Dynapac News no1 2009 by Dynapac Compaction Equipment AB

News Dynapac

NEWS & KNOWLEDGE FROM DYNAPAC • No1 • 2009

COMPACTASPHALT CHANGES THE FUNDAMENTALS OF PAVING

New fast LF plates DON’T MISS THE RED ELEMENT TOUR

Claes Ahrengart

Editorial

President, Atlas copco Road Construction Equipment

New times - new requirements WELCOME TO THE FIRST issue of Dynapac´s new customer magazine. In this time of challenging market conditions and uncertainty about the future, it is more important than ever to be flexible and able to adapt to new situations. At the same time I find it crucial not to loose sight of long term visions and objectives. AT DYNAPAC we put product development high on our agenda and pursue time-to-market speed and quality of new products. Continuous process improvement and increased flexibility in production is also key to us. We strongly believe that our strategy with production units close to all major markets will help us stay flexible and able to adapt to local market demands. OUR NEW DISTRIBUTION set up is another important part, where we foresee both lower costs, increased reliability and efficiency in our logistics chain. Read more about this on page 11.

understanding customer applications still remains on top of our list. We develop new application methods and are actively cooperating with academic research institutes, road authorities and other stake holders to further improve productivity, safety and environmental aspects in many kinds of infrastructure projects. In this issue you can learn more about the unique advantages and many potential savings with the Compactasphalt® method. ENJOY READING and feel free to e-mail your comments or thoughts about the magazine to info@dynapacnews.com.

WHEN IT COMES TO our long term vision, we know what we want to achieve. Always staying close to our customers and

Dynapac Red Element Tour Uniquely Dynapac THIS YEAR DYNAPAC introduces a wide range of new machines, software and aftermarket support tools, all of which are aimed at boosting productivity in infrastructure projects. For the contractor it´s about getting bonuses instead of paying penalties and for road owner it´s about getting sustainable and long lasting results at a low cost and with a minimum of environmental impact. The red element is the name of our innovative new product design concept and it is also the name of our global tour 2009.

DYNAPAC RED ELEMENT TOUR 2009 consists of customer day´s, road shows, events, seminars and trainings etc all over the world. We want to show you that we are serious about supporting you all the way in achieving great results at a competitive cost. TO LEARN MORE about Dynapac Red Element Tour and to get an invitation to a Red Element event close to you, please visit www.dynapac.com or contact your local Dynapac support.

In this Issue New Compaction Plates

Compactasphalt®

Bikers safety at the TT racers CostCtrl tool

8 9

VISIONARY BOARD

New distribution center

NEWS AND KNOWLEDGE FROM DYNAPAC

Publisher: Lotta Bynke Production: Communications For more information please e-mail to info@dynapacnews.com

Fast forward

with new LF plates

DYNAPAC LAUNCHES A SERIES OF FORWARD COMPACTION PLATES WITH IMPROVED SPEED, FLEXIBILITY AND PERFORMANCE. www.dynapac.com/speed

WITH THE EXPERIENCE of everyday use, Dynapac has developed unique solutions to a new range of plates in six different size classes, from the small versatile LF50 to the large LF130 for heavy-duty applications. FOR ASPHALT APPLICATIONS the LF75, LF80 and LF100 are equipped with a new water distribution system without pipes or sprinklers to clean, providing for un-equalled results for all types of asphalt jobs. The water consumption is easily optimized by means of a flow adjustment valve, hich is easily reached by the operator. A large removable water tank, with a secured cap, makes refills quick, simple and less frequent. THE BOTTOM PLATE is the most critical component of a forward plate for asphalt compaction. The Dynapac LF series has a new design of the bottom plate and its edges give a well-defined contact surface that will leave no marks on the surface.

For tight and complicated spaces the handle can even be raised to a vertical operational position. The new Dynapac units have foldable handles providing for easy transportation and storage. All plates have a wide array of optional equipment such as a protection frame suitable for rental applications, lifting handles etc making it possible to customize the machine. ORIGINALLY DESIGNED for high compaction performance and lowest possible vibration level, the new LF range of forward plates out performs its competitors with the LOW-VIB handle (vibration reducing handle) which allows for exceptionally low levels of hand-transmitted vibrations.

