat and light-colored, loose-fitting, and breathable clothing if possible.
Take Rest Breaks Take enough time to recover from heat given the temperature, humidity, and conditions.
Watch Out for Each Other Monitor yourself and others for signs of heat illness.
Find Shade or a Cool Area Take breaks in a designated shady or cool location.
If Wearing a Face Covering Change your face covering if it gets wet or soiled. Verbally check on others frequently.
First Aid for Heat Illness The following are signs of a medical emergency! ?
?
??
??
Abnormal thinking or behavior Slurred speech Seizures
9-1-1
Loss of consciousness
1
CALL 911 IMMEDIATELY
2
COOL THE WORKER RIGHT AWAY WITH WATER OR ICE
3
STAY WITH THE WORKER UNTIL HELP ARRIVES
Watch for any other signs of heat illness and act quickly. When in doubt, call 911. If a worker experiences:
Take these actions:
Headache or nausea
Give water to drink
Weakness or dizziness
Remove unnecessary clothing
Heavy sweating or hot, dry skin
Move to a cooler area
Elevated body temperature
Cool with water, ice, or a fan
Thirst Decreased urine output
Do not leave alone Seek medical care if needed For more information: 1-800-321-OSHA (6742) TTY 1-877-889-5627 www.osha.gov/heat Federal law entitles you to a safe workplace. You have the right to speak up about hazards without fear of retaliation. See www.osha.gov/workers for information about how to file a confidential complaint with OSHA and ask for an inspection.
OSHA 3431-05R 2021
T
he Occupational Health and Safety Administration’s (OSHA) National Emphasis Program (NEP) on heat illness prevention— while functioning as a placeholder while the agency works toward a federal standard for protecting workers from heat-related hazards—has been a long time coming. The October 2019 issue of AsphaltPro reported a representative from California had introduced legislation (H.R. 3668) July 10 that year directing the organization to issue a national standard to protect workers from heat-related injuries and illnesses. But the standard had been set with the National Institute for Occupational Safety and Health (NIOSH) issuing criteria for it in 1972—and updating those criteria in 1986 and 2016. Even the branches of the U.S. Armed Forces and multiple states have established their own heat prevention guidelines or standards. You’ll see that in 2019, sources were reporting that “18 of the 19 hottest years on record had taken place since 2001.” Combine that statistic with an increase in heat-related worker deaths across industries, yet a low incident of heat-related citations per year from OSHA (the average nationwide between 2013 and 2017 was 28), and groups petitioned for action.
The revamped “yellow poster” from OSHA was released in 2021 and is available in English and Spanish. Access it—and additional heatillness-prevention materials—at this link: https:// www.osha.gov/ publications/ bytopic/heat-illnessprevention
Prevent Heat Illness at Work
Even if the “inspection and citation” of enforcement weren’t the actions all industry groups were looking for, the NEP comes with assistance, too, for the purpose of immediately improving enforcement and compliance efforts while the Department of Labor continues long-term work to establish a federal heat-illness prevention rule. To offer comment on the rule, visit www.regulations.gov and submit comments to the docket number OSHA-2022-0006 by Aug. 1. So far, the assistance from OSHA on NEP looks like this: • Proactive outreach and technical assistance on high heat index days; • Outreach to unions, employers, and other organizations to advance protections for underserved workers; and • Assisting employers in developing strategic approaches for addressing heat-related illnesses and injuries via the agency’s free and confidential on-site consultation program for small- and medium-sized businesses (read more about the program in “OSHA’s On-site Consultation Program, Explained” at TheAsphaltPro.com). During the stakeholder meeting, attendees heard OSHA’s Chrissy Morgan further discuss the assistance OSHA can offer. She listed the compliance assistance specialists (CASs) as a group of workers based in OSHA’s regional and area offices across the United States who are tasked with helping in compliance assistance activities. Employers and employees are welcome to find the CAS near you via osha.gov/complianceassistance/cas. Morgan also pointed out the labor liaisons, located in OSHA regional offices, as resources to help with creating or energizing safety programs. Find a regional office near you at osha.gov/workers/liaisons. If you’re seeking assistance for safety training, OSHA has a site for that at osha. gov/training. OSHA’s Jennifer Kim shared during the stakeholder meeting that the NEP has three main goals.
S A F E T Y S P OT L I G H T • Reduce or eliminate worker exposure to heat hazards. • Be proactive instead of reactive, meaning getting to employers before a fatality occurs. • Establish a numerical goal of inspections for OSHA, which equals a 100% increase above past years. Kim shared with the audience that inspectors will observe heat sources, workload exertions, the type of clothing and personal protective equipment in use, duration of exposure to the heat hazard, and so on. The inspectors will look at the company’s heat program and the weather conditions. The agency has released a fact sheet on which it states, “OSHA also recognizes that many businesses want to do the right thing by developing heat illness prevention plans to keep their employees safe. On heat priority days, OSHA field staff will engage in proactive outreach and technical/ compliance assistance to help keep workers safe on the job.”
BUILD A COOL PLACE
Among the many asphalt industry businesses already developing heat illness prevention plans is Austin Bridge & Road, headquartered in Irving, Texas. The company designed a “cooling trailer” to have on site for crews working during the hot paving seasons. When it was first described, my thoughts went to the “outdoor air conditioning” of theme parks and nature centers. Follow-up with sources confirmed the set-up employs fans blowing a mist of water in a shaded area to cool workers while they take a break from strenuous work under the sun. Here’s how you could make a similar cooling station: INGREDIENTS • One gooseneck trailer on which to set all components except the generator • One industrial fan • One water spray system and tank • One canopy, tent topper, or similar “roof ” structure to provide shade • Some cones and caution tape • One picnic table (or two, if your trailer’s big enough) • One large cooler of Gatorade or other electrolyte-rich drinks • One generator set up near the trailer to operate the fan and water spray system DIRECTIONS Place the picnic table and cooler under the canopy, atop the trailer, to provide shade and cold drinks for workers who need a break from hot work. If you don’t wish to build guardrails, place the cones and caution tape along the perimeter of the trailer deck to prevent workers from absent-mindedly stepping backward or falling off the edge. Set up the water spray system in front of the industrial fan with the fan directing a fine mist over this lounge area. Be sure a member of the crew is assigned to double-check the water level in the tank, fuel in the generator, ice and drinks in the cooler, and any other amenities your company can provide for worker health and comfort. Park this trailer in an area that’s convenient to the crew as paving moves along the project. Due to the mobile nature of mainline paving, you may need to have the generator and water tank on wheels as well to accompany a portable cooling trailer to an updated location midday. T.J. Young of T2ASCO LLC suggested using a swamp cooler—such as a Uline or Grainger that might only set you back $750 or so— with the water tank. He also had the clever idea of hiring a high school or college student for the summer months to drive a refreshment truck to each of the crews each day. For a company with crews in one geographic area, it could be feasible to have the “ice cream truck” pull up to the site with cool water, cooling slushy pops, sports 10 | JUNE 2022
drinks, and so on, giving workers a break from hot work under a fold-out awning on the truck. An alternate type of cooling station, one that can’t be easily moved, is described and pictured on the famous “yellow poster” available from OSHA. The poster is now titled “Prevent Heat Illness at Work” and depicts multiple heat-illness awareness and prevention ideas; it’s been revamped and re-released as of 2021 and is available to companies, along with many other materials including fact sheets and pamphlets and so on, at the OSHA website. Click this link to access them all: https:// www.osha.gov/publications/bytopic/heat-illness-prevention. A Quick Tip Remember to lock everything up at night so the generator and other amenities don’t grow legs. Even with radio frequency identification (RFID) tags and robust tracking systems offered by fleet management software today, it’s a nuisance to round up missing equipment if thieves consider your heat-illness-prevention measures an easy target.
COOL THEM DOWN
Not every project will warrant the use of a robust portable cooling station like the one Austin Bridge & Road devised. Sometimes, simple first aid measures will prevent tragedy. John Ball, proprietor of Top Quality Paving & Training, Manchester, New Hampshire, worked with a company in the recent past when one of the
LEARN MORE Heads-up During High Heat As part of the National Emphasis Program (NEP), OSHA will proactively initiate inspections in over 70 high-risk industries in indoor and outdoor work settings when the National Weather Service has issued a heat warning or advisory for a local area. On days when the heat index—not the temperature—is 80° F or higher, OSHA inspectors and compliance assistance specialists will engage in proactive outreach and technical assistance to help stakeholders keep workers safe on the job. Check out www.weather.gov/safety/heat-ww for weather information and download the NIOSH heat app for updates and heat index warnings at www.cdc. gov/niosh/topics/heatstress/heatapp.html. Inspectors will look for and address heat hazards during inspections, regardless of whether the industry is targeted in the NEP. “Our goal is to make it safe for workers in hot indoor and outdoor environments, so that they can return home safe and healthy at the end of each day,” said Assistant Secretary for Occupational Safety and Health Doug Parker. “Working together, we can ensure workers know their rights and employers meet their obligations in order to protect workers from the growing dangers of extreme heat.”
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S A F E T Y S P OT L I G H T laborers began exhibiting signs of heat exhaustion. He noticed the young man’s movements changed. “He was wearing tamp shoes and using the maul, performing a lot of handwork on that job,” Ball said. “We noticed all of a sudden, he started wandering, almost stumbling over his feet. You knew right away something was wrong. He was shaking his head like he was exhausted.” The article “7 Safety Tips to Protect Construction Workers from Extreme Heat” at TheAsphaltPro. com, from Western Specialty Contractors, shares some measures the company takes to prevent heat exhaustion and heat stroke.
Ball said it was surprising to see this person experiencing symptoms of heat illness. “He was a young guy, healthy. It goes to show, you don’t have to be in poor shape for the heat to get you. The heat just took him over.”
LEARN MORE
StaCool with a Vest We shared last summer that StaCool Industries Inc., Lecanto, Florida, had launched its new website. Now the company, which has been manufacturing body core cooling technology since 1997, has a new announcement regarding its micro-thin, highly breathable materials. The company states its StaCool Vest™ Core Body Cooling System, which includes ThermoPaks in the front and back of the vest, are designed to be worn over or under normal clothing. A spare set of ThermoPaks is included with each vest to extend cooling time and comfort when the initial set thaws. All StaCool vests can be made in fire retardant material and StaCool Industries Founder Sylvia Allen shared with AsphaltPro that the industrial vests are available in ANSI-approved safety orange and yellow colors. “We can make them in a wide range of colors; these are special order items and will take a little time.” For more information, contact info@StaCoolVest.com or call (866) 782-2665.
