Asphalt Contractor January 2019

JANUARY 2019

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TIPS

TO AVOID ASPHALT PLANT SHUTDOWN | 16

MAXIMIZE NETWORK BUDGETS WITH NEW

ONLINE TOOLS

›››››››Turn DOWNTIME to UPTIME this Off-Season

| 10

How to Maintain Your MTV | 36

www.ForConstructionPros.com/Asphalt

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GENCOR’S WORLD CLASS SERVICE WE ARE HERE FOR YOU!

Your reliable partner, GENCOR Product Support knows the challenges our customers face on a daily basis. Our Service technicians are welltrained, efficient, and with our customers’ needs always on their minds.

The exceptional service and outstanding equipment is what makes our customers keep coming back to us.

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TABLE OF CONTENTS |

JANUARY 2019

COVER STORY Maintain your MTV for Optimal Performance Preventative maintenance on a material transfer vehicle can help prevent costly breakdowns. | 36 TECHNOLOGY MATTERS

10 Calculating the Cost of Road Maintenance New tool helps asset managers make smarter choices on a project-byproject basis to maximize budgets for networks and roadways.

20 Switching to LNG Can Simply Life for Asphalt Manufacturers Cost consistency, safety and sustainability at your asphalt plant are all reasons to consider a switch.

PRODUCTION NOTES

16 How to Avoid a Costly Shutdown at Your Asphalt Plant Understanding and paying attention to asphalt system life cycle management can help you plan for, and avoid, a breakdown.

44 Jobsite Products Pavers, rollers, MTVs & more.

56 Preservation Products Milling machines, reclaimers, infrared equipment & more.

PRESERVATION UPDATE

28 Cliff’s Notes This month, Cliff asks if your plant is in need of a plant consultation.

Sometimes these visits can save you big money in the long run.

30 Production Products Plants, baghouses, mixers, dryers, automation systems & more to measure the quality of their asphalt.

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JOBSITE INNOVATIONS

48 How to Prepare Pavement for Surface Treatments Proper surface preparation can extend the life of your surface treatment.

IN EVERY ISSUE 8

Editor’s Perspective

66 The Last Exit

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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Your Partner on the Road Ahead is not just a promise… it’s our guarantee.

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dynapac.us | 800-651-0033

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DIGITAL CONNECTION www.ForConstructionPros.com/Asphalt

Report: Reinvigoration of Federal-Aid Highway Act of 1956 Needed to Fix Interstates

[VIDEO] 5 Challenges Asphalt Contractors Will Face in 2019 While 2019 is expected to be a good year for infrastructure, there will still be some challenges asphalt contractors will face.

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New report says a reinvigoration of federal and state partnership that produced the Interstate Highway System is needed to save the interstates.

Top 10 Trailer Safety Tips Transporting equipment between jobsites requires attention to the details.

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Get social with us! Share pictures of what you’re working with over 20,000 other asphalt contractors on our Facebook page: Facebook.com/ Asphalt.Contractor/

Construction Industry Hourly Pay Continues to Outpace Other Industries Average hourly earnings in construction are now 10.7% higher than the average for all nonfarm private-sector jobs.

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CONTRACTOR

LATEST INNOVATIONS FOR ASPHALT PROFESSIONALS PROFESSIONALS LATEST LATEST INNOVATIONS INNOVATIONS FOR ASPHALT PROFESSIONALS

JANUARY 2019 Vol. 33, No. 1

ASPHALT

CONTRACTOR LATEST PROFESSIONALS LATEST INNOVATIONS FOR ASPHALTPROFESSIONALS PROFESSIONALS LATEST INNOVATIONS FOR ASPHALT

Published by AC Business Media.

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 2019 by AC Business Media. 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, 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.

