January 2018
How to Choose an
ASPHALT PLANT | 20
+ IOT
Basics for Construction | 14
COMPREHENSIVE GUIDE
TO ASPHALT PAVER MAINTENANCE | 36
WHICH IN-PLACE RECYCLING METHOD IS BEST FOR YOUR APPLICATION? | 52 www.ForConstructionPros.com/Asphalt
UNMATCHED DESIGN
Heatec has been designing and building tank farms for over 40 years and each project has been unique in some way. That’s because each customer is unique. You have your own business model that may be slightly different or dramatically different from the other guys’. That’s why at Heatec we take a comprehensive approach to designing your tank farm. That means we look at the materials you will be using, all the equipment that needs heat, the piping, and even future plans for expansion. Then we design a system that works for you. And we make it efficient and simple to operate. Heatec is unmatched when it comes to designing heating and storage systems for your asphalt plant. To find out more about our approach, visit us at www. heatec.com or give us a call at 423-821-5200.
H E AT E C , I N C .
an Astec Industries Company
5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com Search: 10073245
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TABLE OF CONTENTS |
JANUARY 2018
COVER STORY Comprehensive Guide to Asphalt Paver Maintenance Failure to properly maintain your paver can result in significant downtime and profit loss | 36 TECHNOLOGY MATTERS
PRESERVATION UPDATE
14 IoT Basics: The Fundamentals of the Internet of Things for Construction
52 To Recycle Pavement Hot or Not? 26 7 Tips for Spring Startup at Your Asphalt Plant
Is hot or cold in-place recycling best for your application?
30 Production Products
PRODUCTION NOTES
20 Cliff’s Notes: Basic Decisions When Buying an Asphalt Plant Choosing what type of plant to purchase can be a daunting task when you figure in how much storage you need, what controls to purchase and more. Here, Cliff demystifies the asphalt plant purchasing process.
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Plants, baghouses, mixers, dryers, automation systems & more.
JOBSITE INNOVATIONS
48 Jobsite Products Pavers, rollers, MTVs & more.
SPECIAL REPORT: NATIONAL PAVEMENT EXPO
58 NPE to Rock Cleveland in 2018 NPE 2018 will be held Feb. 7-10 at the Huntington Convention Center of Cleveland and will feature a large exhibit hall and 54 educational sessions including the day-long pre-NPE Boot Camp and 11 in-depth workshops.
56 Preservation Products Milling machines, reclaimers, infrared equipment & more.
IN EVERY ISSUE 8
Editor’s Perspective
10 New Products 66 The Last Exit
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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DIGITAL CONNECTION www.ForConstructionPros.com/Asphalt
VIDEO: How Can Asphalt Help Save the Environment? Verizon is testing IoT sensors embedded in asphalt that are connected to their network. These sensors are giving cities the ability to cut carbon emissions and commute times.
Infrastructure Push Expected This Month
Search: 20984668
Trump administration officials are finalizing a plan that would allocate $200 billion or more to spur investment in a $1 trillion infrastructure package, and they could push toward adoption of a plan in January. Search: 20985384
Study: Construction Workers Working Longer Hours Over Last Three Years
What the Tax Overhaul Could Mean for the Construction Industry
Data shows that construction workers are working, on average, 39.6 hours a week, which is more than at any point in the last three years.
The tax overhaul could have a positive impact on the public construction sector thanks to the uninterrupted flow of privateactivity bond financing.
Search: 20985680
Search: 20986372
WWW.FORCONSTRUCTIONPROS.COM/ASPHALT WWW.FORCONSTRUCTIONPROS.COM/ASPHALT WWW.FORCONSTRUCTIONPROS.COM/ASPHALT
CONTRACTOR
LATEST INNOVATIONS FOR ASPHALT PROFESSIONALS PROFESSIONALS LATEST LATEST INNOVATIONS INNOVATIONS FOR ASPHALT PROFESSIONALS
JANUARY 2018 Vol. 32, No. 1
ASPHALT
CONTRACTOR LATEST PROFESSIONALS LATEST INNOVATIONS FOR ASPHALTPROFESSIONALS LATEST INNOVATIONS FOR ASPHALT
Published by AC Business Media Inc.
Asphalt CONTRACTOR
201 N. Main Street Fort Atkinson, WI 53538 (800) 538-5544 • www.ACBusinessMedia.com www.ForConstructionPros.com/Asphalt
LATEST INNOVATIONS FOR FOR ASPHALT ASPHALT PROFESSIONALS PROFESSIONALS LATEST PROFESSIONALS LATEST INNOVATIONS
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Published and copyrighted 2018 by AC Business Media Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage or retrieval system, without written permission from the publisher. Asphalt Contractor (ISSN 1055-9205, USPS 0020-688): is published ten times per year: January, February, March/April, May, June/July, August, September, October, November, December, with an additional Buyer’s Guide issue published in August by AC Business Media Inc., 201 N. Main Street, Fort Atkinson, Wisconsin 53538. Periodicals postage paid at Fort Atkinson, Wisconsin and additional entry offices. POSTMASTER: Please send change of address to ASPHALT CONTRACTOR, PO Box 3605, Northbrook, Illinois 60065-3605. Printed in the U.S.A. Canada Post PM40612608. Return Undeliverable Canadian Addresses to: Asphalt Contractor, PO Box 25542, London, ON N6C 6B2. SUBSCRIPTION POLICY: Individual subscriptions are available without charge only in the USA. The Publisher reserves the right to reject nonqualifying subscribers. One-year subscription to nonqualifying individuals: U.S. $45.00, Canada & Mexico $65.00, and $95.00 all other countries (payable in U.S. funds, drawn on U.S. bank). Single copies available (prepaid only) $10.00 each (U.S., Canada & Mexico), $15.00 each (International).
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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®
C R AC K P R O M E LT E R /A P P L I C AT O R S H AV E REVOLUTIONIZED THE CRACK FILLING INDUSTRY • The Industry’s Fastest Material Heating Time • State-of-the-Art Safety Innovations Including the Industry’s Lowest Profile Design - Provides Maximum Operator Safety
ZERO DOWN FINANCING FOR QUALIFIED BUYERS
Backed by Our Nationwide Dealer Network
See us at NPE
View the full line of Crack Pro equipment visit sealmaster.net
LOCATIONS NATIONWIDE (800) 395-7325
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CONTRACTOR
LATEST INNOVATIONS FOR ASPHALT PROFESSIONALS PROFESSIONALS LATEST LATEST INNOVATIONS INNOVATIONS FOR ASPHALT PROFESSIONALS
JANUARY 2018 • Vol. 32, No. 1
EDITOR’S PERSPECTIVE
Jessica Lombardo, Editor jlombardo@ACBusinessMedia.com 920.542.1247
ASPHALT
CONTRACTOR LATEST INNOVATIONS FOR ASPHALTPROFESSIONALS PROFESSIONALS LATEST LATEST INNOVATIONS FOR ASPHALT
Published by AC Business Media Inc.
Maintenance Matters
A
ccording to Mintek Data Solutions, businessess spend about 80% of their time reacting to maintenance issues rather than preventing them. Unfortunately, we know that most of the equipment maintenance that happens today is reactive – machines are only repaired or checked if they break down or seem to be on the verge of breaking down. These maintenance incidents are not scheduled and can happen any time. In the US alone, industrial companies spend about $300 billion to correct the failures of machines, systems and people. But there’s hope. The same data says that ANY business can save 12-18% by investing in preventative instead of reactive maintenance and every dollar you spend now on preventive maintenance will save you five dollars on other expenses. Preventative maintenance helps avoid downtime, delays and incidents that ultimately lead to significant financial losses. Proper maintenance of machines is the first step to attaining that goal and that’s why preventative maintenance is the focus of this issue. For many of you, now is the time of year when you have your plants shut down and equipment in the shop for the slow season. What that means is that now is the perfect time for a complete top to bottom inspection of your equipment before you even think about putting it back to work when the seasons starts. According to Garry Bartecki, managing member of GB Financial Services LLP and a consultant to Associated Equipment Distributors (AED), contractors that follow the “let’s do the least amount possible to keep the machines rolling” policy believe that not performing required maintenance is less costly compared to an ongoing preventative maintenance program. But doing nothing is probably the most costly alternative contractors have.
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Because of the importance placed on maintenance, Bartecki recommends contractors use a formal maintenance program to help keep service costs under control. If you’re just getting started on a formal program, ask your equipment dealer for a copy of its internal policies and examples of the paperwork that goes with them. Outline what will work in your shop. For those already running in-house programs, Bartecki offers these next steps: • Find and keep your good techs. • Send techs for annual training to learn about the latest technology. • Supply the shop with the analytical and shop tools the techs need. • Use telematics systems on your biggest and/ or most costly units. • Keep up with annual preventive maintenance programs. • Measure your techs’ time and dollar utilization. • Compare work orders against expected time to complete the job. • Have “helpers” assist your techs so they can keep wrenching. • Investigate any units that require maintenance costs that equal or exceed 30% of the orderly liquidation value of the unit. Costs that high usually signal a replacement unit is required. In the end, not having equipment ready to roll on a jobsite can lead to total disarray on that particular job, impacting your whole operation and costing you big money. Turn to page 36 in this issue for a little help with our 2018 Comprehensive Guide to Paver Maintenance. What other equipment do you need help maintaining? Let me know a jlombardo@acbusinessmedia.com
Asphalt CONTRACTOR
201 N. Main Street | Fort Atkinson, WI 53538 800.538-5544 • www.ACBusinessMedia.com LATEST INNOVATIONS FOR FOR ASPHALT LATEST PROFESSIONALS LATEST INNOVATIONS ASPHALT PROFESSIONALS PROFESSIONALS www.ForConstructionPros.com/Asphalt
Publication Staff Publisher
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Managing Editor
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Change of Address & Subscriptions PO Box 3605, Northbrook, IL 60065-3605, Phone: (877) 201-3915 • Fax: 847-291-4816 circ.AsphaltContractor@omeda.com
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List Rental Elizabeth Jackson, Account Executive, Merit Direct LLC, Phone: (847) 492-1350 ext. 18 Fax: (847) 492-0085 • ejackson@meritdirect.com
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NEW PRODUCTS CARLSON LAUNCHES ALL-NEW CP-100 II ASPHALT PAVER
T
he CP100 II Asphalt Paver is based off the CP100 model but delivers enhanced efficiency and torque figures over its predecessor. • Cummins QSF 3.8 turbocharged Tier IV Final engine produces 100 horsepower at 2200 rpm • 9.5 ton hopper capacity • Travel speeds up to 255 feet per minute • Features highway-class chains and slats, fully replaceable Hardox floor plates, 13-in. replaceable auger flights and sealed highway-class
auger bearings, providing exceptionally long wear component lifecycle while allowing full rebuilding of the platform • Horizontally sliding damper doors keeps obstructions, such as utilities boxes, from damaging them while open • Cleanout of the hopper is simplified via the flip up apron, highest hopper lift angles in its class, and betweenthe-tracks conveyors, eliminating daily under the hopper cleaning • One-piece forward tilting hood and largest side doors in its class, the
platform provides easy serviceability to the machine’s engine, hydraulics and electrical • 14-in. poly-pad tracks as standard • Planetary drive hubs provide impressive pushing power and are combined with seven heavyduty bogies and single return idler that give the track system greater traction, maneuverability and longer lifecycle Search: 20983741
Cimline Pavement Maintenance Group Unveils C1 Mastic Machine The C1 Mastic Machine is a specialty piece of equipment that's a combination crack seal and mastic patch machine, designed to heat 24,000-lb of mastic material in an 8-hour shift. • Heats on demand in just 40-minutes and keeps the material in working condition all day • Design of the C1 separates the aggregate from the patching material, de-linking it from the binder which enables contractors and municipalities to use locally sourced aggregate, which can then be added separately to the patent-pending mixing chamber • Powered by a 19-hp diesel engine, the pivoting and heated trough on the C1 is designed for ease of material placement, while the side discharge chute allows for easy centerline repairs • At the core of the C1 is MAGMA M Series cracksealer. Standard features on the MAGMA include a stress-free boom with center pivot, weatherproof simple seal controller, performance tank design and lowest load height and largest loading door in its class • Available with a standard heated wand or an optional aluminum wand • Design provides contractors and government agencies the flexibility to perform both crack sealing and mastic patching with just one machine, minimizing the impact on to traffic flow Search: 20982084