12 | JUNE 2022
The laborer (signified by the letter B) spent much time in the tight space of the sloped carport performing handwork to the right of the sidewalk paver, which exhausted its fume and heat away from the operator, but toward its right side (signified by the letter A). By the time the laborer was using tamp shoes to perform compaction and touch-up work, he began stumbling and showing signs of dehydration. These are conditions—and signs—you can be aware of on your projects. Photo courtesy of John Ball, Top Quality Paving
He described the conditions that other crews can watch out for. “It was a hot, humid day. That sidewalk paver has the fume extraction exhaust on the right-hand side, and he was working along the right joint under a sloped carport, doing extensive handwork and using the maul.” Ball then described how the team worked together to assist their crewmember in distress. “We got him out in the grass in the shade and gave him regular water, not ice water. We wiped his face down with wet rags and used the leaf blower near him, in idle, to blow not directly on him, but circulating air against him to help the sweat evaporate from his skin before putting him in the truck. If we’d put him in the air conditioning straight away, he would have gone into shock. “After about 15 minutes, when we made sure he was coherent and answering questions, we put him in the truck with the air on to recover completely. If he didn’t improve, we were taking him to the hospital.” It’s apparent the asphalt industry hasn’t been sitting around waiting for government entities to come up with standards for protecting workers from high-heat days. Now that OSHA has an NEP to guide the agency in launching workplace inspections, it behooves companies to increase heat-illness prevention measures. Take to heart the instructions experts have offered over the years to provide employees with access to water, rest, shade, and proper training on the signs of heat-related illness. Also work toward bringing new workers—and those coming back from winter season layoffs—up to speed before the extreme heat of summer is upon us. For more resources, use the search term “heat related illness” on www. TheAsphaltPro.com and check out OSHA’s “Working in Outdoor and Indoor Heat Environments” page at https://www.osha.gov/heat-exposure.
MIX IT UP
Raise the Resilient RAP Bar A discussion of one plant-based rejuvenator to facilitate higher RAP in the BMD paradigm BY SANDY LENDER
M
embers of the asphalt industry want to do all they can to encourage higher percentages of recycled asphalt pavement (RAP) in mix designs while maintaining or improving performance of the resulting pavement. Let’s look at one additive that’s designed to accomplish a number of goals—such as retaining the effective contributing RAP binder—and is doing so within the balanced mix design (BMD) conversation. Hassan Tabatabaee is the global technical manager—asphalt solutions at Cargill, Wayzata, Minnesota, and he shared how the company’s Anova rejuvenator can assist agencies and producers in realizing a long-lasting, resilient pavement with the best of both worlds: enhanced cracking resistance and low rutting. He explained that the Superpave design method optimized mixes to where they were generally lower in asphalt cement (AC) content than they had been prior to the 1990s. “However, the industry found issues with durability in some regions,” he said. When it came to performance of the mix, “not everyone saw a positive trend on the cracking or durability side.” With the BMD movement taking place around the United States— and abroad—agencies have an opportunity to address additional performance needs, and many are looking to a performance test in the mix design phase where they can raise the bar for optimum pavement performance. Tabatabaee said many agencies are finding the BMD-optimized binder content of an existing mix volumetric/Superpave mix design may need to increase by as much as half a percent, in many cases. If everything else in the mix design remains constant, the 0.5% increase in AC means a more expensive design. Enter innovative materials. With ambitious environmental targets set by industry associations, it behooves all stakeholders to find innovative ways to incorporate more RAP, including adding material to rejuvenate oxidized binder within the RAP. As Tabatabaee said: “Our mission is to responsibly push RAP contents higher. Producers should be able to change their recipes as long as the mix meets that higher performance bar.” He believes BMD takes us part of the way there and Cargill’s engineered, plant-based additive is designed to assist. “Not all of the binder in the RAP is acting as contributing binder,” he explained. “You need to do something to make it effectively contribute to durability, to meet the higher bar.” One method is, of course, to add virgin AC. Along with the additional cost and environmental product declaration (EPD) a producer may wish to avoid1, there comes a performance thought to keep in mind.
“When trying to offset the impact of increased RAP content on cracking performance, softening the virgin AC or increasing the virgin AC content can only take you so far,” Tabatabaee reminded readers. “Before you run the risk of over-softening the mix and creating potential rutting problems,” which puts the balanced-mix designer back to square one. “Without an additional tool, your only dial to adjust mix durability will be the virgin binder, which has a limited range in terms of either AC contents and grade. A good rejuvenator will increase the amount of effective contribution of the recycle binder, giving you a much wider window of opportunity for balancing the rutting and cracking performance of the mix.” Selecting a rejuvenator that can help enhance your mix’s overall EPD makes sense given NAPA’s initiative to move the industry toward net-zero. The offering of Anova rejuvenator has EPDs for some of the company’s European markets where standards for calculating EPDs for asphalt additives have been defined. “These are done by a third party designated by the state. However, we do not have an EPD for North America, pending a defined framework and standard practice for calculating EPDs for asphalt additives.” Cargill shared that it is actively involved with sustainable pavements groups across the industry to develop an EPD for its asphalt additives. “Because these types of technologies are innovative, industry groups are working on developing a framework and standard practices for calculating EPDs for asphalt additives.”
What Anova currently offers producers is a measurable unit of green savings. The product can work simultaneously as a warm-mix additive and RAP binder rejuvenator to lower production temperatures at the asphalt plant and enhance contributing binder availability, as discussed above. The company has learned from the National Asphalt Pavement Association (NAPA): “The estimated reduction of GHG emissions from production of WMA at a reduced temperature can be up to 0.21 million metric tons of CO2e (which is the equivalent to the annual emissions of 46,000 passenger vehicles.)” NAPA further reported “the use of RAP in new asphalt mixtures reduced greenhouse gas emissions in 2019 by 2.4 million metric tons of CO2e, which is equivalent to the annual emissions of 520,000 passenger vehicles.” By incorporating bio-based rejuvenators that pull double duty in balanced design, the asphalt industry can increase its environmental stewardship while improving a mix’s chances for long-lasting pavement resilience.
1 The author does not wish to imply virgin AC is a negative; merely, when contrasting the virgin AC with the RAP binder, one is going to see a more positive environmental credit score for the recycled product.
14 | JUNE 2022
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How to Use DPS for QC in Paving BY BRYCE WUORI
I
magine using a quality control (QC) tool that displays real-time volumetric data anywhere on your asphalt mat within seconds. With such a tool, users scan the entire asphalt mat making pro-active changes with paver setup and rolling patterns to increase density and uniformity of newly placed asphalt in the field. One technology that makes this possible is the Density Profiling System (DPS). The DPS is a non-destructive asphalt assessment tool that implements ground penetrating radar technology to collect surface dielectric of compacted asphalt roadways. Within the asphalt industry, the DPS has, so far, been used as a quality assessment tool for owners. The main objectives of using this tool within a quality assessment process would be to increase safety in the field, decrease the amount of destructive coring performed on new asphalt roads, and generate more data sets that better represent the newly placed asphalt. Using the DPS technology as a quality assurance (QA) tool has a great deal of potential within the industry with many states performing pilot projects and developing new specifications that integrate the technology into current methods. Because DPS can offer such confidence to departments of transportation as a QA tool, it is gaining ground for QC in the field, too. The DPS is Wuori Consulting LLC’s “go to” QC tool when issues develop in the field with density or uniformity. Within this article, users will learn the practice of implementing the DPS as a QC tool for improved project success.
DPS SETUP FOR QC
Within the technology industry, there are numerous equipment companies that have developed a DPS that will satisfy the requirements for implementing the tool for QC. The specific DPS unit that we use at Wuori Consulting LLC is the PaveScan RDM 2.0 developed by GSSI. We feel that it is user friendly, durable and able to produce accurate data sets with maps for real-time evaluation. 16 | JUNE 2022
Getting the PaveScan RDM 2.0 DPS ready for collection takes a few simple steps for assembly and calibration. 1. Connect antennas to the unit 2. Install batteries for power source 3. Mount the collection screen to the unit handle 4. Connect the chords in the correct locations This process takes approximately five minutes and once assembled the unit can fold up into a more compact position for loading or transporting. Once the DPS unit is assembled, users can power up the transmitter and collection screen and move into the project setup and calibration. Project setup within the collection screen establishes your current project and the amount of detail you want included for the project is entirely dependent on the user’s preference. Typically, for QC applications, users will set up a project and input variables that may include project name, mix type and project location. Following the project setup, users can begin the antenna calibration procedure. The air calibration and metal plate calibration will take less than two minutes to complete but must be performed correctly for accurate data collection in the field. With the DPS assembled and calibrated, users can begin data collection procedures in the field.
DPS SETUP FOR ROLLER PATTERNS
Roller pattern setup will differ from one project to the next depending on the variables presented and the project conditions that need to be satisfied. Using the DPS to identify what roller pattern generates the best results to match your project variables and conditions will develop a higher quality project. Higher profits and incentives for ride and density will follow. When implementing the DPS as a QC tool in the field for roller pattern setup, Wuori Consulting LLC will collect most of the DPS data behind the intermediate and finish roller positions. Typically, behind the intermediate roller we have achieved most of our required project density on the asphalt mat,
This image shows the DPS swerve method for quality control data collection.
and the user can still make pro-active adjustments if required. Another reason data is typically collected in these locations in the field, is because the DPS does not respond well to water on the surface of the asphalt mat. If the rollers are using too much water and leaving water lines on the surface of the asphalt, the DPS will identify these areas and produce distorted data for the user. Managing water for rollers is a best practice that should always be monitored in a roller plan and this variable becomes even more important with the introduction of a DPS as a QC tool in the field.