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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 2019 www.ForConstructionPros.com/Asphalt

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Engineered Innovation for the Material Transfer Vehicle Market • • • • • •

Designed around clean-out to simplify daily maintenance and increase component life Variable speed elevator and conveyors reduce wear Hydraulic conveyor chain tensioner automatically sets and maintains proper chain tension Automated tire spray down decreases tack build-up with programmable spray coverage Storage hopper management system notifies crew of material level in the storage hopper Paver hopper management system maintains distance between MTV and paver and manages paver insert material level • Cat® dealer sales, service and support Search: 10075409

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CONTRACTOR

LATEST INNOVATIONS FOR ASPHALT PROFESSIONALS PROFESSIONALS LATEST LATEST INNOVATIONS INNOVATIONS FOR ASPHALT PROFESSIONALS

JANUARY 2019 • Vol. 33, No. 1

ASPHALT

EDITOR’S PERSPECTIVE

CONTRACTOR LATEST INNOVATIONS FOR ASPHALTPROFESSIONALS PROFESSIONALS LATEST LATEST INNOVATIONS FOR ASPHALT

Published by AC Business Media.

Jessica Lombardo, Editor jLombardo@ACBusinessMedia.com 920.542.1247

Turn Downtime into Uptime Make the most of seasonal downtime with these tips

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

Amy Schwandt

aschwandt@ACBusinessMedia.com

Editor

Jessica Lombardo

jlombardo@ACBusinessMedia.com

I

n most areas of the country, January is seen as the time of year where construction companies regroup from the last year and prepare for the busy months ahead. While scheduled downtime may not be your most profitable time of year, it’s an important part of keeping your business up and running. Here are three ways you can make this off-season productive.

1. Reflect & React To maximize uptime, start with where your downtime was last season. Breakdowns in equipment and communication, lack of skilled crew members, etc. are all things that could prevent you from getting ahead this year.

The new year is a perfect time to reflect on your 2018 season. How did your business perform? Were there areas where you fell short of customer expectations? Deals you missed out on because you didn’t have the crew or equipment you needed to get the job done?

Challenges in your operation also present opportunities to grow. Take time now to react to the struggles you encountered in 2018 so you can put them behind you for 2019.

2. Monitor & Maintain We say it all the time, scheduled maintenance is key to the success and long-term performance of your equipment. The best way to ensure you get your money's worth out of your equipment while helping to keep it working properly for its full service life, is to be committed to preventive maintenance. That means having a check list every fall of the equipment in your fleet, monitoring the wear parts on them and making sure those pieces of equipment get in to the shop before heading back out in 2019.

When a piece of equipment is in bad condition, it’s not worth putting it back on-site to

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Asphalt CONTRACTOR

work. To keep your machinery uptime ready, keep them well maintained this off-season. 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.

3. Invest in Improvements During the off-season, many contractors attend tradeshows to get ideas of the new equipment and innovative technology that’s available to help their business improve. Companies that attend these shows have a leg up on their competition, especially if they were able to make an investment in some new iron.

When we say improvements though, we aren’t just talking about equipment. Are you satisfied with your performance in 2018? Did you actively engage your crew to help keep them motivated? It's the job of a construction leader to effectively and efficiently manage their team.

Having a good relationship with your team is beneficial to your uptime. Employees who are unsatisfied with how their bosses treat them are more likely to slack-off at work. If your team isn’t giving 100% to their job, your uptime will not be as productive as you would hope.

Employees who aren’t properly trained are also likely to be less productive than those employees who are continually learning and developing new skills and the asphalt industry is full of theses opportunities.

If 2018 wasn’t so great for your company, don’t let 2019 be a repeat performance.

Reflect. Adapt. Grow.

How do you hope 2019 is better for you company? Let me know at jlombardo@ acbusinessmedia.com.

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ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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TECHNOLOGY MATTERS |

BY JESSICA LOMBARDO, EDITOR

Calculating the Cost of

Road Maintenance New tool helps asset managers make smarter choices on a project-by-project basis to maximize budgets for networks and roadways

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fter three years of research and development, the Pavement Preservation & Recycling Alliance (PPRA) unveiled RoadResource. org. The website was designed to help asset managers and agencies better plan and care for their deteriorating networks.