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ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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Superior Safety Handrail Superior Industries offers a new conveyor component accessory, the Safety Handrail. • Universally mounts to all idler frame • Helps prevent entanglement in belting • Depending on local MSHA standards, operators can use the Safety Handrail in place of an e-stop cable • Diameter of 1 ¼ in. • 8- or 10-ft. lengths Search: 20863038
Falcon 150G &250G Tack Tank Trailers Falcon Asphalt Repair unveiled their Falcon 150G and 250G tack tank trailers. The trailer- or skid-mounted diesel tack tanks are built with the same high quality as Falcon’s various hot boxes and recyclers. • The Falcon tank tanks are available in two sizes, the 150G (150 gallon tank) and the 250G (250 gallon tank) • Automatic thermostatically controlled heat system • Stainless steel flue • Diesel power • Large clean-out port • Insulated tank
IVE TIT B
ND RA
COMPE
Search: 20982709
Search: 10074458
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NEW PRODUCTS Dynapac Introduces New Roller Range of CC1100/CC1200 The CC1100/CC1200 VI Rollers are designed to meet the construction industry’s tough conditions with the operator in mind resulting in a robust, comfortable and modern machine. • The new machine has a unique design with its cross-mounted engine in combination with excellent visibility and massive casted forks with built-in flexible lifting/towing/tie down possibilities • By moving the water tank to the rear part of the machine, the unique design with a cross-mounted engine gives excellent visibility over the drums • Off-setting the front drum makes it easier to compact close to walls and curbs without risk of damages of the machine Search: 20984044
Bergkamp PMA High Shear Colloid Mill Bergkamp Bituminous Solutions introduces the DenimoTECHmanufactured High Shear Colloid Mill for the manufacture of polymer modified asphalt (PMA). • Complete package with mill, motor and seal lubrication system • Designed to address and safeguard the three most critical factors in the design of PMA – milling properties, rotor and stator stability and energy consumption Search: 12315015
Caterpillar Utility Vehicles The 50-hp CUV82 gasoline-powered and 25-hp CUV102D dieselpowered utility vehicles feature a rugged steel cargo bed and offer 1,000-lb. total rear cargo capacity and 2,000-lb. towing capacity. • Four-wheel independent suspension system with a front sway bar to provide enhanced stability at full load • Top speeds up to 45 mph depending on model • Continuously variable transmission • Two-wheel, four-wheel or four-wheel drive/lock modes • Comfortably seat two riders side-by-side with ample leg, elbow and headroom • Include electric power steering, adjustable driver’s seat position and steering wheel, ample behind-the-seat storage and document holder and removable passenger seat base Search: 20983143
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ASTEC Parts. We’re Here. Always. Combine the world’s largest inventory of in stock parts for asphalt plants, the ability to build and machine custom parts and a fully staffed department of salesmen, technicians and engineers and you have ASTEC parts. • Over 100,000 parts in stock • OEM for ASTEC, DILLMAN, Barber-Green, EssTee & McCarter • In-house parts techs and engineers available 24/7 • Over 600 combined years of experience ready to help you
800.251.6042 • www.astecparts.com Search: 10072061
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TECHNOLOGY MATTERS |
IoT Basics: The Fundamentals of the Internet of Things for Construction
P
erhaps the best definition of the Internet of Things (IoT) appeared in a Forbes magazine article written by the futurist Jacob Morgan. According to Morgan, the IoT refers to the concept of “basically connecting any device with an on and off switch to the Internet (and/or to each other).” The technologies behind the Internet of Things have existed for many years in the construction market. Features like remote access, office-to-field data exchange, cloud computing and data storage are not new. It is more about contractors accepting and investing in the technologies. Technology developers in the construction market are now
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focusing on creating easier, reliable access to the abundance of data. “The opportunities are seemingly limitless. The power of IoT provides comprehensive planning, process control, workflow monitoring and extensive reporting that will bring our customers the full advantages of connectivity,” says Ivan Di Federico, executive vice president and chief strategy officer, Topcon Positioning Systems. IOT PLATFORM What is referred to as the “IoT Platform” is the operating world in which the construction market has been evolving. The IoT Platform is meant to
Connected solutions enable contractors to have comprehensive monitoring of conditions, operations and the work site through sensors and data.
provide equipment manufacturers and construction contractors with analytics and reports about various aspects of their tasks and assets in order to enhance the decision-making process and obtain the best possible management of resources, fleets and personnel. In construction, the key is sensors. Sensors make it possible to capture all the information needed to improve decisions with real-time data about the work
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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W! NE and ne iPho oid App r And ovides Pr ote Rem ss to e Acc ater He us Stat
MEEKER PATRIOT
Hot Oil Heater Features: • PLC Touchscreen Technology • “SABER” Stack Cuts Down Stack Temperatures and Saves $$$ • All Heaters Are Test Fired at Factory Before Shipping • Personal Service with Strong Commitment to Customer Satisfaction
Your Preferred Asphalt Equipment Resource
888.333.0323 www.meekerequipment.com Search: 10073849
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TECHNOLOGY MATTERS site and the workforce. Equipping each piece of equipment with the capability of sending and receiving data allows the platform to reproduce a detailed digital representation of the product itself. That is called a digital twin. “Thanks to the digital twins of our products, activities like monitoring, diagnosis and repair can be completed remotely,” Di Federico says. “What this means is we can have experts based anywhere in the world able to provide monitoring, troubleshooting and/or repairs without needing to be physically at the contractor’s location. This would result in tremendous savings of time and travel expenses.” DATA IS KEY Smart, connected construction equipment can allow tracking of how it is being used. Through the accumulation of historical data, the IoT platform can build patterns of information to better understand contractors’ needs and the environment in which they operate, and provide advanced solutions to fit their needs. Data collected from smart, connected products and systems provide detailed information on how the products’ features are used, which are most useful and which are ignored. The collected data (Big Data) provides options for different types of analysis: • Descriptive – to retrieve a detailed report of current conditions and understand what happened in a specific working environment • Predictive – to provide a reliable prediction about product performances and forestall the occurrence of potential malfunctioning or damage • Prescriptive – to know how to optimize and automate the process and the workflow via real-time project maps and plans which feed the machines The platform provides numerous and detailed information that can be selected according to the need at the time. This enables making effective and profitable choices. It is possible to retrieve virtually any useful information, from fuel consumption to equipment productivity, from maintenance services to - in the near
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future - prognostics. In addition, most of the functionalities are completely customizable for meeting specific contractor needs (e.g. dashboard layout, alarms and notifications, CAN-Bus parameters, units of measurement, language). For equipment owners and managers, analytics can be used to compare usage patterns in order to improve services, increase productivity, ensure better quality and create more accurate pricing and bidding strategies.
Providing connected solutions enables contractors to have comprehensive monitoring of conditions, operations and the work site through sensors and data.
The ultimate benefits of Big Data is cost reductions and deeper insights as to what customers need. “Interconnected smart technology is both central to how we engineer our solutions and produce their functionality for our customers,” Di Federico says. “The challenges, as with most innovation, have mostly to do with adoption. Once construction contractors have an opportunity to see first-hand how the solutions we provide make them more efficient, the concept of IoT makes perfect sense. "Greater productivity means undeniable higher profits for their businesses," he continues, "and assists them in meeting what we at Topcon call 'The Intersection of Infrastructure and Technology.' It is the meeting point where construction productivity is improved by applying intelligent positioning technology, and clearly IoT is part of this bigger picture.” For Topcon and other technology companies in its niche, providing connected solutions to the construction market enables contractors to have
comprehensive monitoring of conditions, operations and the work site through sensors and data. This means monitoring knows no boundaries. Assets can be monitored from wherever the contractor happens to physically be. It enables real-time communication and task management with machines and crews on the work site. In addition, the entire fleet of machines working at the site can be connected. “We call it ‘descriptive, predictive and prescriptive’ analytics,” Di Federico says. “The result for customers is higher productivity, less downtime and waste, and ultimately more profitability, combined with less stress. We absolutely design our solutions with IoT top of mind. For example, the Topcon Tierra remote asset management system provides total visibility and control, including diagnostics and maintenance for reducing costs and improving performance. "Our MAGNET software solutions suite provides real-time connected support for hardware, as well as integration with our Sitelink3D service for instant data transfer and connectivity into active project sites," Di Federico says. "Additionally, Sitelink3D allows customers to plan, schedule, assign tasks and get reports, all in real time. When practically any new product or system is designed, integration with these solutions is standard and expected procedure.” The success of technology that enables construction contractors to bid projects more accurately based on their own historic production data and get their jobs completed faster, more accurately and more efficiently using intelligent interconnected technology has raised customer expectations. "For construction contractors and OEMs today, the tremendous benefits of IoT enhances the decision-making process for obtaining the best possible management of resources, fleets and personnel," Di Federico says.
For more information on IoT tecnology, visit ForConstructionPros. com/12169353.
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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SO FUEL EFFICIENT, IT MAKES YOUR HYBRID LOOK LIKE A MONSTER TRUCK.
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Nothing can compare to fuel efficiency of the Ultra II burner. Unbelievable power, unshakable reliability and faster response make it the most dependable burner available. It also runs on almost any fuel making it the greenest burner on the planet. Just one of the many brilliant systems from General Combustion. 5201 N. Orange Blossom Trail ∙ Orlando, FL 32810 ∙ 407.290.6000 ∙ GeneralCombustion.com Search: 10073093
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Dependable Performance CONSISTENT MIX
FOR MORE INFORMATION VISIT ASTECINC.COM/UNIDRUM
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DILLMAN UNIDRUMÂŽ
When it was time to buy two new plants, a Dillman UNIDRUMÂŽ plant was the best fit for us. We like the Unidrum because of its very consistent, homogenous mix and very low maintenance. The Unidrum plants provide more uptime with less routine maintenance.