THE LF75, LF80 AND LF100 ARE EASILY CONVERTED BETWEEN SOIL AND ASPHALT WORK. SEVERAL ENGINE ALTERNATIVES AS WELL AS OPTIONS ARE AVAILABLE.

FOR THE SMALL CONTRACTORS the Dynapac LF50 and LF60 forward plates are ideal when working in narrow trenches or at small jobs. Folded down they are easily transported between job-sites. THE MACHINES ARE FAST, app. 20% faster than thei predecessors, and very manoeuvrable with a tight turning radius.

ONE OF THE FIRST ORDERS OF LF PLATES WENT TO ZAGREB, CROATIA.

Patents under application * UK Patent Application No. 07 04294.8 - Deutsche Patentanmeldung Nr. 102007003927.3 - Svensk Patentansรถkan Nr. 0600513-6

Compactasphalt

- game changing paving Compactasphalt® offers big advantages to roadbuilders and their clients. Roads surfaced using this method last longer and are cheaper to maintain.

THE COMPACTASPHALT® method is revolutionising roadbuilding. With this method, patented in 1993 by Professor Elk Richter at Erfurt, Germany, and now recognised as standard practice, the binder and the wearing course are applied to the loadbearing layer one after the other in a single pass. Conventional roadbuilding involves two separate passes, with the wearing course being applied after the binder has cooled.

makes use of the heat in the thick binder layer that has just been laid to gain time for the compaction of the two upper layers. With the conventional paving method, the binder layer cools before the wearing course is applied. In bad weather this may lead to uneven compaction.

GOOD COMPACTION of the asphalt is crucial in roadbuilding, but the rollers take time to do their job. The cooling of the asphalt during compaction reduces the THE CONVENTIONAL metdegree of compaction and with it hod poses problems here, especially in bad weather. According the durability of the road surface. to the official ZTV Asphalt’ “By laying the binder and the regulations in Germany, these wearing course at the same time, problems can be eliminated we apply a total of twelve centiby using the Compactasphalt ® metres of asphalt,” explains Romethod. The new method not land Egervári, Product Specialist only cuts construction time by Pavers at Dynapac. “Because the half, helping to reduce motorapplied asphalt is thicker, the useway congestion, it also brings ful compaction time is extended tangible technical benefits. It

by a factor of at least seven.” This is especially attractive for roadbuilding in bad weather, when the asphalt temperature falls rapidly. BECAUSE THE TWO layers are applied ‘hot-on-hot’, the Compactasphalt ® method also makes it possible to reduce the thickness of the uppermost layer to two centimetres, as opposed to four centimetres with the conventional method. Since the wearing course mix is particularly costly, this means substantial savings for the contractor and ultimately for the taxpayer. Compared with the conventional method, Compactasphalt ® also gives better bonding between the individual layers, helping to prevent crack formation in the road surface. ROAD SURFACES made of compacted asphalt last longer. On average, the loadbearing layer of a road needs to be replaced

Text JOHANNES WENDLAND

after 40 to 50 years, the binder layer after 15 to 25 years and the wearing course after 10 to 15 years. So the wearing course needs replacing at least once during the normal service life of a binder layer. “This isn’t the case with Compactasphalt®,” says Johan Arnberg, Vice President Paving & Recycling, Atlas Copco RCE Division. “With this method we can extend the service life of a wearing course to match that of the binder layer. So over the entire lifecycle of a road, the operator saves one re-laying every 25 years.” THE EVALUATION OF a long-term trial with Compactasphalt® on a stretch of road in the USA, provides firm evidence of the method’s benefits. The trial stretch, built with a Dynapac paver, was driven over continuously

THE F300CS / AM300 MODULAR PAVER CAN BE USED BOTH FOR THE COMPACTASPHALT® METHOD AND CONVENTIONAL PAVING.