DPS SWERVE PATTERN
There are two methods users will most commonly implement when verifying and modifying roller patterns in the field. These methods consist of the DPS swerve pattern and the transverse slice pattern. The swerve pattern will be the most common method used to collect data behind rollers and identify uniformity and density conditions. This collection method is performed just as it sounds. Users will identify a starting point behind the intermediate roller
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TRAINING and then collect data in a swerving motion with the DPS from roughly one foot inside the centerline joint to roughly one foot inside the shoulder edge or outside edge. DPS data is collected in the direction of construction—or toward the paver—and the user swerves from one edge of the asphalt mat to the next making sure data is collected on the entire compacted asphalt roadway. This data collection method allows users to discover the uniformity of the density across the entire asphalt mat through multiple rolling pattern locations. Users will also recognize data trends that may be caused from improper rolling procedures or improper paver operations. If a specific data trend continues to present itself with DPS data, the user can make an adjustment with rolling patterns or the paver setup to combat this trend and increase quality. One example of a common data trend that Wuori Consulting LLC identifies with the DPS on projects is lower density on the shoulder/unconfined edge of the asphalt roadway. When there is nothing to confine the asphalt from pushing out, density can become an issue in these specific areas. Pay extra attention to these areas to achieve uniform density in these situations. Depending on what the conditions of the project are, users can make a roller plan modification to combat this issue and increase uniform density across the asphalt section. Roller plan modifications to correct these issues may consist of changing knockdown and intermediate temperature zones, moving in static mode to the section of roadway that needs attention, or adjusting roller frequency or amplitude to assist with asphalt pushing or shoving. Once an adjustment has been implemented, users can perform the DPS swerve method again and re-evaluate the data and modifications that took place for quality improvements in the field.
DPS TRANSVERSE SLICE METHOD
The DPS transverse slice method is also a good way to identify asphalt uniformity across a specific transverse section of a recently compacted asphalt roadway. Typically used as verification technique, the transverse slice method ensures that rolling patterns are generating uniform density from centerline to shoulder. 18 | JUNE 2022
Users will collect data behind the intermediate roller from one foot away from the centerline joint to one foot away from the shoulder edge, performing a transverse slice across the asphalt mat. This method takes approximately 20 seconds to perform, and users can pick random transverse locations behind rolling operations for verification of asphalt uniformity. If DPS data is identifying asphalt uniformity that is not falling within the project’s quality limits, users can perform swerve method through these areas to verify data and then make modifications to rolling patterns or paver setup if necessary. Generally, if paving and rolling conditions have not changed on the project, the transverse slice method is a quick verification procedure.
DPS LONGITUDINAL JOINT VERIFICATION
When a longitudinal joint specification is required on a project, every QC manager understands the frustrations of getting accurate data on the joint. Using the DPS as a QC tool for longitudinal joint management has become one of Wuori Consulting LLC’s favorite applications of the technology. Not only is the user getting accurate data from the DPS on the joint, but he is also getting real-time data of the uniformity and condition of the asphalt. The data the DPS provides to the user can assist with setting up correct rolling patterns and evaluating the average density per lot for the longitudinal joint. When collecting joint data with the DPS, the user will follow the seam line within two to three inches on the matching side of the asphalt section. Depending on what the specification of the project allows with longitudinal joint density, the location of the DPS antenna can be shifted to take scans on the exact match line of the joint or in the locations the extracted cores will be taken from the existing asphalt mat. When using a DPS for longitudinal joints, users will find that the tool will provide them with the data needed to be more effective in the field.
DPS CORE VERIFICATION METHOD
Destructive coring is currently the QA method that almost all owners and agencies use to verify field density. Prior to extraction of a specific core location, users can perform the DPS core
This image shows the DPS transverse slice method for quality control data collection.
verification process to determine a projected core density in that identified core location. The core verification method allows users to calibrate the DPS and ensures that the core result data that is developed from standard testing procedures of extracted cores equals the results the DPS generated prior to extraction. Errors can occasionally be performed during core extraction procedures and in the lab, so having a tool that confirms the precision of these results will allow the user to be more confident in actual field density conditions. When control strips are required on a specific project, the DPS core verification process can give the user expected density results of random core locations in a matter of minutes to move forward with the project paving or plan for mainline operations when conventional results are presented. Overall, the DPS core verification method assists users in verifying field density results and planning for operation procedures. As a quality control manager, it is always nice to have an idea of what results will be expected from extracted cores, and the DPS is the tool that generates this data for the user. What the DPS technology does for users in the field for quality is straightforward. The technology identifies issues with real-time data and allows users to make pro-active modifications for increased quality.
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WO M E N O F A S P H A LT
Meet a Woman of Asphalt: Tri-State Emulsions’ Jodi Loud BY SANDY LENDER
B
ack in the late 1990s, Jodi Loud had the opportunity to work at CMA, her brother’s construction company, in a variety of roles. She has carried the experience into her new role as president of Tri-State Emulsions Corp., headquartered in Sandgate, Vermont, which is registered as a DBE/WBE doing business in Connecticut, Massachusetts, New Hampshire, New Jersey, New York and Vermont. Her company performs mostly municipality and city/state work, serving as a subcontractor. She shared that the experience working in the scheduling, bidding, administrative portion of CMA afforded her “a comfort level to jump into the business” and helped her build a mental outline for her own business. “Since I started, I have taken that base to develop a flow and move forward with the learning curve of the nuances of each state, state specific reporting, and of course, connecting to new customers,” Loud shared. She offered how that office environment could be a benefit for women entering the industry today. “For me, I didn’t know every piece of the industry, but I am well organized and have been successful in the past with running businesses in different industries. If you know the general product and industry, it might be worth the try.” Loud took some time to share her story to encourage other women of asphalt.
AsphaltPro: Could you share with readers your career trajectory since high school and what challenges you’ve overcome along the way? Could you share how a nursing degree factored in? Jodi Loud: I grew up in a low-income part of town and my family struggled financially. When I was younger, the only thing I knew was that I wanted to be able to support myself and my family. As for why nursing, when I was in high school, I helped a friend with a splinter, and she told me I should be a nurse. That’s the whole story. I knew I would always have a job and be able to support myself. I put myself through college and got a bachelor’s degree in Nursing by working 40 hours a week (Friday to Sunday) to pay my college bill, attending school full time and graduating in 4 years cum laude. I then passed my boards and got two jobs, one working full time and one part time, so I could afford to live and pay my school loans. I have always been trying out different “side gigs.” I helped my brother with his business, I attempted to start an indoor soccer complex/event venue (this is where I learned about DBE/WBE’s), and I have done consulting work. During all this, I had two young children and was a single mom. When this opportunity came up, I felt like it was a chance to truly own my own business, work in one place only and provide a legacy for my kids to take over when I retire. I have a son who is in engineering 20 | JUNE 2022
Jodi Loud’s daughter is an encouragement and inspiration to her. “I don’t know that I would be able to approach life the way she has,” Loud said.
school and a daughter who is going to school for recreational/occupational therapy. Both of them will have the opportunity to work with me full-time, while they create and grow their dream community outreach programs. My son hopes to mentor young kids in engineering in geographical areas where there is little education and opportunity, and my daughter wants to create recreational opportunities for those with disabilities. I have been working on my CDL for the last 10 months. I originally tried to get it when I bought the business, but COVID hit and all classes were cancelled. In August of 2021, I took my permit test then participated in the classes through my union in New York. Unfortunately, as they were in New York and my driver’s license is from Massachusetts, (and my business is in Vermont) I had to then take private lessons with a Massachusetts school and am pending testing for my license this spring.
AsphaltPro: Starting a business as COVID was interrupting workflows would be a challenge. What other big challenge did you experience as you dove into the industry in 2019? And how did you address it?
Jodi Loud: I couldn’t meet any new potential customers, it was hard to get my foot in the door and get business, so it was a super slow start. I also applied for my DBE and WBE in Vermont, New York, Massachusetts, New Hampshire, and New Jersey. That was a challenge as remote “onsite visits” were a new idea and my business was part of that learning curve, so obtaining those certifications took longer. However, when I did get to the interview point with most of the states, once I was able to answer their questions surrounding the “how and why I run a business in construction” and show them all that I know and do, they became very supportive and excited. Once business offices opened back up, I have been out to meet the crews on the jobs and meet with multiple contractors for meet and greets to get to know them.
Drum mixers
AsphaltPro: How many employees did you start out with when opening for business? Jodi Loud: I started with just myself and one part-time driver. This year I have 2 full-time drivers, myself and an office assistant, and am looking for 1-2 more drivers. AsphaltPro: Could you share some of your daily responsibilities and tell readers which of those are the most rewarding/most enjoyable for you? Jodi Loud: Every day I am working on marketing and sales, general office work, bidding, invoicing, payroll, financials, contract review, accounting, and truck oversight. It’s all rewarding because it is my business. I am really enjoying meeting all these new prospective customers. I am learning every day whether it be different contracts and needs, or just the problem-solving as a business owner, and I love having my own employees and my employer/employee relationships. AsphaltPro: What do you think is the most important skill you’ve brought to your position in the pavement preservation sector? (And how would you encourage other women entering the industry to hone a similar skill?) Jodi Loud: I have a lot of interpersonal, business and organizational skills, which are huge in running a business. On a funny note, I also have found my knowledge in the human body has helped me with the learning curve with the trucks. If you think about it, trucks and the human body all have separate working systems for air, hydraulics, fuel, and general mechanics. It has made it easy to learn the systems and workings of the trucks and to problem-solve issues. AsphaltPro: You mentioned going out to meet face-to-face with contractors during 2021. Would you like to comment on the level of ease or difficulty you’ve had bringing your crew/company to the marketplace, as a female leader? And what tip(s) would you offer a female colleague for introducing a subcontracting company to a marketplace? Jodi Loud: I spent time on the internet to find company contacts and sent an introduction email and followed up with calls. I also reached out directly to the estimators. As a general principle, I approach everyone with respect and appreciation and treat all people like people regardless of who they are or what they do, and thus far, have been treated back the same way.
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WO M E N O F A S P H A LT AsphaltPro: Could you tell us about some changes you’ve seen take place in the asphalt “culture” since the time you worked in your brother’s company? Jodi Loud: Overall, in the asphalt world, like most of construction, more women and minorities are entering the field every day. My experience has been that the culture has been welcoming and it really just comes down to how well you perform. If you perform well, you are treated accordingly. AsphaltPro: Let’s talk about perceptions. It’s a fact that asphalt pavement maintenance and preservation can be hot and dusty. How do you respond to people who say it’s a “dirty job?” Jodi Loud: It is a dirty job. I now have my tack clothes and my good clothes. All you have to do is rub against the arms accidentally and you have been tacked. So, if you want to stay clean, you might want to find a different venture.
Jodi Loud is the president of Tri-State Emulsions Corp., headquartered in Sandgate, Vermont.