Slavic Mokienko,
General Manager, R. E. Pierson Materials Corp. Operating Four UNIDRUM Plants
Search: 10072736
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PRODUCTION NOTES |
BY CLIFF MANSFIELD
Basic Decisions When Buying an ASPHALT PLA
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ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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LANT
Choosing what type of plant to purchase can be a daunting task when you figure in how much storage you need, what controls to purchase and more. Here, Cliff demystifies the asphalt plant purchasing process
S
o you’ve decided to buy your own asphalt plant. Great choice! Now you are going to be called on to make a lot more important decisions like AC plant type, style, size, brand and budget. Once you've made those choices, more issues crop up, such as AC tank size, storage silo size, number of cold feed bins, type of pollution controls and on and on and on... For someone new to asphalt plants these are baffling issues. In what follows, I am going to try to demystify the process through which all these choices are made. I will attempt to explain the various types and styles of AC plants and to help you with those choices. There are two TYPES of Asphalt Plants. Drum Mix and Batch. BATCH PLANTS A batch plant makes mix in batches. Aggregate is fed by the feeders to a rotary dryer where the moisture is removed. It is then transported to a set of screens where it is divided into several component sizes (3/4-in.-1/2-in., 1/2-in.-1/4-in., 1/4-in.-1/8-in. and 1/8-in.-0in. for example) and stored in hot-bins. These aggregates are then correctly proportioned into a weigh bin by the plant's blending computer. From here, it is introduced into a pugmill and dry-mixed for a specified amount of time. The oil is introduced at the proper time and the combination is then wet-mixed for the required time. At the end of this cycle, the pug gate opens and the finished hot-mix is either discharged directly into a waiting truck or it is dropped into a moveable chute which leads to a slat conveyor and then a holding silo. Batch plants range in size from a 250-lb. Madsen (the smallest I know of) up through 18,000-lb. monsters. They are generally rated at one batch per minute, so a 4,000-lb. plant
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would yield 120 tons per hour (tph), while an 18,000-lb. unit would yield 540 tph. Strengths: A batch plant's strength lies in its ability to make salable hot mix out of almost any reasonable stockpile of aggregate. As one old timer put it: "You can feed 'er meteors and coprolites and I'll make spec mix, sonny!" He was one wise old man. Another strength inherent to a batch plant is its ability to switch mix specifications midtruck if needed. Essentially, if you supply the plant with 3/4-in.-0-in. aggregate you can make any mix that uses materials contained within those parameters. Depending on what screens you have installed in the plant, you can make 3/8-in-0-in. mix for one truck, then switch to 3/4-in.-0-in. mix for the next and still be able to blend a nice 1/2-in.-0-in. mix for the third. In some operating situations this is a very valuable ability. Weaknesses: A batch plant utilizes numerous steps to produce hot-mix. It is those very steps that make it so valuable to someone in the position described under strengths. And those same steps are its weakness to an operator who is making the same mix all the long day. What it boils down to is the fact that a batch plant spends about 30% of its time waiting on bins to weigh up, the pug-mill to empty and similar activities. To an operator who does not have to make a lot of daily mix changes and is concerned with high production, perhaps a batch plant is not the right choice. DRUM PLANTS What is a drum mix asphalt plant? Essentially, a drum mix plant is a continuous mix facility that takes the hot-mix manufacturing process to its basics. In the feeders it proportions the aggregates into the correct blend to meet job requirements. This material is then conveyed to the dryer/mixer where the first two thirds of the unit is dedicated to moisture removal. In the last third of the unit, the correct percentage of asphalt is injected and the resultant material is thoroughly mixed. At this point it, is discharged into a slat conveyor for transport to a storage silo where it is distributed to the waiting trucks. Drum plants range from 8 tph toys to 800 tph giants. The most common plants are between 150 & 400 tph.
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PRODUCTION NOTES silos and a sharp operator, but multiple silos are not as practical if you must be portable.
NEW vs USED ASPHALT PLANTS Do you need a new machine or will a used one do? Both have distinct advantages over the other. NEW: The advantages of a new plant are obvious: It’s new, so there is no guesswork as to its condition. It comes with full factory support. This is very important in such issues as DEQ air quality compliance and plant troubleshooting, should any problems develop. Additionally, most factories will assist you in the set-up and startup of their plant. This is a real plus for companies new to the world of AC plants. USED: Used plants offer advantages too. Most notably, they can be considerably less expensive. The trick is to find a used plant that hasn’t been abused to death. And find one that is offered direct from the owner or his primary broker. This is important since a plant may be listed through numerous brokers who work together and if you don’t pick the primary listing agent, you may have to pay finder’s fees to several brokers and not even realize it. In general, try to find out as much information as possible about a particular plant if it catches your eye. Don’t be afraid to ask questions. Most brokers are willing to help you. If they aren’t, find another plant. Once you decide on a particular piece of equipment, have it appraised. Get an impartial opinion of the plant. Several companies offer this service. It is money well spent and could quite possibly save you from major repair bills in the future.
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Drum plants reduce the hot mix process and produce at a higher rate than batch plants but can only produce one mix design at a time.
Drum mix plants also come in two configurations: parallel flow and counter flow. In the beginning, almost all drum mix plants were of the parallel flow variety, meaning that the aggregate and the burner flame travelled down the drum in the same direction. In recent years, the counter flow technology has become dominant. In this configuration, the aggregate travels down the drum toward the burner. Minimizing source emissions is the driving force behind this style of plant. Strengths: The fact that a drum plant reduces the hot mix process to its essentials is its big strength. By eliminating most of the steps taken by a batch plant to produce mix, a drum plant is able to do its job more economically. They will also operate at a higher rate of production for a given drum size, since the mixing process is continuous. Weaknesses: By the nature of their design, drum plants are limited to producing one mix design at a time. If you introduce properly graded 1/2-in.-0-in. aggregate into the unit, you are going to get the same thing out of it. For a contractor who is required to supply several different mix-designs in the same production run, a drum plant may not be the best choice. This problem can be overcome through the use of multiple
PLANT SELECTION SUMMARY Basically, a batch plant is the best choice for an operation where the plant will be called upon to make various blend mixes in the same operational run, or if the plant will be doing a lot of starting and stopping in the course of the day. A drum plant is the correct plant for a company not concerned with switching back and forth to various mixes and foresees the luxury of long production runs. Another consideration is the fact that batch plants utilize many more moving parts than drum plants, therefore they are more expensive per ton to operate and year end maintenance costs are higher. STYLES OF ASPHALT PLANTS There are two styles of asphalt plants, portable and stationary. It's fairly easy to choose between the two, once you know the answers to a couple of questions: Do you need to move your plant? If so, how often will it be moved? One incontrovertible rule is that portable plants cost substantially more than their stationary brethren. If you only need to move your plant once every few years, then it is possible that the cost of moving the plant is considerably less than the cost of portability on the original order. I recommend that companies in this category consider buying a skid-mounted plant with flexible wiring, like SO cord, equipped with quick disconnects. Companies that plan to move their plants several times a year must purchase a portable facility. When looking at these units, it is strongly recommended that a self-erect silo/ drag combination be considered. In the Northwest, a crane to set the silo and drag conveyor can easily cost in excess of $5,000.00 per move. It doesn't take a rocket scientist to see that if you move your plant four times a year, you can pay for the difference in cost for a selferect in about two years.
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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PRODUCTION NOTES SIZE OF ASPHALT PLANT? How much production do you need? This is a difficult question to answer. One of the fundamental mistakes that I see is a company trying to size their plant to their highest production days. I recommend that a plant be sized to the average for a company's busiest month. New companies, without a track record for mix production, must analyze their market and decide from there. If you feel that you can sell 3,000 tons per day 10% of the time and 1,000 tons per day the rest of the production season, I suggest that a 200 tph plant is more appropriate than a more expensive 400 tph unit. Thinking along the same lines, it's difficult to justify the multi-million dollar cost of a new 350 tph plant if you
plan on making 40,000 tons a year, regardless of how fast you can make it. To summarize, plant sizing is a function of market demand. Try not to size the plant so small that in a year or so you will be looking to upgrade to a bigger facility. But then again, don't go so big that the thing is idle for long periods of time. In general, a plant is most efficient when it is running at about 80% of its rated capacity, and the things last longer when they are not stopped and restarted constantly. Another thought: A smaller AC plant with lots of storage capacity can often turn out as much mix on a given paving day, because it might not have to stop while waiting for trucks, while the larger plant fills its silo in a hurry and
If you need to break aggregates down in to more than one or two stockpiles, then consider investing in cold feed bins to separate materials accordingly.
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then must wait for the silo level to go down. This dead time takes away from productivity and adds to the cost per ton of mix. CONFIGURATION There are numerous other factors past price and size that you will need to consider when choosing a plant. Some of these things are: AC Tank Size: How far away from your proposed plant site is the nearest oil supplier? How long does it take to lap a truck from your plant to the refinery and back? These are questions that need to be answered before you can decide on oil storage capacity. In general, a 300 tph plant will use about 17.4 tons of oil per hour at a mix design percentage of 5.8%. A 30,000 gallon tank holds roughly 116.7 tons of oil at 7.78ppg (approximate weight of PGA-58-22 @ 300° F). Since we cannot pull all of the oil out of the tank because they are set-up so that the heaters stay immersed in oil (electric models) let's assume we can use 114 tons of liquid. At 17.4 tph, we can run approximately 6.5 hours on the oil we have. To stay even with our rate of consumption we will need to get a 35-ton load of oil every 2 hours. If this is not possible, we need to increase our oil storage capacity. In general I advise buying as much storage as you can afford. This means you are not as much at the mercy of your oil supplier and his trucks. Hot Mix Storage: Larger silos generally mean less truck turn-around time in the yard, which equates to more money on the bottom line. A large capacity silo can also help a smaller plant perform with the big boys as far as mix shipped per hour, since when the trucks are gone the plant can run longer, refilling the silo. If you start the plant early enough in the morning to have the silo full when the first truck loads, it will help the plant stay ahead of the trucking for several hours. I tell contractors that it's easy to put 50 tons in a 200 ton silo, it's tough to put 60 tons in a 50 ton silo. Cold Feeds: Does your state use mixes that require the aggregates to be broken down into more than one or
two stockpiles, such as 3/4-in.-1/2-in., 1/2-in.-1/4-in., 1/4-in.-10 and 10-0in.? If so, you will need to make sure your new plant accommodates all the materials you will need to be using. If you have to blend sand into your mixes you could find that you need 5 feed bins. Buying an asphalt plant is a big step, and the best advice I can think of is to be thorough. Research your market and know your potential customers. Ask yourself the tough questions: What will it take to get the business away from those who will be your competitors? What do you have to offer them that the other guy doesn't? If you plan to buy a plant to service your own paving operation, then ask yourself how a plant will aid in that operation. Will it give you access to mixes you can't get elsewhere? Will it reduce your paving crews down-time waiting on trucks? Do you have enough yearly volume to support the payments on such a large investment? Once you have a thorough understanding of these issues, you are ready to proceed with the purchase of a plant if it is warranted. Be just as thorough in your investigations of potential pieces of equipment. Ask questions and seek advice from anyone knowledgeable in the subject. Money spent on plant appraisals and consulting help could turn out to be the best investment you make. One last bit of advice: Start on the air quality permit process the minute you decide to get a plant. This process, under adverse conditions, can drag on for months and under some situations actually kill the entire project. Know your prospects for getting all the needed permits first! Cliff Mansfield operates C.M. Consulting, an asphalt repairing, upgrading and operational training company. Visit hotplantconsulting. com for more information.
For more on plant selection, visit ForConstructionPros. com/12154304.
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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PRODUCTION NOTES |
BY MIKE DEVINE
7 Tips
for Spring Startup at Your Asphalt Plant Keep your plant in top operating condition after the cold winter months with these startup steps
Pull off the tarps covering the burner and burner blower, asphalt pump, water pump, exhaust fan and any other key items. Visually inspect the components as you go, looking for worn cables, broken water lines, damaged refractory tubes and loose or missing shields. Courtesy of Asphalt Drum Mixers
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hen winter ends, spring startup begins — and profits are sure to follow. To keep your plant in top operating condition, it’s important not to rush or skip startup steps. Here’s a quick guide to walk you through starting your asphalt plant back up in the spring in a way that will help ensure a profitable summer. Think safety. It’s easy to get complacent after a long winter. Refresh yourself and your team on safety procedures before getting back to work. Check it out. Pull off the tarps covering the burner and burner blower, asphalt pump, water pump, exhaust fan and any other key items. Visually inspect the components as you go, looking for worn cables, broken water lines, damaged refractory tubes and loose or missing shields. Change the oils. If you didn’t change oil in all of the gearboxes when shutting down for winter, do that now. Pay attention to any signs of water or metal shavings, which indicate damage. Also replace the air compressor crankcase oil and any airline oils.
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Inspect. Work your way through the plant, checking for anything that’s worn, damaged, loose or missing after sitting idle over the winter. Start with the drive belts, looking for frayed spots and cracks as well as checking the tension and alignment, ensuring it matches the owner’s manual. Then move to the sheaves, checking for cracks, chips or broken edges. Look over the conveyor belts to ensure there’s no stretching, cuts or excessive wear and check that the drive pulleys’ lagging is intact. Keep it moving. When moving parts don’t do what they should, the whole operation will suffer. Test the venturi gates, watching that they close completely. Check the spray nozzles and, if they became clogged or broken over winter, clean or replace them. Run through all of the gates, as well, ensuring correct operation for the silo gates, cold feed bin gates, gob hopper gates and drag conveyor bypass gates. Test the limit
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switch paddles and then move on to the controls; make sure the indicators and switches all operate properly. Make it level. Check the alignment of the plant frame and, if necessary, level it to ensure the least amount of trunnion wear. Call a pro. Finally, have a qualified service technician come in to tune the burner.