“With Compactasphalt® we can extend the service life of a wearing course to match that of the binder layer.” Johan Arnberg

Vice President Paving & Recycling, Atlas Copco RCE Division

“A client who pays attention to quality and chooses Compactasphalt® can look forward to decades of trouble-free service.” Roland Egervári

Product Specialist Pavers

by 60-tonne trucks, simulating an 18-year service life in just two years. The trial stretch showed not the slightest sign of fatigue in the form of tracks or cracks. “The long-term maintenance of a road is an important cost factor for the owner,” says Egervári. “A client who pays attention to quality when a road is being built, and chooses

Compactasphalt ®, can look forward to decades of trouble-free service.” BY THE END of 2007, Dynapac machines had laid five million square metres of compacted asphalt in Germany, China, Poland and Russia. In Germany, the company has supplied three large type F 300 CS road pavers for Compactasphalt ®. This year, Dynapac will

ROLAND EGERVÁRI

be launching a modular extension of the triedand-tested DF 145 CS paver. This will enable smaller construction firms to switch to paving with Compactasphalt® at a favourable cost. They only need to keep one paver, which can be quickly adapted as the need arises. This brings huge cost benefits, which firms can pass on to their clients – giving them a further argument in favour of Compactasphalt®.

many advantages with the

Compactasphalt

MODULAR DESIGN – TANGIBLE BENEFITS FOR ROADBUILDING using the Compactasphalt® method, Dynapac offers the F300CS high-performance paver. This machine has two hopper modules to hold the materials for the binder layer and the wearing course, and two screeds – a highdensity screed for the binder layer and a normal screed for the wearing course. The two screeds are adjusted relative to each other to ensure that the thickness of the two layers is constant. The maximum working width of the finisher is 13.25 metres. DYNAPAC IS CURRENTLY working on a modular extension of the DF 145 CS series paver for working widths of 2.55 to 7.50 metres. So it will soon be possible to deploy this widely used paver for both the standard method and Compactasphalt®, allowing contractors to exploit their machines far more efficiently.

ENVIRONMENTAL BENEFITS THE OPPORTUNITY to reduce the mix temperatures and therefore reduce pollutant emissions. BY REDUCING the mixed good temperature at 10 °C, approx.0,23 l heating oil per one ton can be saved. LONGER DURABILITY of the wearing course saves energy costs concerning the production of mixed good. REDUCED ROAD REPAIR and maintenance works. NO BITUMEN EMULSION is needed (which is sprayed on the binder layer in case of the conventional laying method) AN ADDITIONAL REDUCTION of the asphalt binder course from 10 cm to 8 cm (highway projects) is possible.

ARNE EICHSTAEDT

method

“We’re convinced of the quality and also see the clear cost and time benefits of the method.” Arne Eichstaedt

Head of Bunte Braunschweig

IMPROVED LAYING QUALITY & HIGHER DURABILITY BY: Creating a thicker asphalt layer during laying and therefore an obviously significant extension of the period of time available for final compaction (t=k*d1,8) [1] and the possibility to optimise the degree of compaction, and positively influence the deformation resistance. t= time, k= constant, d= layer thickness The available time for compaction increases with the power of 1,8 of the actual layer thickness. By increasing the layer thickness from 4 cm to 12 cm, the available time for compaction is increased 7 times! REDUCING THE INFLUENCE OF BAD WEATHER on the compaction properties of thin wearing courses by using the asphalt binder’s residual heat.

JOHANN BUNTE Bauunternehmung GmbH & Co. KG is a leading German construction company based in Papenburg. Since 2004, the company has used the Compactasphalt® method on numerous roadbuilding, paving a total of 1.5 million square metres. The company has a Dynapac F 300 CS / AM 300 modular paver

HIGH AND HOMOGENOUS DENSITY through the complete layer depth (wearing course and binder course) EXCELLENT INTERLOCKING OF THE COURSES (Cut power 37KN) Due to its optimum bonding it will better withstand high vertical forces. This is main criteria for the long service life of the asphalt pavement. REDUCING THE APPEARANCE OF RUTS AND CRACKS as it is possible to take up higher vertical and horizontal forces due to optimum degrees of compaction and high layer adhesion (bonding and tight interlocking). BETTER DURABILITY can be expected due to a feasible high deformation resis-

and also deploys the machine on projects using the conventional method. “For large construction projects, Compactasphalt® is the method of the future,” says Arne Eichstaedt, head of Bunte’s Braunschweig office. “We’re convinced of the quality and also see the clear cost and time benefits of the method.”

tance and good interlocking of the layer, together with optimum air void content. IT IS POSSIBLE TO EXTEND THE PLANNED LIFETIME of the top layer, to be close to the lifetime of the binder course. ECONOMIC OPTIMISATION of the wearing course’s surface properties with regard to skid resistance, brightness and also the reduction of the course thickness. COST REDUCTION Due to a 50 % thickness reduction of the expensive wearing course. No bitumen emulsion is needed between the binder and wearing course. Significant reduction of paving times due to the simultaneous laying of both courses.