“We first started out by looking at what successful road managers and agencies were doing when it came to using recycled materials and preservations treatments and took those traits to build an online resource that everyone can learn from,” Lindsay Matush, CEO of Vario Marketing says.

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The site was designed to help pavement asset managers expand their understanding of various asphalt treatments and solutions, helping them to know when to use what treatment and also give them the technical information and best practices they need to apply the treatment successfully.

“In our research, agencies indicated there was so much good information out there that it was overwhelming to try to access the data,” Matush says. “We wanted to give agencies a consistent and easy to understand resource where they could find what they needed.”

The Pavement Criteria tool is designed to explore cost-effective solutions to pavement at varying levels of distress. Users can input pavement criteria such as primary distress, road and surface type to be given potential solutions relevant to that roadway.

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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RAP IS WORTH WHAT IT REPLACES.

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

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TECHNOLOGY MATTERS

The Life Cycle Cost calculator helps contractors see exactly when a road will start experiencing accelerated deterioration.

NETWORK OPTIMIZATION RoadResource.org features different calculators that help asset managers figure out how to optimize their network. Each calculator helps managers to apply smart strategies that can stretch their resources further.

Which Treatment is Best: The Pavement Criteria tool is designed to explore cost-effective solutions to pavement at varying levels of distress. Users can input pavement criteria such as primary distress, road and surface type to be given potential solutions relevant to that roadway.

“As you enter criteria around your road, treatments that are no longer applicable based on the parameters you enter will gray out leaving you only with options that could be potential solutions,” Matush says.

Each solution then takes you to a high-level description of the treatment along with a cost-benefit analysis.

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Life Cycle Cost: Understanding the life cycle of your roadway and what you can do to help extend that life helps contractors realize the impact of cost-savings over time. This calculator helps with exactly where that road will start experiencing accelerated deterioration and gives options of what to do to prevent a costly mill and fill.

“If we can apply a series of preservation treatments that can help us to get ahead of that deterioration curve, agencies across the board can achieve 40-50 years of life which has the potential to save taxpayers $125M over the life of the roadway,” Matush says.

The calculator allows managers to compare the cumulative impact of less frequent maintenance under a worst-first approach with a preservation approach that treats and preserves your road every few years. Users can input different treatment types to see what type of cost savings they could achieve.

Remaining Service Life: Most agencies are not going to see their budgets increase overtime, so they are tasked with doing more work with less money as their assets deteriorate.

“Agencies have to do the slow, hard work of incremental change that helps them to spend the same amount of money, just differently, to help reverse a deteriorating network,” Matush says.

Understanding Remaining Service Life (RSL) is critical to designing a treatment plan that stretches your budget further and reverses the trend of a deteriorating network. The RSL calculator lets managers explore how different treatment combinations can be varied to inject maximum life into their network and use their resources more wisely.

Cost Benefit Value: Deciding which projects need to be a priority in the year can be tough when you look at the budget dollars you have to work with. The Cost Benefit Value (CBV) calculator offers roadway managers a way to prioritize projects while accounting for the variables relevant to them and the realities of traffic, cost and life extension.

The CBV calculator reprioritizes costly projects and suggests the utilization of efficient treatments over more roadways and adding new life to the network.

The website also features news, casestudies and ways to stay connected with PPRA so users continue to get the most out of the tool.

For more information, visit RoadResource.org

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES

›››››

How to Avoid a Costly Shutdown at Your

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ASPHAL PLAN

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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A malfunction or failure of your PLC may cause the quality of your mix to suffer or worse, force a plant shutdown.

ALT ANT

Understanding and paying attention to asphalt system life cycle management can help you plan for, and avoid, a breakdown

A

n asphalt plant control system consists of a computer (PC) and in many cases a programmable logic control (PLC). The PC and/or the PLC provide commands in sequence to field equipment to allow the plant to produce asphalt to a specifically designed formula. When any part of the system malfunctions or fails the asphalt quality may suffer and the plant may shut down. Avoiding a costly shutdown is best accomplished if you can monitor equipment and component health, schedule preventive maintenance and anticipate repair and replacement to minimize surprises.