AsphaltPro: What do you think is an incorrect perception that we, as an industry, can re-educate young people about to encourage more women to consider a career in the asphalt industry? What is something you would tell a young lady to encourage her in this industry? Jodi Loud: I have my own “young lady” who I am having that conversation with, so I will tell you what I tell her. Just come over and give it a try. There is a real opportunity here for women and I have found that most everyone has welcomed me in and are excited to have more women around, to include the other women in the industry. AsphaltPro: What is the most challenging aspect for you of being in the asphalt business? Jodi Loud: It is the learning curve. I love learning new things but at the same time, I hate not being an expert in my field. I am still learning new products, new laws, new approaches, new vendors, new contractors, new states, etc. AsphaltPro: What is the most rewarding aspect for you of being in the asphalt business? Jodi Loud: In this business, if you put in the work and time, you get the reward. It is not like that in every industry.
The last project of the 2021 season for Tri-State Emulsions was tacking the Westchester Airport in December. 22 | JUNE 2022
AsphaltPro: Will you tell us about a person who served as a mentor for you? What is a piece of advice from this person that you would share with other women in the industry? Jodi Loud: I can’t say I really have a mentor in asphalt. So as far as learning asphalt, I spend a lot of time educating myself on the internet (you know people build whole houses with no experience via YouTube), with literature, with my supplier, with my brother, I have a service BizPlanEZ for certification focused needs, and at times will consult the contractors. But a mentor to take the leap…my daughter has taught me that life is short and that I need to live every day like it’s my first and last. So, if we are talking about encouraging women to take the leap, listen to the words of my daughter, who is just 22, but suffers from Multiple Sclerosis and was diagnosed at 16. I don’t know that I would be able to approach life the way she has with her challenges, and she inspires me every day.
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International Tree Mix BY SANDY LENDER
A
s part of its The Road Forward climate stewardship mission toward net zero carbon emissions, the National Asphalt Pavement Association (NAPA) listed industry goal number three would involve developing a net zero materials supply chain by 2050. This puts an emphasis on Upstream Scope 3 Emissions such as those created or emitted by vendors who supply our liquid asphalt binder or asphalt binder replacements. One of the companies offering to replace a portion of liquid binder in asphalt mix designs is Stora Enso, a provider of renewable products in packaging, biomaterials, wooden construction and paper, headquartered in Helsinki. This unlikely source is one of the largest private forest owners in the world and has found a way to use lignin—one of the main building blocks of a tree—as a sustainable alternative to partially replace liquid bitumen in asphalt mixes. The company explained that its Lineo® product can be used to construct “climate-improved roads that have a lower carbon footprint and that store carbon.” Let’s take a look at this concept starting with a breakdown of what lignin is and how Stora Enso produces Lineo from it and then discussing how Lineo is working in asphalt mixes for Peab Asfalt in Sweden.
Lineo by Stora Enso. The company’s spokesperson, Heikki Lotti, shared: “The carbon absorbed by a tree during its lifetime is stored in lignin, thus making it a perfect raw material to be used in long life-span products such as asphalt where the carbon captured from the atmosphere is stored for decades.” Figure 1. Emissions Statement
BIOENERGY BINDER
“Lignin is an organic polymer that comes from wood,” the company shared. “It is the second most common macromolecule in nature. It binds the fibers of a tree together. It is extracted in the pulp-making process.” Traditionally, lignin is used in energy production or to make bio-based products, and Stora Enso does this without increasing the number of trees it harvests. “The trees that are used to make Lineo come from sustainably managed, traceable forests with FSC®/PEFC™ chain-of-custody and ISO 14004 certifications.” The company produces lignin industrially at its Sunila Mill in Finland, producing around 50,000 tonnes per year. This makes Stora Enso the largest kraft lignin producer in the world, according to the manufacturer. Heikki Lotti, the business development manager for binders at Stora Enso, shared with AsphaltPro that the company provides the full input data for compiling Lineo’s environmental product declaration (EPD) according to EN 15804 +A2:2019. The full lifecycle inventory data is available for the product and is based on its continuously operating production of lignin. “From this third-party verified EPD input data, an EPD for any end-product can be compiled showing the positive impact of replacing the fossil-based components in the end-product,” Lotti shared. “By doing so, users of Lineo can obtain and register a validated EPD for their end-product. In the recent site-specific calculation, a 15 wt% replacement of the virgin fossil-based bitumen with Lineo kraft lignin results in carbon neutral cradle-to-gate asphalt.” (See Figure 1.)
TEST IT OUT
At this time, the 15% by weight of binder replacement level represents more than what early field tests are using, but also represents a figure Stora Enso is preparing to meet and exceed production-wise. 26 | JUNE 2022
Fossil CO2 emissions and carbon stored in Lineo® kraft lignin
“Lineo kraft lignin usage as bitumen replacement is taking its early steps and the demand is increasing, especially in the countries where authorities and companies are putting high emphasis on reaching their climate neutrality objectives,” Lotti shared. “Stora Enso has recently invested heavily in optimizing the logistics chain of Lineo, making lignin even more economically attractive in all destinations globally.” In 2020, Peab Asfalt began testing the use of lignin in its ECO-Asfalt surface mixes in Sweden. Johan Bolander, production manager for Peab Asfalt, shared with the Stora Enso audience: “We see this as a very exciting development, using raw materials from the forest to reduce our CO2 emissions and at the same time make ourselves less dependent on imports. If we can drive the development towards more binders for our paved roads coming from Nordic forests, it is very positive. We see environmental benefits, job creation and more sustainable coatings ahead of us as we now develop the technology of adding lignin to our ECO-Asfalt.” Peab’s laboratory manager, Lars Jansson, also shared excitement with the Stora Enso audience. “We have been working with different
types of lignin for a few years now and it is important that we trial it in real production. Last year [2020], we performed our first test surfaces with lignin and now we are moving forward with developing the concept. It feels very exciting and important to have this cross-industry collaboration and to work closely with our customers to develop a climate-approved and more durable asphalt pavement. We are pleased that we can put these test stretches in place and contribute to municipalities meeting their environmental goals.” In 2021, Peab placed a test section along with the Swedish road and infrastructure operator Svevia. A recent test is being conducted on Bråtvägen road in Forshaga municipality where the amount of lignin used in the binder is 10%. In addition to lignin, Peab has included 30% re-used asphalt from milled road surfaces. During the testing period, the roads have been subjected to tough winter conditions, spiked tires and snow ploughs, showing the roads with Lineo-based asphalt are durable. “Regarding the test results with Peab and Svevia, the paving projects done by our partners in the past with Lineo lignin containing asphalt, have all proven to work well,” Lotti shared. “Although, more time is needed to demonstrate the full performance of the road. Our confidentiality obligations limit Stora Enso from sharing any specific measured parameters collected during the tests. The paving works communicated in the public domain by Peab Asphalt have performed well and have stayed free from any failures, despite the harsh winters and very hot summers we have behind us in the Nordics.” Lotti stated the objective of replacing a portion of the virgin bitumen with Lineo is to improve the carbon footprint of the asphalt blend without compromising on the technical performance, and they are seeing that objective met. “Currently, the lignin-containing asphalt shows equal properties compared to standard PEN-grade bitumen-containing blends,” Lotti shared. “There are some indications showing improved stability, rutting-resistance and improved water resistance. The objective is, however, to be on par when it comes to the technical performance when replacing virgin bitumen with Lineo kraft lignin. “It is considered that the potential improvement of technical performance merits further study. Especially the performance with polymer-modified bitumen-containing blends.” As noted above, Peab mixed in reclaimed asphalt pavement (RAP) on a project as well. “Kraft lignin, like Lineo by Stora Enso, contains various components with antioxidant and rejuvenating properties,” Lotti shared. “The study of the impact of these properties on recycled asphalt pavement (RAP) and the recycled bitumen behavior is at a very early stage. There is still limited historical data available to validate any such impacts on the milled road surfaces or the recycled bitumen content.” The Peab asphalt plant uses renewable fuel (bio-oil) for drying and heating the stone material and Lotti told AsphaltPro the Lineo product can support reduced hot-mix asphalt (HMA) production temperatures. “Lineo kraft lignin does not require high temperatures to melt or to activate its binder properties,” Lotti shared. “This allows the plant operator to reduce the blend temperature if required. The use of lignin also supports the current trend of reducing blend temperatures and shifting towards WMAs, thus contributing to lower plant energy consumption and carbon emissions.”
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4/25/22 4:50 PM
FAMILY CONNECTIONS JM Fahey celebrates 50 years with CWMF’s stationary full plant build
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BY SANDY LENDER
Replacing the original plant at its Holliday Drive, Kansas City, Kansas, location represented the icing on the cake for the 50-year anniversary of JM Fahey Construction Company, Grandview, Missouri. Joseph M. Fahey founded the company in 1971 with his son Kevin Fahey and grandson Andrew Fahey at the helm today. They’re not only celebrating five decades of quality workmanship from the early days of cold milling to acquisition of land and facilities for quarrying and asphalt production, but also celebrating growing a family-oriented company that takes its commitment to employee, community and vendor relationships seriously.
28 | JUNE 2022
Read the history of J.M. Fahey on the company website at https://www.jmfahey.com/history.
A TEAM BUILD Andrew Fahey, president of the company, spoke proudly of the team at JM Fahey when describing the new plant now in service for them. He also spoke of the team and family atmosphere of the vendors his company elected to work with for the build. Those vendors, CWMF Corp., Waite Park, Minnesota, and Motion Engineering Inc., Kenosha, Wisconsin, also have family histories as their backbones.
The Revolution drum from CWMF for JM Fahey’s new plant is 10.5 feet in diameter, 54 feet long and includes a RAP collar.