“The method of the future” 7

DYNAPAC PL350T COLD PLANER SPEEDS UP CRITICAL DEMARCATION WORK REQUIRED FOR THE ISLE OF MAN’S TT MOTORCYCLE RACES.

AS THE HOME OF the world famous TT motorcycle races, the Isle of Man has more than its fair share of road markings. During two weeks every year in June, the eyes of the world turn to the island – with a population of 80,000 and in the very middle of the Irish Sea between the UK mainland and Ireland – as the finest road racers on the planet pit their skills against the 37 miles of public roads that form the legendary TT mountain circuit. THE TT FORTNIGHT, which attracts around 40,000 visitors each year, takes months of meticulous planning, and not least by the island’s Department of Transport, both in securing the route for bikes, which thunder through the tiny villages at speeds of 190mph, and in ensuring the safety of both riders and spectators. THE ROUTE FOR the riders must be crystal clear at all times, because at the speed they’re going, there’s no time for any indecision. So when the markings need to be removed, it’s essential that a completely smooth surface remains, posing no danger to the bikers.

THE THREE-WHEELED Dynapac PL 350Tplaner is easily manoeuvred and very flexible. For flash cutting along walls or curbs, the right-supporting wheel can easily be folded in. The Isle of Man machine was equipped with a special micro milling drum, containing 117 bits, compared to the standard 38, spaced at intervals of 3 mm as opposed to the conventional 12mm. “For demarcation work a micro milling drum is essential,” explained Dynapac technician Marco Dahms, who provided training for the Department of Transport’s maintenance team. “The main aim is to completely avoid damaging the asphalt or concrete pavement.” IN ADDITION, to avoid a sharp edge at the sides of the demarcation area, the drum is slightly offset by 1 or 2 mm at the edges – although very flat across its 30 cm surface. This is essential in avoiding any danger to the high-speed bikes. “Another important feature, and a real benefit on the PL350T, is that because of the larger drum diameter, standard bit holder blocks can be used,” Mr Dahms added. “Other drums with smaller diameters cannot accommodate the standard bit system, which means the Dynapac bits last approximately four times longer than competing drums which always have to use the mini-bits.” THE DYNAPAC’S additional 600 kg of ballast on top of the cutter housing ensures minimum vibration during milling operations and a much smother and uniform result. “We have been using standard blasting equipment to remove road markings up to now, but this was a highly manual operation, and at best we were able to remove a stretch of just a few metres in a single day,” said Department of Transport Engineering Works assistant engineer Kerrin Wells. “We were very impressed with the trials of the machine, and look forward to greatly improving the standard of lining removal and renewal. We plan to use the machine on a stretch of the TT course immediately after this year’s event is over.”

www.ManxPhotosOnline.com

Securing bikers safety at the TT races

TOP PERFORMANCE PAYS BACK FOCUSING ON PURCHASE price

alone, when buying road construction equipment can prove to be very expensive. Why is that? Well, when calculating the total costs of owning and running a machine, there are several other parameters that must be taken into account. Costs for service and maintenance, fuel consumption, operator wages, second hand value and machine uptime, are parameters that have a big impact on the real cost of ownership.

WHEN WE ASK our customers what matters most to them with their Dynapac equipment, the answer is clear: reliability! Reliability is also a remedy for keeping major cost drivers at a low level throughout the lifetime of a machine. In this perspective, the actual purchase price becomes less important and to pay a premium for good performance and low downtime can be very well invested money. TO MAKE IT EASY for customers to under-

stand and control all costs and to see the true cost of ownership, a new easy-to-use tool ihas been launched for all roller models; Dynapac CostCtrl. With Dynapac CostCtrl you can easily calculate all the different parameters that drive costs. Used in combination with PaveComp or CompBase optimization tools you can be in full control of your complete cost picture. To learn more about Dynapac CostCtrl, please get in touch with your local Dynapac sales engineer or visit www.dynapac.com/ costctrl.