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For more tips on preparing your asphalt plant for production season, visit ForConstructionPros. com/12294511. Mike Devine is the president of Asphalt Drum Mixers. His 17 years of industry experience help him in his role overseeing all aspects of the company. Reach him at 260-637-5729 or mgdevine@ admasphaltplants.com.
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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PRODUCTION NOTES Astec Six Pack Portable Asphalt Plant Astec Six Pack portable asphalt plant is designed for portability and productivity. • Standard setup comes with the Double Barrel drum mixer, cold feed, scalping screen with inclined conveyor, baghouse, surge bin drag conveyor and control house • Loads ship complete with ductwork, dust screws, electrical switchgear, cables and controls • Motors and electrical components come pre-wired from the factory Search: 10086334
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Dear Paving contractor, The 2017 construction season is over and with planning for 2018 did you have the software to support your staff and business to provide the wanted infrastructure? Do you want to make more money while making doing business easier with more empowerment? Do you want help with your business strategic planning or sales training? PROcru is the essential software for you! PROcru is now offering CONSULTING SERVICES for the paving industry and seeking paving companies that are looking at exit strategies for a sale. PROcru’s unique “one-stop” software offers: • A single entry CRM (customer relationship management) and dashboards for each employee’s needs • Speedy an accurate estimating tool with details for point-and-click entry (less time per estimate = more proposals per sales person) • Built in measuring tool that provides colored maps of the property that is being serviced ... and much more • Proposals with auto follow-ups and system alerts to remind clients about needed sealcoat upkeep x-years later. (Just two examples of many on keeping clients from falling through the cracks.) • A scheduling component that turns an industry weakness into your greatest strength. PROcru reminds the client automatically that their hired services are scheduled to be performed and reminds them it is upcoming. • An iPad app to show the day’s schedule and to report costs/labor hours. • Job-costing within 24 hours of performing the work, so you know your gross profit for every job the day after completion. • Reports and graphs that allow you to manage your business and not be stuck working “in” your business. • Invoicing for work performed • Connector to QuickBooks to push contacts and invoices All of the above — and so much more! Allow me to schedule a personal tour for you, or please take the time to watch the recorded tour at www.procru.online/demo I look forward to hearing from you and discussing how PROcru will transform your business, see www.procru.com.
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ADM Storage Silos Asphalt Drum Mixers offers stationary and self-erect asphalt storage silos, compatible with ADM and similar competitive asphalt plants. • Stationary and self-erect designs can be used in various plant configurations • Self-erect silo capacities ranges from 30 to 75 tons, and stationary silo models hold between 100 and 300 tons • All models equipped with alarms to alert operators when asphalt levels are high • Fiberglass blanket insulation provides superior heat retention while mixture is stored • Heavy-duty steel design with barrel continuously double welded at the seams Search: 10082676
Stansteel Combo Plants Combo Plants combine new, used or reconditioned equipment from different suppliers and manufacturers to create an effective and low cost alternative to buying an all brand new plant. • Can save the contractor $1 million, $2 million or more over the price of an all new hotmix asphalt facility Search: 10146942
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ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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Get fast, relevant product information in the Buyers Guide at ForConstructionPros.com
B&S Light EZ-Blend Total Plant Control System B & S Light Industries has added new control options for the EZ-Blend total plant control system. • Warm mix additive control with optional pressure monitoring and purge control • Four additional RAP bin controls have been added for a total of six • Standard 64 starters, 12 amp meters, 12 cold feed bins, two A/Cs, four liquid additives, three dry additive silos, baghouse pressure and gob hopper control are designed for any asphalt plant in production Search: 10118291
CMI Pulse-Jet Baghouse For situations where more aggressive cleaning is required, the pulse jet baghouses can provide significantly better bag cleaning due to "pulse" of compressed air that is applied to cause the bag to ripple down its length. • CMI BH30R baghouses feature a large filtration area with high air volume and high filtration efficiency Search: 12320517
Gencor MEGAPLANT Gencor designs and builds the biggest installed base of Megaplants across North America each producing over 50% RAP and achieving production levels of over 800 tph. • Incorporates the Ultradrum design which maximizes heat transfer • Use RAP and RAS • Patented positive reclaim system Search: 10860316 Search: 10073668
www.ForConstructionPros.com/Asphalt
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JANUARY 2018 ASPHALT CONTRACTOR
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PRODUCTION NOTES Tarmac Dryers
Vulcan Burners Vulcan burners have been developed with quality, efficiency and safety as key factors. • Excess air limitation control • Optimum adjusting combustion chamber performance • Combustion box temperature sensor • Combustion air pressure with compensation control • Ambient air compensation • Airflow diagnostics • Inverter controlled burner blower • Manual and automatic temp control • Dual fuel capacityconveying track Search: 20863915
Tarmac’s counter-flow dryers offer longer combustion flights for better flame development. • Moving slinger belt to adjust gas temperature to baghouse • Three RAP entry location options for higher RAP percentages • Insulation available • Trunnion or chain drive Search: 11564655
Dade Lintec Ixon Asphalt Plants The LX series plants are offered in 80, 120, 140 and 160 TPH versions. • All models are offered with independent cold feed systems or as a combined unit with all components mounted on a tri-axle fifth wheel chassis • A full line of asphalt storage tanks (with hot oil heaters), asphalt mix silo systems, mineral filler systems and RAP processing equipment are available • Standard equipment included in all models: Dynamic Weighing System, External Mix System (Twin Shaft Mixer), Baghouse Filter, Fines Return System, RAP Collar, 3 or 4 Bin Cold Feed Systems, Drag Slat Conveyor with Batcher, Computerized Control Cabin Search: 20866237
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Schutte-Buffalo’s heavy duty hammer mills are designed specifically for the challenges of processing asphalt road millings; producing perfect particle size in a single pass, without the need for screening. Find out how we can improve your process today! www.hammermills.com | 800/447-4634 Schutte-Buffalo is actively looking for sales agents and distributors for our asphalt processing equipment. Contact us today to find out more about joining our team! Search: 10076385
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ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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Improved Efficiency INCREASED PRODUCTION V-Flights Shower Material Along the Edge of the Notch as Well as the Tip
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V-PAC
S TA C K T E M P E R AT U R E C O N T R O L S Y S T E M V-Pac U.S. Patent No. 8,863,404 B1
To meet market demand, we change mix design often. The frequent changes push our plants to the limit. ASTEC suggested we add the V-Pac stack temperature control system. We started using the V-Pac system and, without a doubt, it has improved efficiency and increased our production capability.
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Production Manager, CR Jackson Inc. Operating the V-Pac Stack Temperature Control System since 2011
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JOBSITE INNOVATIONS |
BY JESSICA LOMBARDO, EDITOR
Comprehensive Guide to
ASPHALT PAVER MA
Failure to properly maintain your paver can result in significant downtime and profit loss
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sphalt pavers are a big investment for your company and their performance helps determine the entire success of a job. “The paver is the most critical part of an
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asphalt paving jobsite,” Brodie Hutchins, vice president dealer development at Wirtgen Americas says. “Everything revolves around that paver. If it goes down, the plant goes down, the rollers go down, the trucks and mills go down, you have fines that can happen, etc. You need to do everything you can to make sure that paver does not break down.” Machine downtime is not only bad for the life of the roadway, it's extremely bad for your bottom line.
It’s important to take the time to make sure your paver is in prime operating condition and your paver operators are the key to this. They know how the machine performs each day and will be paramount to understanding when something isn’t right. This is why they should be the ones to perform the daily maintenance checks on the machine.
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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MAINTENANCE
"A lot is on the line every day you go out to pave and down time is extremely expensive," Pete Fredrickson, asphalt product application specialist at Dynapac says. "Consider the in place cost of asphalt far exceeds $100.00 per ton. The average truck holds 20 tons and a contractor will have on average, two to 30 trucks on the road. You can’t afford to let a lack of maintenance shut your project down." This is why paver manufacturers agree
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that the best way to ensure you get your money's worth out of your paver while helping to keep it working properly for its full service life, is to be committed to preventive maintenance. “Performing simple maintenance on any machine can prevent major issues and save major dollars in the long-term,” Kyle Neisen, product manager at Roadtec adds. “Beyond the cost of preventable breaks, the downtime that can come from poor upkeep can be a significant cost driver. If a paver goes down when five trucks full of mix are already lined up in front of it, the costs for wasted time and material are into the thousands before your mechanic even starts working again.” AN OUNCE OF PREVENTION It’s important to take the time to make sure your paver is in prime operating condition and your paver operators are the key to this. They know how the machine performs each day and will be paramount to understanding when
something isn’t right. Asphalt pavers are This is why they should a big investment for be the ones to perform your company and their the daily maintenance performance helps checks on the machine. determine the entire “Operators have success of a job. a direct impact on paver condition by relaying information to service personnel about the performance of the machine,” Steve Goutermont, training consultant at Caterpillar Inc. says. “Is it running rough, steering erratically, making un-suspected noise?” And while full daily equipment walkarounds used to take an operator over an hour to complete, pavers today can basically tell you if something is wrong instead of the operator having to guess. “Daily checks can basically all be done from the dashboard now when you start up the machine,” Hutchins says. “The paver will provide fault codes and let the operator know if coolant, engine oil, hydraulic oil and fuel system levels are low.”
JANUARY 2018 ASPHALT CONTRACTOR
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JOBSITE INNOVATIONS
Complete Each Week Each paver and manufacturer have different guidelines on the maintenance schedule and contractors should always defer to that schedule when completing maintenance tasks. “50 hours can be a very important interval, especially if it’s the first 50 hours on a paver,” Pete Fredrickson at Dynapac says. “If that’s the case, make sure to follow the manufacturers recommendations. This can be a critical first time gear oil change interval. After the first change it might be another 1,000 hours before changing it again, making the first change very important.” Weekly checks beyond those first 50 hours and every additional 50 hours are also important. “As a generalization I would recommend changing the engine oil and filter, fuel filter and separator and also the hydraulic filter to remove manufacturing debris that has been flushed through the system at the end of each week,” Ken Graham at VT LeeBoy says. “All of the machines we manufacture go through an extensive quality control inspection including filtering the hydraulic oil to a purity specification of ISO code of 18/16/13 but it’s still a good idea to replace the filter. Check all chain adjustments for initial stretch and adjust as needed. Lubricate and inspect per chart in operators manual.” “On wheeled pavers, Caterpillar recommends you lubricate your bogie wheel assemblies, check the tire inflation per the type of tire you have each week,” Steve Goutermont says. “On the track machine, the track roller frames need to be lubricated. On both types, lubricate the hopper cylinder bearings.” During this service, Goutermont says contractors need to also be on the lookout for other issues and attend to them as necessary. Even still, operators should complete a visual of the inspection of the machine before it leaves the shop for the day. “A machine walk around should be conducted, looking for loose fasteners, damaged components, oil leaks to name a few things,” Goutermont says. “The machine is in an environment where the components are in high heat, working with highly abrasive material and will wear out.”
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You need to make sure the machine is clean at the end of each day. If you don’t clean the old asphalt out, the heat of the new asphalt the next day will loosen up cold chunks causing conveyor chains to jump or even worse break.