The robust control house is centrally located where the operator has a bird’s eye view of loadout and production. All photos courtesy of CWMF
“This is our first experience with CWMF and we’re looking forward to that relationship moving forward,” Fahey said. The company’s management team was able to meet with the ownership of CWMF before design conversations or permitting applications began. “CWMF is a family-owned business, which was important to us,” Fahey said. “That was meaningful to us on the front side of this. You don’t see enough of that anymore, but you can learn a lot about somebody by sitting down with them for a while and learning their values. We had that opportunity with CWMF. They’ve got a lot of skin in the game, and we understand that better than anybody.” Wally Olson, regional sales manager for CWMF, explained he and owners Travis Mick and Carmie Mick were about to meet with Fahey’s management team before design and engineering conversations got started. “We went to Kansas City, and I thought I’d need to present all the ways we could help them, build a plant for them. All they wanted to do at that time was meet, get to know us. We were
building a relationship between a family-owned group and a family-owned business.” The custom-build conversations began around December 2019. By December 2020, CWMF had a commitment from the Fahey company to bring the build to fruition. “It took all of a year for the permitting,” Olson explained. “What CWMF was providing was good to help in the permitting process, but more information was needed from our engineering department due to the nature of a custom-built design to facilitate permitting and for management to come to final decisions.” The physical on-site build began when the first truckload arrived at Holliday Drive Feb. 15, 2022. Over 30 truckloads would be delivered over the next 20 days, complete with some weather interruptions. The CWMF and Fahey teams didn’t have to go it alone, though. CWMF hired its trusted subcontractor, Motion Engineering, to erect the plant. “My dad had a long-standing relationship with CWMF,” Mike Petrie, owner/operator of Motion Engineering said. “Travis [Mick] calls us up, we bid the project, and go from there.” After winning the JM Fahey job, Petrie went over the project with their project manager. “They had made the decision on the placement for the plant, provided drawings and layout.” Because the new plant would ultimately rest upon the old plant’s foundation, the Motion Engineering crew arrived and set the components in place. “On this project, there was no electrical for us to perform,” Petrie said. “Motion Engineering does electrical, builds control houses, motor control centers, but this project didn’t require that of the crew.” Motion Engineering does everything from smaller repairs to full plant installs and teardowns. The company erects silos, handles retrofits and is a Honeywell/Eclipse/Maxon Channel Partner. “I ran an asphalt plant for seven years,” Mike Petrie explained. “We get involved in almost any project for any brand.”
What the Fahey project did require of all crewmembers was flexibility. “We had snow that threw us off course a little bit,” Petrie said. “Pretty heavy snow conditions. You just have to roll with it WWW.THEASPHALTPRO.COM | 29
When the plant started operation May 1, the set-up personnel vehicles were gone and the sloped ground leading up to the cold feed bins and recycle bins was complete. By creating a ramp up to the bins, the Fahey team gives loader operators a better opportunity to maximize fuel efficiency and optimize feeding the plant during production. Also notice the covered conveyors and covered and skirted transfer points for material to assist in controlling dust during production.
With the moon setting in the background, the team of JM Fahey, CWMF and Motion Engineering worked through record snowfall to stay on schedule with the new plant build. 30 | JUNE 2022
and do what you can get done, then get up the next day and just keep going.” Olson and CWMF’s engineering manager, Luke Vossen, commented on the efficiency of the Motion Engineering team members staying on task despite weather or other delays. It was the kind of energy needed in an industry like construction, and Fahey attributed everyone’s success on the project in part to industry knowledge. “In this business, you better be ready to pivot,” Fahey said. “This team did an amazing job of adapting and making every day count. Not every day is perfect and you have to do what you can on the imperfect days.” Asphalt Plants Manager Britt Jaudon described one imperfect day as starting with about an inch of snow on the ground at 7 a.m. By 10 a.m., they had 8 inches of snow on the ground and near-blizzard conditions. “We were on a deadline, so we kept one eye on safety and kept pushing forward,” Jaudon said. “We had a good group of guys who knew we were on a deadline.” “We did have some extreme weather conditions that our team had to fight through during the set-up of the plant,” Petrie shared. “There was a record snowfall during that timeframe, but our team was able to communicate and plan ahead to meet the deadlines that CWMF and Fahey had for the project. We received excellent feedback about our team on that project by CWMF as all were pleased with the outcome of the project. “If you’re waiting on trucks or a delayed delivery of equipment, my guys are jumping on putting up handrails and other miscellaneous stuff to keep the project moving forward,” Petrie continued. “You keep identifying what needs to be done next and tackle that.” Sara Petrie explained, “Our guys are away from their families four to six weeks at a time, so they’re a cohesive team that works together well. And it’s a team driven to get a job done in a timely manner.”
LEFT: Included in this image above the plant, you can see the hose leading from the mineral silo to the Dust-Eater 90,000-CFM pulse-jet baghouse. Rather than build and maintain a mini baghouse atop the mineral silo, the team lets stray dust carry to the baghouse, which serves as the filter. RIGHT: At the bottom right of this picture, the black pipe delivers air into the adaptor flange on the mineral silo’s weigh pod.
By March 5, 2022, JM Fahey had its plant in place. As of May 1, the plant was in production. “It was a mutual process with CWMF and the customer throughout the design and build phases,” Vossen said. “We had countless virtual meetings to ensure we were building what they wanted.” Olson and Vossen said that included: • 10.5- x 54-foot drum with RAP collar • 90,000 CFM pulse-jet baghouse • Three 250-ton silos • Drag slat and transfer conveyors • A tank farm with two 30,000-gallon and one 15,000-gallon AC tanks, plus the metering, unloading & pumping packages • Feed bins and scale conveyors • A two-story control house discussed below • Systems Equipment controls • A complete auger package (driven by the customer) to feed dust return to the drum and to the existing mineral silo
BUILDING A WORK ENVIRONMENT
Along with building a new asphalt mix production facility, JM Fahey Construction was building a new work environment for its team at the Kansas City, Kansas, site. To that end, Fahey, put much consideration into the workspaces. One of those spaces is the control house. “The control house had a separate permit for inhabited structures,” Olson said, not hiding how impressed he was with the planning Fahey put into the building. “You should see how cool this thing is. It’s state of the art. It’s the biggest control house I’ve seen.” Fahey explained the separate permit was a building permit ensuring the structural integrity of the control house and showing inspections of the foundation work they poured. “We took that in stride,” Fahey said. “CWMF did a great job getting all the necessary engineering approvals.” The new control house offers more than a central location for plant controls and ticketing. Garage doors on the ground floor open to reveal an electrical hub, easy for maintenance personnel to access. The garage bay doubles as tool and equipment storage, providing a secure and dry place to lock pricy and “easily mobile” items when the crew is
TOP: Along with the metering, unloading and pumping packages, CWMF provided two 30,000-gallon and one 15,000-gallon AC tanks for JM Fahey’s new tank farm. BOTTOM: The team held a ribbon-cutting ceremony May 2. WWW.THEASPHALTPRO.COM | 31
away. The building also offers a comfortable environment with breakroom and office space. The control house now offers the team—and new members to the team—a pleasing environment to conduct business. “People who aren’t familiar with an asphalt plant don’t realize how much business takes place inside the control house and how busy it can be,” Fahey said. “This larger structure allows an office with a door that allows a little more business to take place and lets Britt [Jaudon] or any of the plant managers stay in one spot to get work done and handle the logistical challenges of the plant. Getting all of that scheduled down to extreme detail is an enormous task; having a place to accomplish those tasks is important.” Providing the best for the workforce is important to Fahey. “With anything you do today as it relates to your employees, you want to make coming to work a better experience,” Fahey said. “That’s low-hanging fruit. That’s not only benefiting the individual worker, but it’s also benefiting the company as well.” To prove the point, both Jaudon and Fahey remarked on the current workforce’s contributions to the plant build’s possibility. “JM Fahey Construction employees need to understand, their efforts are what made this all possible,” Fahey said. “Britt and his team, there are too many to list all the workers who had a hand in making this happen. Forming the relationships with CWMF and Motion Engineering is part of it, but this wouldn’t have happened without our team.” “It took all those guys to make this come together,” Jaudon said.
BUILDING DUST CONTROL
Another aspect of the build that took a team effort was the dust return. Jaudon explained the system they created was an amalgamation of technologies seen around the industry. No matter which brand of plant or baghouse you look at, he said, there are different aspects of the dust-return systems that are excellent. “All these systems are different, and we designed our own as a combination from multiple plants we’ve been around over the years. With it, we have the way to pull dust out and add dust in simultaneously.” With material fed via augers, the plant operator can move air locks to feed dust from the baghouse to the drum collar or to the mineral silo, from the baghouse to both the drum and silo, or to feed dust from the mineral silo to the drum. The concept is an example of Jaudon’s ingenuity, nurtured in an environment like JM Fahey and encouraged by the engineering camaraderie with CWMF. “The customer one hundred percent drove that design,” Olson said. “It’s a custom reverse auger.” “It’s all driven by the industry’s higher specs,” Fahey said. He explained that the asphalt industry must still meet stringent specifications that incorporate fines and changing designs while maintaining the ability to modify and experiment with materials. “How do we meet those requirements and still have some flexibility?” he asked. Being able to auger fines to the location they’re needed, as they’re needed, gives JM Fahey plant operators that flexibility. Other dust control around the plant is less technical, but just as important. Visitors to the new plant may notice the site isn’t fully paved, and that’s by design. In the city, stormwater run-off regulations depend on one’s square footage of paved property. “The more you pave, the more run-off you create,” Fahey explained. “If we did decide to pave the lot, we would have been required to put in a retention pond, which we don’t have the space for in our footprint.” Instead of having a completely paved lot, Fahey has a water truck almost full-time on the site to keep dust down and the drive leading into and out of the site is paved to keep traffic from kicking up too much dust. 32 | JUNE 2022
LEARN MORE
Move Dust for Quality Control The team at JM Fahey had been brainstorming ways to improve mix quality for their customers, according to CWMF’s Wally Olson. During the plant designing process from 2019 to 2021, they came up with the ideas for CWMF to design. The result is the system in these images. It may look complex at first with enclosed augers crisscrossing this flat image, but the design contained within the space of the pertinent components allows the plant operator to physically meter fines to his mix. In the photo below, you can see a forward auger (the base of which is indicated by the letter B) to move dust from the baghouse (indicated by the letter A) to the drum. The system gives the plant operator the ability to block the rotary airlock and reverse the auger (indicated by the letter C) to move dust up to the mineral fill silo.
The hose leading from the top of the mineral silo to a flange on the baghouse (indicated by the letter A) represents another innovation from JM Fahey and CWMF. Olson said this idea not only reduced maintenance by eliminating the need for a “mini baghouse” atop the mineral silo, but also lets the Dust-Eater from CWMF serve as a filtration for the dust silo.
From creating a comfortable environment for workers to forming lasting relationships with similar family-oriented businesses, the team at JM Fahey has shown workforce-building and quality-minded growth since 1971. Now the 2022 construction season has launched with a state-of-the-art facility built to attract business, quality and workers for the future.
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BEFORE IT’S TOO LATE: TALK ABOUT IT
The asphalt industry prepares to stem the tide of construction industry suicide
I
BY VINCE HAFELI AND SANDY LENDER
In society, you may hear someone caution you that talking about suicide will put the idea of self-harm into someone’s head. This myth must be dispelled, and we must talk openly, clearly, and succinctly about the epidemic of suicide in the construction industry if we are to protect our colleagues from despair and bring about a mental health wellness culture. We could fill this article with alarming statistics about opioid dependence brought about by musculoskeletal strains and injuries on job sites and the horrifying “success rate” of life-ending methods by men versus women. Or we could point you to websites like The Center for Construction Research and Training (CPWR) and Construction Industry Alliance for Suicide Prevention (CIASP) where those statistics will be accompanied by materials your safety and human resources directors can use in concert with insurance companies to put an Employee Assistance Program together immediately.1 In the construction industry today, we will lose 3 workers to work-related fatalities. We will lose 15 to suicide.