A new generation of compact planers! DYNAPAC IS INTRODUCING a family of heavy duty cold planers for cutting widthÂ´s from 350 to 1000 mm. The new range of compact planers offers superior cutting performance, a perfect view towards the cutting edge and an intuitive control system. The excellent operator comfort and visibility result in increased speed and better results of all minor planing operations. Learn more at www.dynapac.com

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Visionary board

W i t h THE FUTURE I N MI N D

FRE D RIK Å KESSO N HEAD OF DYNAPAC COMPETENCE CENTER

FREDRIK ÅKESSON, head of IHCC recently initiated Dynapac Visionary Board; a forum for discussing trends, techniques and new discoveries in road construction. The first meeting was held in November 2008 in Stockholm. Fredrik why have you initiated the Dynapac Visionary Board? -As one of the leading manufacturers in the road construction industry, we must keep up to date with the latest developments in the academic world as well as demands from contractors and requirements from authorities. What was on the agenda during the first meeting? -This time focus was on discussing challenges and opportunities in infrastructure projects from an academic research viewpoint. Participating in the board

DYNAPAC HIGH COMPETENCE CENTER (IHCC) IS A WELL KNOWN INSTITUTION IN THE WORLD OF ROAD CONSTRUCTION. OVER THE YEARS, IHCC APPLICATION SPECIALISTS HAVE GIVEN ADVICE AND SUPPORTED NUMEROUS CONSTRUCTION PROJECTS. were professors from universities in Poland, Italy, Germany and Sweden. What was the outcome of your discussions? - One common point from all participants was a clear focus on quality improvements. Higher quality will, apart from the increased ride quality and safety, also reduce the environmental impact. Higher quality means longer lifetime and reduced need for rehabilitation and renovation of the road network. The fewer times deteriorated wearing courses needs to be removed and replaced, the fewer traffic disruptions will occur. Less and less energy will be spent on mixing asphalt etc. Then how can higher quality be achieved? - There are different ways to reach qua-

Questions& Answers

about trends in Road Construction

BJÖRN BIRGISSON is Eur Ing. Ph.D., P.E. Professor and Head of Highway and Railway Engineering Division, Royal Institute of Technology, Stockholm Professor Birgisson is a member of Dynapac Visionary Board

In which way do you see trends leading the asphalt (Road) construction industry in the short term? The focus is increasingly on warm and cold asphalt technology for new pavements and well as in-place recycling of existing pavements. This is driven primarily by increased cost of energy and the need for reducing CO2 emissions. There is also an ever increased pressure to recycle not just old pavements but other materials such as truck tyre rubber into asphalt pavements. There also appears to be an emerging reduction in the supply of bitumen that is driven by the oil companies developing

lity improvement, ranging from reduced temperature in the asphalt mixes to improved practices in the construction phase. Improving the skill of operators and giving them proper tools to evaluate the progress of paving and compaction, was also considered important. We have a number of projects ongoing to achieve these goals. Several cooperation initiatives have been taken that span over all steps in the asphalt industry. Everything from aggregate and binder properties, over mix design and manufacturing as well as transportation, paving and compaction of asphalt mixes will be evaluated. What will be the next step for Dynapac Visionary Board? -The Visionary Board will continue to cooperate and interact with different stakeholders.

increasingly innovative technologies to get higher value products out of each barrel of oil. The reduced supply of bitumen has also led to more variability of bitumen sources than previously, causing problems for agencies and contractors alike. Public agencies are also gradually moving toward performance-based specifications, percent within limit specifications, and warranty projects. This means that new compaction technologies, sometimes referred to as “intelligent compaction” will be increasingly more important in providing a more homogeneous final compacted pavement layers. Finally, there is a strong trend toward the use of polymer modification to increase the life of pavements. Would this have any impact in the way road construction equipment is designed or used? (in which way?) The focus on cold and warm in-place pavement recycling technologies has already led to new innovations in paving equipment where steam is introduced into the bitumen in order to cause the bitumen to foam. There are also a number of emerging technologies that allow for the manipulation of binder viscosity and thus lower mixing and paving temperatures through chemical modification. Similarly, the focus on performance-related specifications, percent within limit specifications, and warranty projects is leading to an overall increased pressure to increase the quality of paving jobs. Segregation is now being recognized as a problem that can be fixed through good paving and compaction practices. There are likely going to be new types of compactors shortly that further minimize segregation problems and promote homogeneity of air void distributions within the compacted layer. Finally, we will see much wider use and further development of compactors with some kind of “intelligent compaction” technologies that allow for a reduction in the variability of the compacted pavement and thus increased pavement life.