The diagram on the next page is a typical schematic of a PC/PLC system and the peripheral equipment involved.

The PC serves to provide information necessary for the PLC to function and control the operation of the peripheral devices as well as record necessary data that may be used for reporting or inventory reconciliation.

PC PERFORMANCE IS KEY The life cycle of a PC varies depending on the environment it is kept in, and the hardware used to configure the PC. Typically, a PC life expectancy is 3-5 years and should be replaced accordingly as it is an essential piece to keeping your operations up and running smoothly, however, computers that are housed in a clean environment can have a longer life.

Communication between the PC and PLC is managed by a software algorithm, that once installed is consistent and unchanged throughout the duration of the PC. The data brought back to the PC is stored in a data base and requires little maintenance depending on what was supplied with system. Software changes from your system vendor can occur on a

›››››

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JANUARY 2019 ASPHALT CONTRACTOR

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PRODUCTION NOTES This diagram shows a typical schematic of a PC/PLC system and the peripheral equipment involved.

›››››

regular basis and though they may not be required for your existing system, they usually contain enhancements and features that can improve performance when installed. PC systems retain collected data for a limited period of time and usually based on the amount of data collected. It is recommended to back-up your system data so there are no surprises when data recovery is required. Keeping in close contact with your manufacturer regarding your control system is recommended in order to determine what data base maintenance should be performed, along with the frequency of system backup and system updates.

PROTECT THE PLC The PLC in the diagram provides commands to field devices and assures they are operating in a safe and sequential manner to produce quality asphalt. The PLC also collects and communicates data back to the PC that operational commands have been actuated or completed. The PLC also provides measured values used for transactions and inventory reporting where appropriate. The communication between the PC and PLC, as well as to and from the peripheral devices, relies on stable connections between devices and consistent dependable power.

“Historically, 20 to 30 percent of calls received by my service department are related to plant electrical issues,” Bob Gardner, director of field service at WEM Automation explains. “The

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issues can range from damage caused by lightning to a loose wire connection on a communication card. When a situation surfaces where it is suspected there is a lost connection, and there has not been a thunderstorm in the area, a quick check of wire or cable connections can sometimes resolve the issue.”

PC’s and PLC life can be severely impacted by lightning. Isolation of peripheral equipment from the PC and PLC through the use of fiber optic Ethernet cable can protect from transient current impacting the life of other equipment on the same network.

PC’s and PLC’s are typically supplied with surge protectors to protect from line spikes or lightning. Even though the surge protector continues to function it has undoubtedly been weakened and should be replaced following a lightning strike.

Peripheral field device life cycle can also affect plant performance and inhibit the ability to reach peak plant performance. To help maximize useful life, maintenance management systems are available to provide preventive maintenance schedules.

These systems are typically configured by the individual plant and measures time related events such as RPM’s or TPH that will indicate a period of time elapsed and preventative maintenance should be scheduled for the individual device or even a scheduled plant maintenance. Some types of activities that can be managed

are bearing lubrication, gearbox oil evaluation/replacement and belt adjustments.

While your plant may be running today without issue, it is recommended to periodically review your equipment with your supplier to make sure what you have is current, and not beyond its useful life. The same holds true for your control system. Control systems can last in an asphalt plant for 10 years or more though it is recommended to periodically check with your vendor to see what may be outdated and what is new.

Failure that results from issues that go unresolved for a length of time can put strain on the rest of the system, or put the process on the edge of acceptable performance. Both of these cases can have a huge impact on quality and plant operations. Regularly scheduled review of control systems and plant equipment is crucial to maximize equipment life and plant production.

Authors Kayla Stone & Hans Anderson are with WEM Automation, a supplier of control systems that help to keep your asphalt plant investment operating at peak levels.