Operators should also do a visual check of the screed to make sure it’s level prior to paving. “Operators need to make sure the screed is flat and complete extension leveling per manufacturer specifications prior to paving,” Tom Travers, sales manager at Carlson Paving says. “If the screed is not level, it’s going to impact the quality of the mat you’re laying. Making sure the main screed is flat and the extensions are level will help you avoid poor joint quality or an invert or crown in the mat.” Keeping the screed clean is also important. "You don’t want to wait for today’s HMA to heat up yesterday’s mess you walked away from," Fredrickson says. "With the screed up and supported, run the end gate jacks down and scrape any loose asphalt that might harden and bind them from free floating the next day. Then crank them back up. Power tunnels and screed extensions have been known to not move in the morning if proper steps aren’t taken at the end of a day to clean them out. Taking care of them can be as easy as fully extending the extensions all the way in and out a couple of times."
Make sure you grease the machine at the end of the day. The lube will flow more easily – and get to the right spots – when everything is still warm.
CLEAN MACHINE Cleaning your paver at the end of each day is also imperative in order to maintain a reliable and long lasting piece of equipment. Failure to remove all excess asphalt from your paver will result in premature failure and excessive wear of vital components of your machine's operation and will eventually lead to downtime. “If the old asphalt is not removed from the machine at the end of the day, it can cause big problems when you start the machine up the next day,” Mike
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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JOBSITE INNOVATIONS
Complete Each Month Each month, Kevin Neisen with Roadtec says contractors should change engine oil and check all fluids on the machine and also inspect the material feed system and adjust chains if needed. “Inspect/adjust/replace all belts each month,” Steve Goutermont at Caterpillar adds. “Check conveyor and auger drive chains and adjust. Complete oil level checks for the conveyor, auger and final drive planetaries. Clean the radiator, adjust drag conveyor, take an engine oil sample, lubricate idler bearings and check the tracks and tension.” It is also up to the operators or those who are responsible for the machine to keep the paver greased at the proper intervals. “The auger and conveyors need to be lubricated twice daily, mid-shift and at the end of the shift while the machine is hot to purge out any contaminants out of the bearings,” Goutermont says.
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Neal, paver product specialist at Volvo says. “If you don’t clean the old asphalt out, the heat of the new asphalt the next day will loosen up cold chunks causing conveyor chains to jump or even worse break. Once that happens, you could be down for hours.” That’s why the number one thing a crew can do at the end of every day is clean the machine. “Following a strict cleaning routine at the end of every day should be part of the paving job you are completing and added to the time and cost allowed,” Ken Graham, product support technician with VT LeeBoy says. “If the asphalt is not removed you can expect a very high labor charge from your dealer to remove it manually without even starting the necessary repairs or service you brought it in for.” “A clean machine makes it much more likely to spot issues while they are still small and easily corrected,” Niesen adds. “You should also grease the machine at
When the machine is in the shop for the winter, you will want to take the time to not only measure screed wear, but also make sure that the screed is in prime condition for the upcoming season.
the end of the day. The lube will flow more easily – and get to the right spots – when everything is still warm.” Don’t forget about safety: check the seat belts, check any decals that may need to be replaced and walkways that need to be cleaned. Check the backup alarm, switch functions and lights for night paving. It’s these things which make the crew and the job successful and it all starts with daily maintenance. “Abuse and neglect of a machine will always cost you something,” Hutchins says. “If all this is done the night before the paver goes out to work, it’s going to make that walk-around a lot easier the next day and help ensure that paver isn’t going to break down on the job.”
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JOBSITE INNOVATIONS OFF-SEASON TO-DO LIST Right now is the slow season for many of us throughout the country, making it an ideal time to complete those maintenance tasks that may have been put off during the busy summer season. “At the end of each season you should thoroughly clean the paver removing all covers and guards to gain access to all the fines and hard to reach areas that you cannot get to during your daily cleaning routine,” Graham says. Neisen agrees, adding that contractors should deep clean the machine when the season is done. “Flush and change hydraulic and coolant systems, gear boxes and other fluids. Inspect the machine frame, conveyors and screed. Adjust all as needed. Screed plates and auger flights may need to be replaced, pending wear patterns,” he says. “A lot of times, the operating crew members are the mechanics,” Hutchins adds. “That’s an advantage because they know the machine and are invested in making sure that the machine is going to work the way it should.” Manufacturers suggest contractors check augers, auger drive chains, conveyor chains and conveyor drive chains for wear and tension. Also inspect your drive tracks, idler rollers and drive
Tier 4 Final Improving Machine Maintenance With the of Tier 4 final machines, many pavers are becoming easier to own and operate. “With the Tier 4 final machines, we were able to do away with the 250 hour maintenance check and move to a 500 hour check, saving contractors time and money,” Mike Neal, paver product specialist at Volvo says. “We also moved to synthetic fluids that tend to last longer than standard oils and that helps keep the machine out there running. The less time the machine is in the shop being serviced, the more time it’s out there working and that’s what we want.” New machines can also monitor the machines at the dealer level. “Dealers can contact customers when service intervals are coming due and let them know they need to get it done,” Neal says. system for wear and operation. The engine and hydraulic coolers should also be inspected and cleaned. “Due the usage of the on board spray down system and exhaust from the engine when the operator is spraying down the hopper with their release agent, the mist from the nozzles is often drawn into the engine compartment by the cooling fan,” Graham says. “This coats the cooling fins on the radiator making a sticky surface for dust to cling to and eventually causes overheating and again more downtime.” Graham says to make sure this area is cleaned out each year and to inspect all flight screws and bearings for play and screed wear plate thickness.
Along with the above list, deflectors on the front of the screed, guards on the conveyors and flashing on the front of the paver should all be checked and replaced if necessary. All these checks can help ensure a reliable start and productive paving season. “Basically, if you’re not confident that something is going to last the whole next season once you put it back to work, you should replace it now,” Hutchins adds. Of course this is assuming your area has a down season, if not, it's your responsibility to schedule downtime to keep that paver properly maintained. "In the northern states where weather conditions can shorten or stop paving operations, they have the luxury of a rebuild season," Fredrickson says. "In the southern states we see folks paving year-round so they need to take advantage of days not paving to perform routine maintenance and wear part changes. This can include any time it rains or the temperatures are too low and they can’t pave." RELATIONSHIPS HELP ENSURE SUCCESS If you let them, your dealer can play a big part in making sure your machines will keep running smoothly all year. Most manufacturers will provide dealers with a maintenance and inspection program that can be deployed during the off season. “We give our dealers and customers the incentive to have our paving Here, the screed is being checked for a flat tail and lead crown using the string line method.
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JOBSITE INNOVATIONS
Don’t Neglect the Screed When the machine is in the shop for the winter, you will want to take the time to not only measure screed wear, but make sure that the screed is in prime condition for the season. “The good thing about the screed is that when it’s out running, it will talk to you and tell you something is wrong,” Tom Travers at Carlson Paving says. “If you look behind the machine and see imperfections in the mat, something is out of alignment and needs to be addressed.” Downtime like that during the season can be avoided with proper screed maintenance now. Travers says now is a good time to do a measurement of the plate thickness and the best way is to conduct an ultrasound test. The machine is put up against the screed plate and it tells you how thick the steel is. If it’s too thin based off manufacturer specifications, it should be replaced. “You will also want to check the slide track performance,” Travers says. “The slide track is what the extension runs in and out of and if it’s loose, tighten or replace the bushings so your extensions run properly all season.” It’s also important to check the screed heating elements to make sure they are applying consistent heat to the mat. “This is done with and ohm test (ohmmeter),” Travers says. “Manufacturers provide you with a plus or minus on what temperature you should expect to see coming off the elements. Anything more or less than that spec would give you a strong hint that your element is not functioning to its maximum potential and you may be in the process of losing it.” In addition to checking the thickness of the end gate runner wear parts and replacing if necessary, Travers also recommends you check the depth cranks for wear as a loose depth crank will cause a screed to rock forward and backward on its pivot, creating poor mat quality. Finally, pull off the screed cover and remove any debris that might have gotten stuck throughout the season. “You’d be shocked at what we’ve found underneath the screed cover,” Travers says. “We’ve seen cups, bottles, cans, spray paint and more in there. These are fire hazards and could even explode if not properly removed.” Travers adds that now is the time you will want to make any adjustments that will both prolong the life of the screed and help build a quality pavement. specialists come out during the off season and help customers complete thorough inspections,” Hutchins says. “They help find potential problems they might not know to look for but that we see every day because we designed and built the equipment.” Once these specialists identify problems, many manufacturers offer discounts and incentives for having the parts replaced before the season begins. Volvo’s Mike Neal says they recommended their Winter Rebuild program to contractors to help them ensure everything is running smoothly. “We go over all their wear parts for material handling like conveyor chains, conveyor floor plates, auger flights, screed plates, etc., and measure them to see how much life is left in them,” he says. They then use these measurements to verify the condition with their wear check manual. “If their floor plates get down to 1/8-in. we will require that the contractors change them because they won’t last another season.” The slide track is what the extension runs in and out of and if it’s loose, tighten or replace the bushings so your extensions run properly all season.
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When the machine is in the shop for yearly maintenance, if you’re not confident a component will last the entire next season, consider replacing it now before it causes problems during the paving season.
Hydraulically Speaking
Paver specialists can also be deployed at the beginning of each season for a crew refresher course on paving and machine maintenance best practices. Check with your dealer to see what your paver manufacturer provides as many of these services are complimentary. “If you’re ever in doubt about anything on your machine, get a hold of your dealer,” Hutchins says. “They can help you make sure everything is 100% before that equipment goes back out to pave again.” And don’t forget the main resources that were provided to you with your paver, the manuals. “One of the most useful tool on a paver is the operators manual but unfortunately it is too often ignored and
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placed on a shelf or in a desk drawer,” Graham says. “There is so much useful information vital to a successful paver operator or service technician and different operation features you may not be aware of. This manual should be read thoroughly prior to operating the paver each season and left on the machine for future reference. After all, your paver is the backbone of your business and requires the care your customer deserves.”
For more on asphalt pavers, visit ForConstructionPros.com/ specguide/asphalt-paver.
The hydraulic system powered by your engine provides all your material delivery and movement of your paver. If the hydraulic systems is poorly maintained it can cause serious damage to pumps. “Hydraulic oil is the life blood of a paver,” Pete Fredrickson at Dynapac says. “Just like in the human body where arteries can get clogged, a hydraulic system lives and dies based on how we maintain it.” It can’t be stressed enough that any time a system is opened up and exposed to outside elements, measures must be taken to not introduce contamination into the oil. This includes when preforming routine maintenance like replacing filters at recommended intervals, changing oil or any other repair that opens the system to the environment. Technicians need to know the system they are working on and how to avoid cavitation when changing the oil. If the proper steps are taken, you can 100% eliminate any cavitation on startup. “The cleanliness is the most important factor for keeping the system running smoothly,” Mike Neal at Volvo says. “If debris gets in the system, or filters are not kept fresh, tiny particles can do big harm to the pumps.” You also want to make sure there is enough oil in the machine before it starts every day – low oil can cause overheating. “We recommend a complete hydraulic oil change at 1,000 hours,” Ken Graham at LeeBoy says. “The hydraulic oil not only provides the power the cylinders and motors need to operate but also lubricates the system and like all oils will break down of time and use.” Failure to properly maintain hydraulic oil levels and service intervals will significantly decrease the life of your hydraulic systems and will result in high repair costs and poor performance, slowing down your operation which can cause a profit loss on the job.