An Employee Assistance Program should identify—among other things—your policy for helping, without judgment, a worker who comes forward seeking help with a substance-abuse problem. As company executives, we are responsible for discussing mental health and suicide within our industry and encouraging our employees to openly and honestly discuss the topic without fear of repercussions. These discussions are important to “Gen Z,” which also ties into workforce de-
velopment, recruitment, and retention within our industry. Keep in mind, a dependence on opioids, which research shows can develop after a mere three days of use, is not the only stressor leading to mental health unwellness in the construction industry.2 Mental health wellness is a complex issue—dependent on individual experiences—that people aren’t always ready to talk about. The team at Ajax Paving Industries of Florida discovered this truth firsthand after a discussion with department heads in August 2021. The meeting in August took place with the company president; human resources; the vice president of construction and four area construction managers; the general manager of plants and materials and two regional plant managers; the director of safety; the quality control manager; the fleet manager; the IT manager; and the trucking manager. These are leaders in the company who employees look up to. When Hafeli shared his personal story—unplanned—from 2007 with these managers, no one knew how to respond. Thus no one responded. This further supported what the literature research revealed—this is a complicated topic and people avoid discussing the issue. But Ajax leadership decided to make a mental health wellness culture change. They hosted a Safety Day Jan. 3, 2022, in which over 430 employees participated. At the presentation where leadership announced Jan. 3 as Day 1 of Ajax beginning to discuss mental health and suicide, Hafeli made a statement when talking about suicide that he had been there. While he gave no details that day, this powerful statement resonated across the company. Later that day, he received an email from an employee thanking him for opening the door. That employee worked with a superintendent
1 Visit CPWR at https://www.cpwr.com/. Visit CIASP at https://preventconstructionsuicide.com/. 2 During a webinar hosted by CIDCI March 11, 2022, CPWR’s deputy director, Rick Rinehart presented data on opioid prescription frequency and the ease of substance addiction. More statistics can be found at the Substance Abuse and Mental Health Services Administration website https://www.samhsa.gov/.
34 | JUNE 2022
WEB EXTRA Web Extra: Watch the webinar “Shining Light on Mental Health & Suicide Prevention” presented to the Women of Asphalt by Cal Beyer, vice president of Holmes Murphy & Associates, and Vince Hafeli, March 2, 2022. It’s hosted at the WofA website on the Conversations to Lead and Inspire page.
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Reach Out Respond Connect
Together,
we can help prevent Suicide in Construction. Reach Out Respond Connect If you or someone you know needs immediate help, contact the National Suicide Prevention Lifeline at 1-800-273-TALK (8255) or text “HELLO” to 741741 to connect with a crisis counselor.
©2020, CPWR-The Center for Construction Research and Training. All rights reserved. CPWR is the research and training arm of NABTU. Production of this document was supported by cooperative agreement OH 009762 from the National Institute for Occupational Safety and Health (NIOSH). The contents are solely the responsibility of the authors and do not necessarily represent the official views of NIOSH.
During the CIDCI webinar March 11, the team from CPWR shared the mantra: Reach out. Respond. Connect. Reach out means to be direct; just ask someone if you notice they seem “off” or distracted. Respond by listening without judgment and without making promises. Let them know you care too much to keep their distress a secret if they need help. Connect means getting help for your colleague. Connect to a safety director or supervisor or, if necessary, call a suicide prevention help line for immediate, professional counseling to safeguard your co-worker. Infographic courtesy of and available from CPWR
who had seemed “off ” for quite some time; however, he didn’t know how to approach the topic. After leaving the safety day meeting, the two had an hour-long conversation revealing issues that the worker went to seek counseling for. Also after that safety day meeting, over 20 employees posted on the company’s Facebook page thanking management for discussing mental health, saying it was long overdue, calling it a great discussion on mental health. The journey continues at Ajax Paving. The company took the pledge with CIASP.3 The safety director has scheduled talks on mental
health and suicide prevention for each quarter of 2022. The Safety Stand Downs during the week of March 21 included discussions on this topic. And Hafeli, as the company president, has been discussing the topic when visiting employees in the field. It’s time for the industry at large to make that discussion widespread. Talking about mental health wellness and suicide prevention is key to helping a colleague rise out of despair. Each member of the industry has the ability to protect and safeguard his or her struggling co-worker. And each member of the industry who has struggled and overcome has a story of success and continuing men-
tal health work to share. AsphaltPro Magazine invites you to share your struggle and your rise, for the benefit of others who may be where you once were. We’re offering space in our pages to share, with compassion and discretion, information that could help save a life. It’s time to erase the stigma of mental health struggles and help one another. Vince Hafeli is the president of Ajax Paving Industries of Florida, North Venice, Florida. To reach him, email vhafeli@ajaxpaving.com. To share your story with the industry, reach out in confidence to sandy@theasphaltpro.com.
3 Take the pledge to stand up for suicide prevention here: https://preventconstructionsuicide.com/STAND_UP_for_Suicide_Prevention
36 | JUNE 2022
P R O D U C T GA L L E RY
Paver Roundup From World of Asphalt BY ASPHALTPRO STAFF
N
ot every paver-related original equipment manufacturer (OEM) brought a new launch to World of Asphalt 2022 in Nashville, but some of the iron on the tradeshow floor was seeing its debut for a North American market or for a tradeshow audience. For example, the 8520B asphalt paver from ST Engineering LEEBOY Inc., Lincolnton, North Carolina, was updated with assistance from the team at American Pavement Specialists LLC, Danbury, Connecticut, for the industry in 2021 and was on display for the first time at WOA, according to a LeeBoy salesperson onsite. Another paver OEM who had a significant offering on hand was WEILER Inc., Knoxville, Iowa. WOA attendees would have seen a number of commercial class pavers in the vendor’s booth, as well as a variety of products for the paving contractor. The base designs for Weiler self-propelled road wideners and asphalt windrow elevators were created by Barber-Greene®, which many readers may remember was purchased by Caterpillar in the early 1990s. Weiler purchased designs from Caterpillar in 2005 and established the Weiler brand name. Since then, Weiler has manufactured products for the asphalt paving market including pavers, remixing transfer vehicles, road wideners, windrow elevators, static split-drum compactors and front-mount screeds. For more information, visit https://www.weilerproducts.com/. The team from BOMAG not only showcased its CR1030 T paver, but also hosted a fundraiser for Construction Angels at the booth. The paver offers SideView, SMARTRAC, Frame Raise and Telematic technologies from Bomag in this 10- to 30-foot-wide paver. The fundraiser brought in $1,300 for the Construction Angels mission to provide immediate financial assistance and grief counseling to the families of con-
This tracked paver from Bomag, displayed during WOA, features a 10to 20-foot screed with ability to stretch to 30 feet with extensions. Feed that from a 14-ton-capacity hopper. 38 | JUNE 2022
CHOOSE YOUR FEED SYSTEM ON THE NEW DYNAPAC HIGHWAY CLASS PAVERS—DUAL SENSOR MODE, QUAD SENSOR MODE OR FLOW GATE. struction workers who have lost their lives while working on the job site. For more information, visit https://www.bomag.com/us-en/. ASTEC Industries, Chattanooga, debuted its new, modern operator control system, which is available on all Roadtec RP-series highway class asphalt pavers. The RP paver line has been updated with operator controls to provide improved functionality and a compact, modern feel. All highway class asphalt pavers are now outfitted with an innovative digital control system and easy-to-understand touch screen interface. These updates are designed to deliver a balance of intuitive technology and simplified operation. Keith Hagy, product manager for Astec paving products, described the control system as “highly functional, technologically-advanced,” while “still simple to operate and service.” The control system includes: • Digital operator panel with clear and easy-to-understand digital icons, allowing operators to easily monitor machine status • Ergonomic experience - Stations are conveniently positioned within reach of the operators' fingertips • Touch screen display
The new operator control system from Astec allows both ergonomic ease and touch screen interface for the operator’s choice.
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For more information on the items above and more, call or visit our website. Our trusted and reliable asphalt experts will come to your site and appraise your equipment or plant. All you will have to do is sit back and let us bring approved buyers to you! Turn your surplus asphalt plant equipment into much needed plant upgrades.
Inspection Marketing Showing Sales
Availability, price and condition subject to change by Stansteel®. Specifications are accurate to our knowledge, however; they are not guaranteed. All prices are in U.S. dollars unless otherwise noted. Equipment is sold on the basis of as is, where is, therefore, Stansteel® recommends inspection by buyer of any used equipment to determine suitability to their requirements. Gencor® and Bituma® are trademarks of Gencor® Industries, Inc. and Stansteel® is not related to or licensed by Gencor® Industries, Inc.