For more information on optimizing asphalt plant downtime during the off-season, visit ForConstructionPros. com/12098559

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES

Switching to LNG Can Simply Life for

ASPHALT MANUFACTURERS

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here is no lack of challenges confronting asphalt manufacturers in today’s highly-competitive, cost-driven marketplace. Project bidding processes are complicated by wide swings in the price of fuel, which is a critical element in any estimate. Compliance with a range of environmental regulations requires constant vigilance. And ensuring workplace safety is an ever-present concern.

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Recently, a growing number of asphalt manufacturers without cost-effective access to natural gas have discovered a simple solution to addressing each of these challenges. They have switched to using liquified natural gas (LNG) to fuel their stationary and temporary asphalt production facilities. They are finding LNG to be more stable in terms of price, more sustainable and much safer than fuels traditionally used to produce

Two vertical LNG storage tanks, with a combined 28,000 gallons of capacity, were installed when the California Commercial Asphalt plant in Lake Elsinore, CA was transitioned to LNG as a fuel source.

CLEANCOR LNG worked with the company and local permitting authorities to make the required changes in the air permits to enable the switch to LNG.

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES asphalt. Here is a closer look at some of the advantages LNG has over other fuels in manufacturing asphalt.

SIMPLIFIES BIDDING PROCESS Accurately determining cost per ton of asphalt is a key to asphalt manufacturers being awarded Department of Transportation (DOT) contracts.

However, for those who use propane and diesel in their plants, there is an added

degree of complexity in the bidding process, because the price of these fuels can vary by as much as a dollar per gallon over the course of a year in some circumstances.

By comparison, asphalt manufacturers who use LNG as the fuel source in their plants are finding the bidding process greatly simplified. This is due to the stability of LNG prices, which typically vary by no more than a few cents per gallon over a 12-month period thanks to the abundance of natural gas in the U.S.

MORE SUSTAINABLE THAN OTHER FUELS Mike Acott, president of the National Asphalt Pavement Association (NAPA), says that for decades, the asphalt pavement industry has been proactive in reducing the impact of its operations on the environment. That proactivity is why the sustainability aspects of LNG are so appealing to those who are using it to fuel their asphalt plants.

Asphalt manufacturers are learning that LNG is the cleanest burning fossil fuel. That is because it is the simplest hydrocarbon – one carbon atom and four hydrogen atoms (CH4) – and the simpler the hydrocarbon, the cleaner it burns.

A mobile storage tank enabled California Commercial Asphalt to convert its temporary plant in Lakeside, CA to LNG as a fuel source. The conversion from propane to LNG was completed in four hours. The mobile tank has the capacity to store 33,000 gallons of LNG.

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ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES

“Temperatures coming from the burner after the LNG switch are typically more consistent and controllable which equates to better mix and better compaction at laydown,” John Greenwood at California Commercial Asphalt says.

Diesel fuel, by comparison, is much more complicated than LNG. It consists of a mix of long-chained carbons, with sulfur and other molecules attached. As a result of this complexity, its emissions levels are dramatically higher than LNG. SAFER THAN OTHER FUELS Another important differentiator for LNG as a fuel source is that if a spill or other type of incident occurs, it will quickly evaporate and become non-hazardous because LNG is lighter than air and acts more like helium in its gaseous state, quickly rising and dissipating into the atmosphere.

This is in stark contrast to spills involving propane and diesel. For example, when propane, a heavy fuel, is spilled, it is extremely hazardous until fully mixed with surrounding air. In the interim, the combination of an ignition source and the presence of propane in a low area or corner of an asphalt plant can create an extremely hazardous situation for employees, first responders and others at the scene.

Diesel fuel spills are another case in point. Depending on the amount spilled, they could require a full HAZMAT response team and could contaminate the soil in the area, requiring a costly removal and cleanup process.