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JOBSITE INNOVATIONS Weiler E2850 Remixing Transfer Vehicle Live Bottom Trailers
Heavy Duty Trailers
Weiler's E2850 Remixing Transfer Vehicle (RTV) is designed to help improve smoothness and handle large volumes on high-production paving jobs. • 300-hp Cat C9 engine with Acert Technology • Working speeds up to 194 fpm • 25-ton hopper capacity • Optional rear steer provides a tight inside turning radius of 14 ft. • Material flow divider with a momentary switch provides equal force to the front and rear wheels for enhanced traction when working on uneven terrain • Hydrostatic drive’s joystick control and variable speed dial make it easy for operators to match the pace of the paving train Search: 10983840
Sakai SW654ND Oscillatory Roller
Asphalt Distributors
Bomag BW120SL-5 Tandem Vibratory Roller ChipSpreaders
Asphalt Transports
Bomag increased the vibration frequency of its BW120SL-5 tandem vibratory roller 7% to 4320 vpm. Vibration can be imparted to both drums, front drum only or rear drum only. With 0.020-in. amplitude, the roller generates 8,993-lb. centrifugal force. New to this class of Bomag roller is a pressurized water spray system for both drums that is double-filtered. • 40% gradeability and +/-10° oscillation • 25-hp Kubota diesel engine meets Tier 4 Final without DPF • Two spring-loaded scrapers per drum
The SW654ND oscillatory tandem drum roller has a 58-in. drum width for speedier, more profitable compaction • Side clearance is 2.5 in. with a curb clearance of 28 in. ND-series models have independent dual drum vibration or oscillation capability from twin eccentric shafts • Amplitude and frequency are 0.021 in. at 2,940 vpm • Powered by a Kubota 3.3L, Tier 4-compliant engine coupled with ECO Compaction Mode (ECM) which reduces fuel consumption up to 37% • Maximum operating weight (with ROPS) is 16,250 lbs., with a front axle load of 7,740 lbs. and rear axle weight of 8,510 lbs. Search: 12314955
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Pioneer HR2500 PowerGlide Tarping System
E. D. Etnyre & Co.
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Pioneer launches the HR2500 PowerGlide tarping system for medium-duty applications. • For single and multi-axle roll-off hoists • Slides forward and backward 24 in. to accommodate various size containers • Hydraulic system includes an adjustable gantry that moves 60 to 96 in. • Heavy-duty windscreen prevents whipping of the tarp • Maintenance-free slider carriage bearings provide easy movement Search: 12315417
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Vögele MT 3000-2i Material Transfer Vehicle The newly designed MT 3000-2i material transfer vehicle from Vögele weighs 56,000 lbs., with 18-ton storage capacity, and offers a low profile. • Can move 1,300 tph • Active remixing is achieved by two 16-in. diameter conical augers in receiving hopper • Both primary and secondary conveyor belts are 43 in. wide and are heated to keep material from sticking and eliminate “warm up” loads • Secondary conveyor can swing 55° • Heated scrapers keep belts clean • Passive remixing 17- or 22-ton “receiving insert” in paver hopper • Grate system in the receiving insert breaks up cold crusts as they enter the insert, allowing smaller clumps to absorb heat from the hotter surrounding mix • Tier 4-interim emissions-compliant
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JOBSITE INNOVATIONS Volvo PT125C Pneumatic Roller Volvo Construction Equipment’s PT125C nine-wheeled pneumatic tire roller is designed for roadway construction and resurfacing applications. • Employs a kneading action for the compaction of hot and warm mix asphalt • Heavy-duty 14-ply tires are ideal for chip seal applications • Central tire inflation system • 9,826-lb. operating weight (with ROPS) • 68.2-in. drum or rolling width • 74.3-hp Tier 4 Final D3.3 Volvo engine
VT LeeBoy 8520 Asphalt Paver The 8520 Asphalt Paver has continuous rubber tracks and a 9-ton hopper capacity. • 106-hp Kubota Tier 4 Final engine • Enhanced hydraulic system optimizes system performance • Paving width: 8-ft.to 15-ft. • Legend 815 heavy-duty electric screed • Under auger material cut-off gates Search: 12313458
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Dynapac FC1600C Paver The paver is a highway class paver in a commercial class package, offering extreme grade poly pad tracks, rebuildable wear-resistant conveyor floor plates and segmented high-wear augers. • Offers a hydraulic tow point, power crown and power match height. • The state-of-the-art drive system and material feed system makes this paver a great choice for commercial paving applications • The innovative COOL BOX cooling system keeps the drive components operating at optimal performance even on hot days Search: 12314994
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Supplies are limited.
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PRESERVATION UPDATE |
BY JESSICA LOMBARDO, EDITOR
To Recycle Pavement
HOT OR NOT? Which in-place recycling method is best for your application?
T
here are many forms of in-place pavement recycling that have been used to rehabilitate and maintain pavements in the United States since the 1930s. With an ever-present focus on penny-pinching, along with a growing emphasis of “green practices� contractors have been using these sustainable processes more frequently. Both hot in-place recycling (HIR) and cold in-place recycling (CIR) eliminate the cost of transporting, processing
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and stockpiling recycled asphalt pavement (RAP) while eliminating the need to create expensive hot mix asphalt (HMA). Studies estimate that these recycling trains reuse up to 85 percent of existing pavement, saving money and virgin materials. But which in-place recycling method is best for which project? HIR is an on-site in-place method for rehabilitating pavements. The process is used to correct surface distress such as cracking, raveling, low friction values and distortion confined to the wearing course such as corrugations and shoving. HIR cannot be used to correct structural
HIR is used to correct surface defects up to 2-in. deep.
failures and can only be used to fix distresses to a maximum of 2-in. deep. CIR is also considered an on-site application for moderate- to low-volume roadways that do not have major underlying structural issues, such as deep cracking, poor draining, pumping and saturated subgrade materials but it can be used to fix distresses 2-in. to 6-in. into existing pavement. This method is recommended for roadways that instead are suffering from raveling, weathering,
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HIR at a Glance • HIR heats the pavement surface • The material is scarified and/ or milled into RAP • The material is mixed with a recycling agent or new HMA and/or additional aggregates • RAP is paved and compacted
bleeding, corrugations, shoving, slippage, rutting, cracking and shallow potholes. Using this process eliminates damaged layers, resulting in a crack-free layer that provides a new base for a new HMA overlay or surface course. HEAT IT UP HIR is used to correct surface defects in an HMA pavement surface. It is not the right treatment for a pavement that has a base course or a subgrade failure. Before considering HIR, the thickness of the existing layer should be at least 3-in. and should not contain a geotextile interlayer within the recycling depth. The presence
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of surface treatments, rubberized crack sealants, thermoplastic paint stripes and specialty mixes may present problems and are not ideal candidates for HIR. The HIR process softens the existing HMA pavement structure with heat, removes/scarifies the surface material, mixes the material with a soft asphalt or recycling agent along with additional aggregate and then places and compacts the new recycled asphalt surface right on the roadway. HIR can be broken up into three categories: 1. Surface Recycling Surface recycling, or heater-scarification during HIR, starts with heating the
top layer of an existing pavement. This is done with indirect radiant or infrared heaters. Multiple heating units close to each other maximize the penetration of the heat into the pavement. Once the material is between 230° and 300° F, the softened material is then scarified and a recycling agent is added (if required). At this time, a pneumatic roller in breakdown, followed by a static steel-wheeled or double-drum steel vibratory roller should be brought in for compaction. Static rolling however is preferred when compacting these thin lifts to avoid damaging the mat. This compacted layer can be left as the wearing course on a lowvolume roadway or it can function as a pretreatment for an HMA overlay or surface treatment. 2. Repaving Similar to the recycling process, the repaving process consists of heating, scarifying the softened pavement, applying a recycling agent and spreading the material to form a leveling course. However, at this time a lift of new HMA is placed directly on top of the recycled material before compaction. 3. Remixing Remixing consists of heating the roadway to a depth of 1-1/2-in. to 2-in. then scarifying and collecting the softened material into a windrow. The material is then mixed with virgin aggregates, a recycling agent or new HMA if required, in a pugmill. The material is then put back down into a new HMA layer. This method is used when the repaving procedure is not sufficient to make the necessary corrections to the existing roadway. It’s mainly used to
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PRESERVATION UPDATE
During CIR, the surface distresses are milled 2 t0 6-in. before the material is recycled and used as a base or placed as a new layer of hot mix.
make changes in aggregate gradation, improve skid resistance and to adjust the mix to improve rutting resistance. Remixing can also be done in a multistage process that consists of one or more pre-heaters, two heater-milling units, a pugmill mixer and a standard paver and compaction equipment. The multistage process recycling train can treat pavements 1-in. to 1-1/2-in. on the first pass while the second unit follows closely behind, picking up the milled material from the first unit. COOL THINGS DOWN If the pavement is in need of deeper repair and an overlay, then look to CIR. CIR begins with milling from 2 to 6 inches of existing pavement which is then processed, mixed with a recycling agent (either emulsified or foamed) and then repaved and compacted. Traffic can’t be allowed on this surface for a couple of
CIR at a Glance • Roadway is milled to create RAP • RAP is crushed to create aggregate • Material is mixed with a recycling agent and then paved and compacted • The surface is now ready for an overlay or surface course
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hours and a top overlay is then needed as a final touch. For CIR to be effective in providing a long life pavement structure, as much of the existing HMA layer as possible should be treated. The Asphalt Institute suggests that at least 70 percent of the existing pavement thickness be treated and that at least 1-in. to 2-in. of pavement be left in place to support the weight of the recycling train. Processes for CIR used include a single-unit, double-unit or a multipleunit recycling train. 1. Single Unit Train: The single-unit train consists of a milling machine that does the milling, RAP sizing and blending at the cutting head. These single-unit trains do not screen and crush the RAP which can make controlling the particle size difficult. Therefore, a single-unit train should not be used for pavements with severe alligator cracking because it is so difficult to control the maximum particle size. The milling chamber acts as a scalping device and spray bar or foaming nozzles are located in the cutting chamber to add the asphalt emulsion or foamed asphalt which is provided by either an internal tank or from a tanker truck pushed or pulled by the machine. Aggregate or dry additives can be added to the pavement ahead of the milling. The processed RAP is placed in a windrow and picked up by a windrow pickup device or it’s deposited directly into a paver for placement.
2. Two-Unit Trains: Two-unit trains consist of a milling machine and a pugmill mixer-paver. The pugmill is a cold-mix paver with an internal pugmill that is used to blend the millings, emulsion and any additives. This method also does not control the particle size and the RAP is fed directly into a pugmill that controls the amount of asphalt emulsion and water being added to the RAP. The advantage of the two-unit train is its simplicity of operation and high production capability. 3. Multi-Unit Trains: Multi-unit trains consist of a milling machine, a portable screening and crushing unit and a portable pugmill mixer. The mill controls the depth of the pavement and the RAP is picked up and deposited into the screening and crushing unit. The RAP here can be consistently sized, providing better gradation and mixing control than the single and double unit process and it results in a more uniform asphalt-treated base. CIR mix can be placed in a windrow or directly into a paving machine. However, unlike HMA paving, the screed must be operated cold because a heated screed causes the emulsion to break and the mix to stick. According to the Wisconsin Department of Transportation (WisDOT) CIR projects in 2016 showed an average cost savings of 17 percent per mile compared to mill and overlay work. The total savings the agency realized reached $1.47 million. The agency says it was able to reuse approximately 93,450 tons of material on resurfacing 28.47 centerline miles. This would be enough material to fill more than 4,600 quad-axle dump trucks, WisDOT reports. No matter what in-place recycling method you choose, the efforts made have a substantial impact on the environment, saving valuable virgin materials while reducing transport costs and preserving the roadway at a lower cost than with new HMA construction.
For more information on asphalt recycling visit ForConstructionPros. com/12182357.
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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Retrofit Controls
A Heart Transplant for Your Plant
The control system: it’s the heart of your plant, reaching every aspect of your operation. ASTEC Retrofit Controls expand and improve your capabilities with an all new control system customized to fit your needs. It’s like a heart
‘‘
Pictured from left to right Roy Bryant, Plant Foreman Ricky Pendergrass, General Superintendent Bailey Watkins, Asphalt Plant Manager
When our outdated controls started to give us problems, we knew it was time to upgrade. We chose Astec because of the service. Astec has the absolute best service.
your Includes an updated A Stransplant T E C , for IN C .plant. an Astec Industries Company 4101Control JEROME Center, AVENUE Power • CHATTANOOGA, TN 37407 USA • 423.867.4210 • FAX 423.867.4636 • astecinc.com Center and all new The new system communicates timing and tolerances when switching mixes extremely well. Now we know when the mix is in tolerance; therefore, we waste less asphalt.
electrical switch gear.