P R O D U C T GA L L E RY The improved RP-series highway class pavers will now include the upgraded control panel technology standard on all models, according to the manufacturer. For more information, contact (423) 265-0600 or visit https://www.astecindustries.com/. At the booth for DYNAPAC North America, Fort Mill, South Carolina, WOA attendees could check out the newest range of highway class pavers and screeds built specifically for the North American market: the D30T (10-foot track), the D30W (10 foot-wheel), the D25T (8-foot track), the D25W (8-foot wheel), Mat Master 16R (8to 16-foot screed), and Mat Master 20R (10- to 20-foot screed). The D30T and D25T models offer iTrack ultra duty rubber track design and the D30W and D25W models offer dynamic suspension control (DSC) for optimum tractive effort and results needed for highway paving. The Mat Master screeds are equipped with DiveStop and Active Screed Assist. The new pavers are built with dual independent tractor consoles and include the Dynapac smart dashboard and HMI design on the tractor and screed. Operators have access to Dynapac PaveManager, and assistance such as FeedAssist, CleanAssist, ImpactAssist, DiveStop, LightAssist are built in. The user-friendly swing out dashboards are equipped with toggle and rocker switches within easy reach. The contractor can customize the feed system on the new Dynapac highway class pavers to fit the comfort level of the crew—choose proportional dual sensor mode, proportional quad sensor mode or flow gate. If the crew will be performing night paving, Dynapac points out its Flicker-free Generator system design, which allows the crew to directly connect the night-lights to the paver easily. The need of renting external generators and plugs are completely removed. For the contractor looking at The Road Forward, Dynapac highway class pavers are equipped with ECO-Mode engine technology for lower fuel consumption and the overall design allows to operate the paver at lowest possible engine RPM, according to the manufacturer. Screed heating is also possible with ECO Zonal heating, designed to consume less power and fuel. The Mat Master screeds are also de-
The modular machine concept means the SUPER 1800-3i Sprayjet by Vögele can be used as a spray paver or as a standard screed to pave thin layers as well as conventional binder and surface courses.
signed to handle a variety of mixes such as rubberized asphalt and warm-mix asphalt and others. The manufacturer states “We are with you to reduce carbon footprint with innovative mix design.” For more information, contact vijayakumar.palanisamy@dynapac.com. The WIRTGEN booth included a cross section of Vögele pavers, including the SUPER 1800-3i SprayJet with fixed-width screed VR 600. The spray paver offers a unique modular machine concept allowing it to be used as a spray screed or as a standard screed to pave thin layers as well as conventional binder and surface courses. It has a maximum spray width of 19 feet, 6 inches. With the rear-mounted VR 600 screed, it’s designed to fulfill all requirements for asphalt paving. The paver presented at the WOA was equipped with an additional emulsion tank, which can store 1,320 gallons emulsion in addition to the standard emulsion tank that stores 555 gallons. For more information, contact matt.graves@wirtgen-group.com or visit www.wirtgen-group.com. At the CATERPILLAR booth, the company displayed its new compact line of asphalt pavers and screeds, launched in November 2021. These standard 8-foot size paver and screed combinations include the AP400, AP455, AP500, and AP555 asphalt pavers as well as the SE47 V and SE47 FM asphalt screeds. They come equipped with features for both urban and rural applications to fit the needs of both large and small contractors. The compact size and small footprint combine with maneuverability for more opportunity to pave in confined areas such as narrow streets, small parking lots, and other urban-type applications. The standard paving range using the SE47 V screed is 8 feet to 15 feet, 6 inches (2.4 to 4.7 meters) with a maximum width of 20 feet (6.1 m), while the standard paving range of the SE47 FM screed is 8 feet to 15 feet, 6 inches (2.4 to 4.7 m) with a maximum width of 20 feet, 6 inches (6.2 m). Paving depths up to 10 inches (254 mm) support aggregate paving applications. For more information, visit your local CAT dealer.
ALLU The new highway class pavers with Mat Master screeds from Dynapac offer two heating modes—Heat Boost and Eco Mode. The Heat Boost mode heats the screed fast to get you going on cold mornings. The ECO mode keeps the heat uniform across the screed, saving fuel. 40 | JUNE 2022
ALLU Group showcased the ALLU Transformer crushing and screening attachment for skid steer loaders at World of Asphalt 2022. The ALLU Transformer D series crushing and screening buckets and the ALLU AC crushers are designed to be used on base machines such
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P R O D U C T GA L L E RY as excavators from 4 to 60 tons, and skid steer and backhoe loaders from 4 to 30 tons. The Transformer is designed to turn the loader into a mobile processing plant. When using the machine in this new way, companies will benefit from reduced investment and operating costs, have a smaller carbon footprint and lower transportation costs, by transforming material into a valuable product on site. Bellamy Paving in New Jersey is a construction company using the Transformer DL 2-17 model to crush and screen asphalt material. Joe Bellamy explained: “By processing the waste with the ALLU DL Transformer, there were considerable savings made in landfill fees and transportation costs as only about 10% was transported to landfill. The waste paving we used to send to landfill we are now able to crush ourselves and reuse. It’s saved us $40K USD in one season.” Bellamy said the attachment has also helped the company win more work, as the company can prove it’s offering a full service, with recycling solutions for customers. For more information, contact Edison Rocha at (800) 939-2558.
CM LABS
CM Labs Simulations, Montreal, Quebec, developer of Vortex® training simulators, offers the Vortex Edge Plus, which runs CM Labs’ full fleet of earthmoving, lifting and forestry equipment training packs including the excavator, backhoe, dozer, wheel loader, motor grader, and other heavy equipment. Its ease of transport makes the Vortex Edge Plus an optimal hands-on tool for attracting talent at job fairs and career development events, according to the manufacturer. It can also be used to assess the skill level of new operators. Hardware includes a laptop, monitor, industrial-grade joysticks and pedals, as well as a steering wheel to support specific earthmoving equipment. CM Labs’ Construction and Forestry Product Manager Julien Richer-Lanciault said: “With the construction industry doing absolutely everything it can to eliminate barriers to training, this is an ideal solution to getting the next generation of skilled labor exposed to the challenges and rewards of a construction career.” The Vortex Edge Plus runs on the same engineering-grade software that powers CM Labs’ fully immersive Vortex Advantage simulators, used by training schools and fleet owners internationally. Vortex® is a registered trademark of CM Labs Simulations. For more information, contact info@cm-labs.com.
EARTHWAVE
Earthwave Technologies, Indianapolis, includes features to prevent theft and aid in equipment recovery in its FleetWatcher telematics platform. The GPS technology allows users to see where any piece of equipment is at any given time, while an included proactive Unauthorized Use feature alerts user if equipment is started after hours. With mobile equipment, time is of the essence, and this proactive feature gives users a heads-up that the equipment was started when it shouldn’t have and allows users to alert the police quickly. In addition, a breadcrumb feature shows the machine’s location activity in real-time and every minute if the machine is being towed, and the info is available from a browser or a mobile device. Together, these features can notify users of a theft in process so that the theft can be thwarted or that the equipment can be easily located if the heist is completed. 42 | JUNE 2022
FleetWatcher’s telematics platform includes anti-theft and equipment-recovery features.
For more information, contact (800) 553-0027 or info@ earthwavetech.com.
ROAD WIDENER
Road Widener, Delafield, Wisconsin, now offers a spray bar system to increase the versatility of its patented offset vibratory roller attachment. The spray bar accessory fits on all the offset vibratory roller attachments and is designed to aid in suppressing dust particles, compacting aggregates and preventing clumping when rolling hotmix asphalt. The spray bar system comes with two 7-gallon tanks for each side of the roller and can pair with any-sized water tank that may already be on the host machine. For more information, visit the Road Widener website.
WEILER
Among the paving products manufactured by Weiler Inc., Knoxville, Iowa, is the self-propelled road widener, available in the W330B, W430A, W530B and W730B models. The machines are designed to place a specific amount of material at the correct grade and slope in one pass, whether on a shoulder or other area with precise strikeoff. For the W730B, the strikeoff tools are 25 inches tall, to widen from 1 foot to 14 feet, and are capable of placing material up to 12 inches above and below grade, according to the manufacturer. Multiple tool sizes, plus hydraulically adjustable tools, allow the operator to set precise strike-off and exact grade and slope. The controls are located on a single panel and the sliding control console enables both left and right side access to all machine controls. The operator is located back from the dump hopper and toward the outer edge of the machine for increased visibility. The hopper is 3.5 cubic yards, with a 30-inch-wide belt with a belt speed up to 800 feet per minute for quick placement of materials to either side of the machine. The hydraulically adjustable dump hopper accommodates various types of trucks. For more information, visit https://www.weilerproducts.com/ equipment/road-wideners/w730b/
If this looks familiar, we’d like to talk.
“Overall, we have cut our downtime due to control issues to zero hours across three plants!” Brandon Watson, Quality Control & Asphalt Plant Operations Manager
The MindsTronicTM family of automation systems optimizes production, collects key performance indicators, standardizes workflows, simplifies maintenance, allows the standardization of operator training, and improves workplace collaboration. Drums, Batches, Combos, Emulsion, and Liquid terminals Loadout, (e)Ticketing, Cloud-based Desktop, and Mobile Apps Proven industrial PC, Fieldbus, and sub-concepts technology Professional hotline and remote support
Better data. Increased control. Higher profits. S A L E S I N Q U I R I E S : 8 5 5 - 9 6 3 - 49 76 co nt a c t@ min d s u s a . co m min d s u s a . co m
NEW TECH
PaveScan MDM Offers Real-Time Density Data BY SARAH REDOHL
I
magine being able to know the density of the entire pavement without having to take a single core. That’s the ultimate goal behind the new PaveScan MDM (Mixed Design Module) from Geophysical Survey Systems Inc. (GSSI), Nashua, New Hampshire. When used along with GSSI’s PaveScan RDM (Rolling Density Meter) or RDM 2.0 systems, PaveScan MDM is used to correlate dielectric values with the known densities from gyrotory pucks directly from the asphalt plant to the PaveScan RDM system. In layman's terms, dielectrics refers to how permeable/permitive the substance is. The dielectric constant of a surface (for our purposes) is the ratio of how permeable it is compared to the permeability of free space—and this is expressed by how much electric flux is involved. For a scientific, in-depth explanation of dielectrics, visit www.vedantu.com/physics/dielectric-constant.
Paving Consultant Bryce Wuori of Wuori Consulting has used PaveScan RDM 2.0 since 2019 and has tested out the MDM system on more than 30 projects in 15 states since 2020. “I use PaveScan RDM 2.0 as a real-time quality control tool, whereas the MDM system is the calibration kit from dielectric to density. I consider it the link between PaveScan RDM and the asphalt mix being produced.”
FROM DIELECTRIC TO DENSITY
Since the launch of GSSI’s first PaveScan RDM model in 2016, the RDM system can be used to calculate the asphalt dielectric values for the entire pavement in real time. The dielectric values are based on the pavement’s void content, a relative indication of density. Visit theasphaltpro.com/articles/ gssis-pavescan-rdm-asphalt-density-assessment-tool/ for a full explanation of how PaveScan RDM works. “The dielectric maps can help show pavement uniformity and areas that are lower or higher in density,” said GSSI Business Development Manager Rob Sommerfeldt, “but alone it can’t tell you density values.” In the past, it was possible to convert dielectric data into density only after the job was cored. Only after the density of the cores was matched to the dielectric values that PaveScan RDM collected at the coring locations could a calibration curve be created, which converts the dielectric map to a density map. Since the launch of GSSI’s PaveScan MDM calibration system in January 2022, it is possible to use the RDM system to map the density of the entire pavement while there is still time to resolve potential issues. PaveScan MDM can be used to convert dielectric to density using pucks instead of cores. “Then, instead of seeing the dielectrics when using the RDM on the job site, the crew and DOT will be able to see 44 | JUNE 2022
These charts from the Ohio Department of Transportation shows how PaveScan RDM’s results correlate with nuclear and non-nuclear density gauges. Courtesy of GSSI
the density displayed on the RDM’s screen from day one of the job,” Sommerfeldt said. It’s even possible for this calibration to be done during the winter for a variety of common mix designs, so long as the same mix from the same plant gets used. Although Wuori has been using ground penetrating radar (GPR) technology for many years and has grown familiar with dielectric data, he said being able to see density data on the RDM’s screen, when used alongside MDM, is useful for those with less familiarity with dielectric data. “Dielectric doesn’t mean anything to many people in the asphalt industry,” he said. “Converting dielectric into a term they’re more familiar with helps the user better understand what’s happening with the asphalt.”