BJÖRN BIRGISSON

Please, read more at www.dynapac.com/knowledge

Centralised distribution for better

service & efficiency

DYNAPAC IS CONSOLIDATING EUROPEAN DISTRIBUTION OF LIGHT & CONCRETE EQUIPMENT AND SPARE PARTS TO POWER TOOLS DISTRIBUTION CENTER (PTD), IN BELGIUM.

SINCE DYNAPAC became part of the Atlas Copco Group in 2007, it has been on the agenda to consolidate and integrate the points of distribution. PTD is one of Atlas Copco’s state-of-the-art distribution centres and is well known for a high level of customer satisfaction.

LOWER FREIGHT costs will benefit everyone involved. Other advantages of centralised distribution include improved stock availability, better monitoring of stock, and faster, direct and more accurate deliveries.

Per Hörner, Vice President for Purchasing and Logistics, sees great benefits for both customers and group companies. “This will give us an increased service level, higher efficiency and better availability of our products,” he says.

DESPITE THE FACT that PTD is a separate company, it is a fully owned by Atlas Copco and a well integrated part of the day-to-day operations. “It is important to understand that we are a very active partner in this system. We are represented on the board of PTD and share responsibility for the Hoeselt operation,” Per Hörner explains.

TRANSFERRING the distribution of light compaction and concrete equipment and spares to Belgium will allow the factories to focus on their core activity, production. Deliveries for the aftermarket are also part of the new distribution scheme, with all shipments being sent from PTD in Hoeselt. Centralised distribution will lead to better service and efficiency.

IMPLEMENTATION OF the European distribution changes, will be completed by August 2009. From a customer point of view, the change will have no noticeable effect on the way orders are placed. “The first line of support interacting with the

customer will remain as it is today, and we are strengthening our back-office functions to better support our customer centres and distributors,” Per Hörner says. THE LONG-TERM AIM is to have distribution centers in Europe, Asia and the Americas. Europe is first, but changes are in the pipeline for North America. Distribution from the factory in San Antonio, Texas, will be moved to the Atlas Copco distribution centre in Allen, Texas. Companies in Canada and Mexico are next in line to benefit from this reorganisation, with all shipments being delivered from Allen, Texas.

Product News A NEW RANGE OF 7-9 TTANDem ASPHALT ROLLERS THE NEW RANGE is designed to meet the needs of contractors, road contractors and rental companies worldwide. To achieve high quality surface finishes, the new Dynapac rollers are equipped with a very flexible sprinkler system with the possibility to choose between the central water tank or a separate emulsion tank.

OPERATIONAL FEATURES also includes ‘soft’ starting and stopping to prevent bowing or cracking in the asphalt layers; allowing even unskilled roller operators to start and stop without leaving marks. AS A SAFETY feature, the machine will drop out of the ‘soft’ mode and brake immediately

if the lever is moved quickly, signalling the need for an emergency stop space.New features simplify and speed servicing to guarantee maximum availability. MANY OF THE enhancements

bring environmental benefits through reduced consumption and/ or quieter operation. Efficiency enhancements have saved some 8 kW in the operation with consequent improvements in the running cost and the noise level.

Service made easy It goes without saying that planned, regular service is a must. But service must never cause unnecessary interruptions. Every Dynapac machine presents unique features for enhanced productivity. One is the modularity. Standardized parts that fit several models saves money – and it certainly makes the technician’s job easier. Add to that a large hood over the rearmounted engine, providing swift access to all service points – without crawling underneath. These are only a few of the reasons why Dynapac’s service philosophy will keep your uptime up. Want to know more? We’re at your service at dynapac.com.