— Bailey Watkins Asphalt Plant Manager, Fred Smith Company
’’
ASTEC, INC.
an Astec Industries Company 4101 JEROME AVENUE • CHATTANOOGA, TN 37407 USA • 423.867.4210 • FAX 423.867.4636 • astecinc.com Search: 10072061
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PRESERVATION UPDATE Etnyre Centennial Black-Topper Asphalt Distributor Etnyre Centennial Asphalt Distributors provide one-person operation. • Fingertip control of distributor functions • Computer-controlled spray • Available with cab controlled variable width or standard spray bar
Bergkamp SP Series Spray Injection Pothole Patchers
Search: 10147283
Kasi Patriot The Kasi Patriot uses infrared technology to blend new asphalt in with the original by heating an area 6 to 8 in. beyond the perimeter of the repair. • 2-, 4- or 6-ton asphalt reclaimer • Large tool storage area • Compactor compartment • Dumping waste bin • Battery system can be recharged from the vehicle or an overnight charging system • 30-gallon water tank and a timer that alerts the user when asphalt is heated to temperature Search: 10079102
Bagela BA4000 Portable Asphalt Recycler
Roadtec RT-500 Recycling Trailer The Roadtec RT-500 is a mobile recycle trailer that can either be pulled and fed by a Roadtec RX-900 milling machine for cold in-place recycling (CIR) or set up on a site as a central cold-mix plant. • Designed for maximum throughput of about 500 tph • Closed loop sizing with an onboard vibratory screen and horizontal shaft impact crusher • 5-ft. x 14-ft. double-deck screen • 48-in.-diameter twin shaft 6-ft. pugmill mixer • 3048 HSI Crusher with heavy-duty main shaft and bearings Search: 10079702
The 4,400-lb. BA4000 trailer-mounted, continuous operation asphalt recycler processes either broken chunk or milled (RAP) asphalt at a rate of up to 4 tph. • Uses convection type heating (280° to 350° F) via a 0.48 MBTU/hour diesel heating system • Flame from burner does not come in direct contact with material inside
• Material loaded via a hydraulically operated hopper and discharged through the rear of the mixing drum • 6.6-hp Hatz diesel engine Search: 12122447
The SP5, SP8 and SPT Spray Injection Patchers from Bergkamp come with an exclusive dual-chamber aggregate hopper that allows users to apply two grades of aggregate for more efficient repair of deeper potholes. A version with automatic operations from the truck cab is available in addition to manual operations from the ground in front of the truck. The trailer-mounted SPT patcher is manually controlled. • Two-piece folding boom (front mounted) provides a working radius of up to 13 ft. Search: 11131584
Wirtgen W 50 Ri and W 60 Ri Cold Milling Machines Wirtgen offers its new generation of small milling machines with the market launch of the W 50 Ri and W 60 Ri cold milling machines. • Level Pro Plus levelling system supports intuitive and simple operation to produce precise and high-quality milling results • 8-in. maximum milling depth • Slimline chassis provides unobstructed view of the milling edge to the front as well as of the left and right side plates, while the compact suspension of the loading conveyor affords an unhindered view of the milled area behind the machine • Automatic tracking function of the rear inner wheel when folded increases maneuverability Search: 11564717
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ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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PAVING THE FUTURE The Largest Asphalt Show and Educational Conference in North America Reduce downtime & increase efficiencies with new products from 350+ exhibitors and insights from 90+ education sessions.
March 6-8, 2018 • Houston, TX, USA Co-located with
Register in advance and save over 35% at www.worldofasphalt.com Search: 10075260
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NPE SPECIAL REPORT |
BY JESSICA LOMBARDO, EDITOR
National Pavement Expo to Rock Cleveland in 2018
F
or the first time in its history, National Pavement Expo (NPE) will visit Cleveland, OH, home of the Rock and Roll Hall of Fame and Museum. The 2018 NPE will be held Feb. 7-10 at the Huntington Convention Center in downtown Cleveland. The convention center is connected to the 600-room Hilton Cleveland Downtown, which is among the hotels NPE will be utilizing. The 2018 NPE follows NPE’s 2017 conference and trade show in Nashville, which was the largest and most successful event in NPE’s 32-year history. The 2018 educational conference will feature 54 sessions including the day-long pre-NPE Boot Camp and 11 in-depth workshops. The remaining 42 sessions are 90 minutes each. Of the 54 sessions, 39 are new and several will be updated with new video. Conference sessions will cover a broad variety of paving topics. Asphalt paving sessions will cover the basics for crew members and those new to the business as well as more advanced “how to” topics for those looking to improve efficiency. Here’s a paving-and-repair focused sampling of some of NPE 2018’s sessions. Applying “Best Practices” to Your Paving Operation, presented by paving jobsite specialist John Ball, Top Quality Paving, is an annual 3-hour “how
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to” program that takes contractors step-by-step through the paving operation. Ball relies on videos he’s taken on consulting jobs throughout the year to demonstrate various paver operations, proper and improper techniques, paving “best practices,” and problems and their solutions. Ball will make his presence known throughout the NPE conference (he presents four sessions) including Solving the Paving Puzzle: Video Solutions Show How a Job Fits Together and Diagram It! How to Pave a Parking Lot & a Cul-de-Sac from Start to Finish, which will use step-by-step diagrams (and some video) to teach how to determine the amount of mix for each type of job, how to determine haul truck size and delivery schedule, how to “line-out” the start of the work and plan the paving, and how to achieve the required slope and density. He’ll also present “best practices” to guarantee quality and efficiency. An annual NPE paving expert, Jim Scherocman, P.E., Consulting Engineer will present Identifying, Preventing and Solving Mat Problems, which will cover how to differentiate among four primary problem areas: the properties of the mix itself, site-related conditions, equipment-related problems, and long-term durability issues. Then he’ll discuss how to prevent specific problems in each area from happening and how to fix them if they do occur. Scherocman follows that session with Effective Compaction of Hot Mix Asphalt, in which he will outline the basic elements of compaction and the use of various types of rollers, including
static steel wheel, pneumatic tire and vibratory steel wheel rollers. He’ll cover compaction of both stiff and tender hot mix asphalt mixtures and will emphasize the use of different rollers and rolling patterns for different paving situations. Nigel McKay, Weiler, will present a new session, Fundamentals of Asphalt Pavers and Asphalt Paving – an introductory class that covers paving equipment basics. He’ll discuss each component of the paver – augers, screws, conveyors and screeds – including what each component does, how each works, how the components work together, and how operators can adjust components to get the desired end result of a high-quality mat. He also will provide a checklist of tips to help operators make sure the paving machine is operating at peak performance. How to Run the “Perfect Paving Project” is a new paving session from Pavement Advisory Board member Connie Lorenz, Asphalt Restoration Services, who says that while “there’s no such thing as a ‘Perfect Paving Project’ – commercial customers still expect it.” So Lorenz has developed a “pursuit of perfection” session that will cover what to include in the essential pre-con meeting, tips on communicating with clients (and a unique suggestion to help them better grasp what’s going to be happening on their property), how to plan for and handle the “unexpected issues,” and how a “team walk-through” leads to a successful end-of-project client meeting. For details including complete session descriptions and the full four-day schedule visit www. nationalpavementexpo.com
For more information on asphalt paving sessions at NPE, visit ForConstructionPros. com/20972516.
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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INDUSTRY LEADING INFRARED ASPHALT EQUIPMENT INFRARED FEATURES:
> EFF ICIENCY: Heat cycling technology > MANEU VERAB LE: 4 independent swivel casters > SAFETY:Automatic pilot ignition > TRANSPORTATION:Folds into self trailering unit > VERSATI LE: 4 idependently controlled heating zones
ADD AN ADDTIONAL REVENUE SOURCE FOR YOUR BUSINESS
Search: 10073532
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CLASSIFIEDS
ASPHALT PLANTS Contact Denise Singsime Print and Digital Advertising
920-542-1245
dsingsime@acbusinessmedia.com
·
· · · ·
· ·
PUMP PACKING Stop your pumps from leaking!
Pre-cut packing sets proven within the Asphalt Industry. Viking®, Roper, Rotan, etc. Call Scott at 1-800-231-4209 www.rainsflo.com
Denver Workshops 2-5 Days
· · · · ·
ADM 350 TPH Portable Counterflow Drum Mix Plant ADM 225 TPH Portable c-flow drum plant 300 tph counterflow drum and baghouse ADM 110 tph portable ADM 110 tph stationary drum plant w/ silos and recycle Astec 10,000# Batch plant 10,000# H&B Asphalt Batch Plant with silos Astec 75-100 Ton Self-erect silos Standard Havens 200 ton silo/slat Astec 150 ton silo/slat 80,000 CFM Baghouse Portable 20,000 gallon asphalt tank
· · · · · · · · ·
CMI 51,000 CFM Baghouse Portable 46,000 CFM Baghouse Almix 250 tph slat conveyor Astec 500 TPH Double Barrel only Two bin rap system Almix 120 tph drum & baghouse 7’X30’ portable drum mixer ADM 750 barrel self-erect lime silo Wylie 3140 40 tph asphalt plant
Please Call For Complete Inventory
Plant for sale? Call Clancy! Serving the Asphalt Industry for over 45 years
E.T. CLANCY COMPANY 219-879-8231 • 800-348-8553 Email: sales@etclancy.com • www.etclancy.com
Aggregate Designs Corporation Serving the Aggregate, Asphalt , Concrete & Mining Industries
*Plant Operation 2/19-20/18
Ph: 970-260-2435 www.aggdesigns.com
*Rocky Mountain Expo 2/21-23/18 Conference & Equipment Show 952-939-6000 Carrie carrie@clarencerichard.com www.clarencerichard.com 303-551-3266 Becky- Rocky Mtn broland@phoenix-amc.com www.rmaces.org
ADM 300tph Counterflow Drum Plant Gencor 400 UltraDrum - Counterflow Asphalt Plant
SPECO 170tph Portable Batch Plant
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ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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CLASSIFIEDS KEEP YOUR AGGREGATE MATERIAL COVERED WITH A
CLEARSPAN FABRIC STRUCTURE F or
nearly 40 years C lear s pan F abriC s truCtures has been covering aggregate materials with dependable structural solutions.
i ndustry -l eading W arranties - ClearSpan structures are built to last. With triple-galvanized steel frames and durable covers, they can withstand corrosive environments and will compliment your business for decades to come.
GET INDUSTRY-SPECIFIC INFORMATION AT CLEARSPAN.COM
C ost -e FFeCtive b uilding s olutions - Drastically reduce construction costs, monthly utilities and maintenance requirements, while getting a structure that is superior in quality. F inanCing a vailable - Speak to your Truss Arch Specialist today.
V isit WWW . Clearspan . Com or call 1.866.643.1010 to find out how we can help with your structure needs
DRYER/DRUM SPECIALISTS “Serving the rock and asphalt industries since 1985” WE ARE SECOND TO NONE IN SERVICE AND SATISFACTION ALIGNMENT
Just as your vehicles need proper alignment, so does your dryer. Nearly all external dryer problems are caused by trunnion and frame misalignment. Long-term mis-alignment causes damage resulting in downtime and costly repairs. Even units that seemingly float properly can in reality be drastically out of alignment.
SIGNS OF MIS-ALIGNMENT
✔ Metal flakes from tires or trunnions ✔ Trunnion mis-location and trunnion bearing failure ✔ Poor wear/contact on tires and trunnions ✔ High drive motor amperage ✔ Excessive vibration ✔ Thrust roller and bearing damage ✔ Tire pad and keeper wear ✔ Lack of proper floatation Evans & Daniels uses precision laser and sighting techniques to restore your unit to proper alignment settings.