QUALITY CONTROL, QUALITY ASSURANCE
Not only can PaveScan RDM and MDM be used as quality assurance tools by agencies, the systems can also be used as quality control tools by contractors. “Contractors are making tons of decisions every day,” Sommerfeldt said. “This is a tool that can help them evaluate the job immediately.” For example, PaveScan RDM was used on a recent job in Texas where the crew realized they were seeing a pattern of low density. They were able to stop the job to diagnose and resolve the issue (the temperature on the auger of the paver wasn’t hot enough). This is how Wuori prefers to use the PaveScan RDM system. In fact, he uses RDM to set up roller patterns for all his projects, but also to adjust roller patterns as needed. “Since it produces real time data, we can walk behind the intermediate roller and look at rolling consistency in real time, to see density from the centerline to the shoulder in real time,” he said. If an area isn’t achieving the density required to satisfy a percent within limits (PWL) specification, Wuori and his contractor client can change the rolling pattern immediately to ensure uniform compaction.
NEW TECH “With a nuclear gauge, I can’t collect enough data to identify issues and make adjustments in real time,” Wuori said. However, he still uses a non-nuclear gauge; for example, if Wuori identifies an area with low density using PaveScan, he’ll use the non-nuclear gauge to verify those results. Although those benefits could already be realized with the PaveScan RDM, MDM makes it possible for contractors to know the density numbers right away. “If they’re just using the RDM, they can see the pavement’s uniformity via the dielectric data, but not many people are familiar with the term dielectric,” Sommerfeldt said. “MDM can be a complement to the RDM system to help a contractor use numbers they’re used to.”
FULL COVERAGE DENSITY DATA
Sommerfeldt said PaveScan’s most significant benefit beyond its instantaneous feedback (dielectric with RDM, and density with RDM and MDM) is that it offers full-coverage density data. “Instead of spot-checking, PaveScan RDM can tell you what percentage of the total pavement meets density specs and show exactly where there are areas of low density.” “Whether you’re coring or using a nuclear gauge, you don’t always know how large an area of low density might be,” Sommerfeldt said. When in doubt, he added, contractors usually end up repairing a large area, perhaps larger than the actual area experiencing low density. “Forensics like what we offer with our PaveScan RDM system helps agencies know how large of an area contractors need to repair.”
Although Wuori sees the value of the PaveScan system as a QA tool, he prefers to use the system proactively. “I use the system to fix any issues before they show up during QA,” he said. “That’s my hope for how this technology will be used in the industry.” Wuori does see the benefits of full-coverage density data: “I can find things with PaveScan RDM that I’d never find with other QC procedures, simply because other methods don’t gather enough data to identify trends. With this, I can identify ways for the contractors I work with to improve their quality in ways that weren’t possible in the past.” And, he sees the benefits of being able to identify exactly where to start and stop any repairs that may be required. However, Wuori believes there will be a transition phase among contractors who may be hesitant about the capture of so much data. “This technology will show flaws anywhere on the road, which is very different from coring here and there,” Wuori said. “What I stress to contractors is that this is an identification tool that will help them get better and give them a chance to fix issues before they become a problem.”
CORE NO MORE?
So far, GSSI’s RDM and MDM systems have been tested by several DOTs alongside nuclear gauges to see how the density numbers it measures compare to density numbers measured by the nuclear gauge. “It isn’t that we can get better data, but that we have better data because we collect more data since we have full coverage of the area,” Sommerfeldt said. “We know 10 cores can’t represent 20 miles of road.” Although coring continues to be the method most states measure (and pay for) density, Sommerfeldt said he hopes the PaveScan RDM system paired with the MDM system will eventually be another option—and perhaps one that reduces or eliminates the need for coring. “When you core, you’re putting holes in the road you’ve just paved and those spots are often where potholes start,” Sommerfeldt said. Furthermore, he added, a reduction in coring can result in improved safety. “Coring is by far one of the most dangerous aspects of an asphalt paving project,” Wuori said. Not only are these operations not accompanied by the lights and visibility of the paving train, but they also often happen during low-visibility hours—at night or early morning before sunrise—so the pavement has had time to cool. This is particularly relevant as longitudinal joint density specifications become more common, requiring coring at a particularly dangerous location, he added.
FUTURE-FOCUSED TECH
Wuori is currently working to develop a specification for the use of this technology in Alaska, adding that Minnesota and North Dakota aren’t far behind. “I think we are going to see less coring in the near future as a result of this technology,” Wuori said, especially with dielectric-to-density conversion tools like the PaveScan MDM. As the technology gains traction, he anticipates destruction coring could be a thing of the past in the next five to seven years. “I think this is the future of QC/QA in the asphalt paving industry,” Wuori said. “It’s just a matter of time before it gains traction. Once it does, it’s something that’s going to improve our infrastructure because it’s pushing the industry to be better. Anything that can improve the quality of our roads will be beneficial to the whole industry.” 46 | JUNE 2022
Elise Posillico 781.738.5805 Peter Brickman
516.353.9177
WWW.THEASPHALTPRO.COM | 47
We’re on it.
BROCK is proudly manufacturing equipment and supplying parts for hot mix asphalt plants. www.brock.llc | 2011 West Polymer Drive, Chattanooga, TN 37421 | 1.800.441.9528 | 1.423.476.9900
AD INDEX ALmix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Asphalt Drum Mixers, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25 Astec Industries . . . . . . . . . . . . . . . . . Inside Front Cover, Inside Back Cover, 11 Blaw-Knox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Bomag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 BROCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 CWMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 19 Fast Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Gencor Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Greenpatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Meeker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Meyer Labs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Minds, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 NAPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 NCCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 PetroCanada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Reliable Asphalt Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover Stansteel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 39 Systems Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Tarmac, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Top Quality Paving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Weiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Willow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Wirtgen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Women of Asphalt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Wuori Consulting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 AsphaltPro’s advertiser index is designed for you to have quick access to the manufacturers that can get you the information you need to run your business efficiently. Please support the advertisers that support this magazine and tell them you saw them in AsphaltPro magazine.
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Paver and Distribution Setup
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Paver Mounted Thermal Profiler
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Our asphalt release agents are state DOT-approved and NTPEP tested and listed.
All our proprietary asphalt products and equipment are proudly formulated and manufactured in the United States.
WUORI CONSULTING, LCC
(701) 426-7873 wuoriconsultingllc@gmail.com
"Since making the switch to Meyer Laboratory’s asphalt release agents and drag slat cleaners at all the All States Materials Group plants throughout New England more than 2 plus years ago, we are extremely pleased with the performance of the products and customer service provided. I have also received positive feedback from our paving superintendent that Meyer’s products have performed much better than our previous products used on the tools, transfer machines, rubber tire rollers and pavers in the field. Thank you again for everything - Todd Jarvis, Plant Operations Manager - Trew Stone, LLC a division of All States Material Group
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Specially formulated temporary and semi-permanent release agents and coatings, drag slat cleaners, and extraction solvents. Designed to work on all asphalt mix designs, including on all PG grade asphalt mix designs such as PG-76-22 and 70-22.
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H E R E ’ S H OW I T WO R K S Step 2
Step 1
Step 4
A loader or excavator feeds material to the 11-cubic-yard capacity hopper.
The operator lowers the run-on legs and extends the plant’s conveyors to prepare for operation.
Material that has bypassed the impactor, and material from the crusher, are deposited on the crusher discharge conveyor, and then transported to the two-deck screen with third reliever deck for sizing.
Step 3 Material is screened via the 2-step, 5-foot grizzly deck to remove smaller material and bypass the impactor.
Step 6 The return conveyor transports oversized material from the screen to the hopper, where it is introduced directly into the impactor for re-crushing.
Step 5 Material that meets intermediate or final spec product is discharged onto the side discharge conveyor or fines conveyor, respectively, for stockpiling.
Eagle Crusher’s RapiDeploy 1000
T
he team from Eagle Crusher, Galion, Ohio, offers the RapiDeploy® 1000, which includes the features of the original RapiDeploy (now called the RapiDeploy 500®), plus the Eagle Crusher UltraMax 15 impactor. The RapiDeploy 1000 is designed to crush, screen, separate and stockpile—all in one pull. Here's how it works: Material is dumped into the vibrating hopper. At the end of the hopper, material flows across the two-step, 5-foot grizzly deck. Smaller material slips between the bars, allowing it to bypass the crusher and be screened first, reducing wear on the impactor. Material that bypasses the impactor is deposited on the crusher discharge conveyor where it rejoins material crushed in the 50 | JUNE 2022
impactor and is transported to the two-deck screen with third reliever deck. The third reliever deck is two-thirds the length of the full screen decks to help bypass the close-tosize material through the screen to the absolute decks, while retaining the larger, oversized material. This gives the screen more opportunity to size the close-to-size material without blinding itself with too much oversize material. Oversize material is returned via the return conveyor to the hopper, where it is introduced directly into the impactor for re-crushing. Material that meets the producer’s intermediate or final specs is discharged off the side discharge or fines discharge conveyors, respectively, for stockpiling.
Optionally, smaller material that falls through the grizzly bars can be removed by the throw of a lever onto the optional grizzly discharge conveyor. For more information, contact (800) 2532453 or sales@eaglecrusher.com.
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If you’re an original equipment manufacturer with a complex product, let us help you explain its inner workings to asphalt professionals. There’s no charge for this news department, but our editorial staff reserves the right to decide what equipment fits the parameters of a HHIW feature. Contact our editor at sandy@theasphaltpro.com.
BUILT TO CONNECT
Power and Portability Our portable plant configurations feature a variety of components including jaw crushers, cone crushers, impact crushers and a variety of screening plants. Without sacrificing power or productivity, portable options deliver efficient and reliable performance with extra portability and adaptability.
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