RESURFACING
Evans & Daniels uses highly specialized grinding equipment that can fit into the tightest of spaces. We resurface tires, trunnions, thrust rollers and tire thrust faces. We don’t require cranes, lifting assistance, or steel framework. In most cases, we can grind during regular production conditions.
COMMON WEAR PATTERNS ✔ Tapers ✔ Washboard ✔ Concave / Convex ✔ Shoulders ✔ Lumps / Divots / Cracks ✔ Rollover
TIRE & TRUNNION RESURFACING — TRUNNION ALIGNMENT — PREVENTIVE MAINTENANCE
www.evansanddaniels.com — 570-779-1982 www.ForConstructionPros.com/Asphalt
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CLASSIFIEDS CMI PORTABLE PARALLEL FLOW DRUM PLANT • PVM 2500. NOMINAL 400TPH. MODEL YEAR 1988 • PORTABLE PF DRUM W/ RECYCLE COLLAR, SJ580 BURNER (OIL ONLY), SADDLE CHAIN DRIVEN, QUAD AXLE, SLINGER INLET, SHELL HAS BEEN LINED AND REPAIRED IN NUMEROUS PLACES. TIRES AND TRUNNIONS LOOK GOOD. • CMI 4 BIN PORTABLE COLDFEED 9X14 24’’ FEEDERS. W/ COLLECTING BELT. TANDEM AXLE • CMI AUTOPULSE2 BAGHOUSE 76,000CFM AUGER BOTTOM • CMI SEB. NOMINAL 65 TON 34’’ DRAG, DUAL CHAIN, AR450 FLOOR, ESTIMATED 400,000 TONS LEFT ON FLOOR. CABLE ERECT, NEED CRANE TO ERECT.
• HEATEC 30,000 GALLON PORTABLE AC TANK, DIRECT FIRED BUT ALSO HAS NOMINAL 1.0MBTU HEATER ON THE GOOSENECK RUNNING ON OIL, TANK EQUIPPED W/ METERING AND UNLOADING PUMP SYSTEM. MODEL YEAR 1990. • BARBER GREENE REBUILT PORTABLE RECYCLE BIN 9X14 38’’ FEEDER, W/ HYDRAULIC LIFT GRIZZLEY AND REPLACED DRIVE COMPONENTS. • PORTABLE CONTROL HOUSE W/ MCC 1800 AMP. SYSTEMS BLENDING AND LOADOUT, PLUG IN CABLING THROUGHOUT. UPGRADED TO SYSTEMS CONTROLS TEN YEARS AGO. • PORTABLE PARTS TRAILER INCLUDED
RAP-15218 H&B 10,000 LB. BATCH PLANT
CEDARAPIDS E400 COUNTER-FLOW DRUM MIXER
RAP-14645
RAP-13250
• H&B 10K COMPLETE TOWER & ELEVATOR • CEDARAPIDS 10028 DRYER (NO BURNER) • 10X13 GENTEC RAP SYSTEM • HYWAY 2.0 MBTU HOT OIL HEATER • 100 TON BARBER GREENE SILO SYSTEM
• STATIONARY DESIGN • CEDARAPIDS 126MBTU BURNER • RECYCLE COLLAR
BARBER GREENE PARALLEL FLOW DRUM
1994 ASTEC PORTABLE DOUBLE BARREL PLANT
RAP-14952
RAP-14936
• 7’ X 43’ SHELL W/ 8’ EXPANDED ENDS • TRUNNION DRIVEN (4) 20 HP MOTORS • RAP COLLAR
• 2006 PORTABLE8’ ASTEC DOUBLE BARREL DRUM MIXER • SHAGGY DOG QUAD AXLE WHISPER JET BURNER • 2001 PORTABLE 5 BIN COLD FEED SYSTEM NOMINAL 10X14 • PORTABLE AGGREGATE SCALPING SCREEN AND SCALE CONVEYOR • HORIZONTAL CYCLONE
3Qualified listings 3Complete retrofit capability 3All types of component reconditioning
TWO BITUMA/ BARBER GREEN 200-TON SILOS
RAP-14950
(2) STATIONARY HORIZONTAL AC TANKS
RAP-14457
• 200-TON CAPACITY PER SILO • SAFETY GATES • TRANSFER CONVEYOR • TWO OUTSIDE SILOS
• 20,000 GALLON CAPACITY • SMARTBOB CAPACITY GAUGE • COILED FOR HOT OIL HEAT
GENCO/ HYWAY PORTABLE FUEL TANK
RAP-15106
ASTEC 42K CFM BAGHOUSE
RAP-14635
• 20,000 GALLON SINGLE COMPARTMENT • MODEL 20FTT SN 946 • DATE 1996 • TANDEM AXLE PORTABILITY • ATTACHED FUEL PUMP AND STRAINER
• NOMINAL 42K CFM • EXHAUST FAN / STACK • TWO SECTION • SINGLE MOTOR EXHAUST FAN, PADDLE WHEEL 200HP • ENCLOSED HOPPER AUGER • 10FT BY 4.5IN BAG
3Custom engineering 3Experience with all types of plants 3Complete plants and stand alone components VIEW ALL OUR INVENTORY ONLINE AT:
Inc.
PO Box 519, Shelbyville KY 40066 • Fax 502.647.1786
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www.ReliableAsphalt.com 866.647.1782
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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CLASSIFIEDS
THE 4X6 PORTABLE HEATER
Infrared VersatIlIty
Made in the USA
Pot Hole • Bird Baths • Ugly Joints Oil Spots • Tire Indentations • High Spots Utility Patches • Low Spots Surface Cracks • Stamped Asphalt Hot Patches • Drainage Repairs
✔ Lightweight ✔ efficient ✔ DurabLe
1-877-4-reHeat
(608) 298-9301 www.asPHaltreHeat.com www.ForConstructionPros.com/Asphalt
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CLASSIFIEDS E
AV
S
Butt Joints/ End-of-Day Joints Butt Joints
Steel Plate TempRamps
Steel Plate Ramps
Cost 30% less & are 80% lighter, but still durable to End-of-Day Joints withstand many uses under heavy traffic. · Ramps taper from 1/4” to 1” or 1.5” · Interlocking sections to build Manhole Section any width of roadway · 2-12’ lanes installed in less than 20 minutes by one person · Removal time is less than 10 minutes · Absolutely nothing to clean up Manhole Ramps · Environmentally friendly
TempRamps pay for themselves in two uses. No Clean-up—No Trucking—No Disposal of Cold Patch No safety Claims
10948 Locust Rd - Tremont, IL 61568 Phone: 309-925-7623 sales@tempramp.com
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See us at World of Asphalt Houston, TX March 6-8, 2018 Booth 3647
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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Index Advertiser Index
PAGE
Advertiser Index
PAGE
Aggregate Designs Corporation
60
LeeBoy
41
Almix
9
Libra Systems Corporation
31
Asphalt Drum Mixers
28 -29
Meeker
15
Asphalt Reheat Systems LLC
63
National Center for Asphalt Technology
50
Astec Inc.
13, 34 – 35, 55
ProCru
30
Carlson Paving Products Inc.
67
RC Musson Rubber Company
64
Clarence Richard
60
R & D Trench Paver
64
ClearSpan Fabric Structure
61
Reliable Asphalt Products
62
C M Consulting
50
RoadWidener
32
Dillman
18 – 19
Roadtec an Astec Industries Co.
11, 68
Dynapac Fayat Group
39
Schutte Buffalo
32
Eager Beaver Trailers
23
SealMaster
7
E. D. Etnyre & Company
48
Superior Tire & Rubber Corp.
43
E. T. Clancy Company
60
Systems Equipment Corp.
33
Evans & Daniels Inc.
61
Tarmac International
12
EZ Road Inc.
64
Weiler
27
Fast Measure By KTP Enterprises
63
WEM Automation
25
Gencor Industries Inc.
3
Wirtgen America Inc.
5, 46 – 47
General Combustion
17
World of Asphalt
57
Heatec Inc.
2, 49
Willow Designs & Fabrication LLC
63
K-M International
59
ASPHALT INDUSTRY
DIRECTORY
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THE LAST EXIT |
BY JESSICA LOMBARDO, EDITOR
Waste Not
When mixed with other ingredients, the cellulose from recycled toilet paper looks and feels like regular asphalt, keeping the sludge out of the wastewater system
The cellulose found in waste toilet paper is being used as a binder for asphalt mix designs like open-graded friction courses that require a higher amount of bitumen.
I
t seems like they’ll throw any waste product in asphalt these days just to see what works. From pig manure to algae and cigarette butts, our asphalt roadways and parking lots are creating opportunities for waste products to be reused instead of being left to rot. Toilet paper is the latest waste product to be tested in asphalt and a 0.6-mile bike path in the Netherlands connecting two towns and is the first to be paved with the repurposed material. WHY TOILET PAPER? Most roads in the Netherlands are paved with open-graded asphalt friction course (OGFC), which is porous and water permeable. Compared to more
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run-of-the-mill types of asphalt, OGFC requires higher volumes of bitumen, which binds together the stones and sand that make up the asphalt. Cellulose is added to thicken the mixture and prevent the bitumen from dripping off the aggregate during processing, transportation and paving. “When roads get wet, [they get] slippery, so we use this asphalt because it takes water away from the road surface quicker,” says Ernst Worrell, professor of energy, resources and technological change at Utrecht University. Wicking water from the road is an important safety measure for a country that sees 27 to 35 inches of rainfall per year. Meanwhile, the Dutch flush an estimated 180,000 tons of toilet paper annually. That paper makes its way to wastewater treatment plants, where it’s filtered out with the rest of the solids. The resulting sludge is dried and incinerated. Aside from producing large amounts of CO2, the incineration process destroys many valuable resources found in wastewater, one of which is cellulose. The bicycle path uses what’s called tertiary cellulose, extracted from waste streams, says Erik Pijlman, director at KNN Cellulose, one of the partners on the project. “We take the cellulose out of these streams and once again make it into a [raw material],” he says. There are plenty of materials that contain cellulose, but paving roads is a pretty good use for the one type of recycled cellulose that can’t be incorporated into a lot of other products: the kind that comes into regular contact with waste. People tend to not want to come in contact with things that have touched waste, though, so no amount of
sterilization makes it OK to turn the product into recycled napkins or other paper products. But since toilet paper is typically a source of high-quality cellulose fibers (from wood chips or recycled paper), it would be a shame to waste it. Hence the pavement, which is mixed at such high temperatures that the manufacturing process would kill off any remaining pathogens that might possibly lurk within the post-treatment toilet paper. The recycled toilet paper in this case is collected during wastewater processing, where it’s separated out and then sterilized, bleached and dried for reuse. The result is a fluffy, grayish material. To do this, the paper fibers are sifted out of the wastewater by a 0.35 millimeter industrial sieve before proceeding through a series of machines to be cleaned, sterilized, bleached and dried. “If you look at it, you would not expect it to have originated from wastewater,” says Chris Reijken, wastewater treatment advisor at Waternet, one of 22 water authorities in the Netherlands, and part of the working group overseeing the project. “You can touch it, you can use it, it’s no problem.” The toilet paper asphalt has been around for about a year now, and according to CityLab writer Tiffany R. Jansen, it looks almost identical to the rest of the bike path. The toilet paperlaced asphalt has since been used to pave a parking lot and a dyke in the region, as well.
For more information on green roadways, visit ForConstructionPros. com/12209353.
ASPHALT CONTRACTOR JANUARY 2018 www.ForConstructionPros.com/Asphalt
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Search: 10072346
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Dedicated to Success.
®
© 2017 ROADTEC, INC. ALL RIGHTS RESERVED Search: 10074458
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