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EASY AND BENEFICIAL TRANSITION TO LNG An important reason for the growing use of LNG in asphalt plants is its widespread utility. Any stationary or temporary plant that is currently operating on propane, diesel, recycled fuel oil (RFO) or waste oil, including hot oil heaters and power generators, is a perfect candidate to convert to LNG. The first step in transitioning to LNG is a thorough evaluation of the site or sites involved. The evaluation is designed to answer the following questions: • What fuel or fuels are being used at the location and in what applications?

• Does the plant have a dual fuel gas train if it is operating on diesel or waste fuel or will one need to be installed?

Cost consistency, safety and sustainability at your plant are all reasons to consider a switch to LNG.

• Are the burners already equipped to operate on natural gas or will a conversion be required?

• How many tons per year of asphalt is the plant producing?

• Where will the LNG storage tanks will be located?

• How long will the plant be at its current location?

• Does the plant have adequate power supply or is a generator being used as the primary power source?

“Once the evaluation has been completed, the transition to LNG as a fuel source is relatively fast and easy and can be scheduled any time there is an available window,” John Greenwood, general manager of California Commercial Asphalt in San Diego, CA says.

While the installation is under way, plant managers simply coordinate with the maintenance department to dial in the burner to the appropriate oxygen content during commissioning or simply tweak the burner to run efficiently with the cleaner fuel source. The entire process can be completed in as little as four to six hours.

“At our plant, we’ve found that LNG is a great alternative to burner fuels and diesel for two important reasons."

Greenwood says. "First, it’s generally more cost effective. Second, the AC temperatures coming from the burner are more consistent and controllable, which equates to better mix and better compaction at laydown.”

SIMPLE SOLUTION TO MANY CHALLENGES “Simplicity,” it has been said, “is the ultimate sophistication.”

That rings particularly true with respect to asphalt manufacturers who are converting to LNG to fuel their stationary or temporary plants. Not only are they finding the conversion process surprisingly simple, but they are also finding LNG to be a simple solution to many of the complex challenges they face on a daily basis.

Author Scott Johns is president of CLEANCOR LNG, whose mission is to promote the use of liquified natural gas (LNG) in a variety of industry segments.

CLEANCOR, LNG is a business unit of CLEANCOR ENERGY SOLUTIONS, a division of Seacor Holdings, Inc (NYSE: CKH). He can be reached at sjohns@ cleancorenergy.com.

For more information on using natural gas at your asphalt plant, visit ForConstructionPros. com/20975892

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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12/18/18 3:16 PM

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REGISTER TODAY February 27 - March 2 Music City Center • Nashville, TN

National Pavement Expo brings vendors and contractors together who make their living from asphalt and concrete paving, sealcoating, striping, sweeping, crack repair, pavement repair, and snow removal to network with other paving professionals, attend industry workshops, and learn new ideas at our leadership boot camp.

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12/18/18 3:16 PM

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A commitment to service is a commitment to your success. For the Astec service team, education is an integral part of demonstrating that commitment. From VISIT US AT PARTS the renowned Astec customer schools, to on-site training sessions, Astec service makes education a priority.

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PRODUCTION NOTES |

BY CLIFF MANSFIELD

Is It Time for an

ASPHALT PLANT CONSULTATION Sometimes these visits can save you big money in the long run

O

ver the last year I have been to over 50 asphalt plants in several countries, appraising equipment, troubleshooting ongoing problems, designing upgrades and training operators. One of the more

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vexing issues I encounter is when I am asked to set-up a plant that was sold by some plant broker who knows very little about asphalt plants, to someone new to asphalt plants. To add insult to injury, the plant is then taken down by some hack-n-slash “expert.” Such was the case at a plant this last summer in southern Texas.

I got a call from a new owner needing help to get the plant up and running.

He had called me earlier in the year

Cliff ’s Notes

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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I can fix most things and get it running, but this TM 40 Stansteel on Wake Island was a bit too far gone....I was out there for International Bridge. The owner, Bill Toelkes was a bit of a comedian, I learned. On the way out to this plant he told me we needed to be running in two weeks. I assured him I would do my best. Imagine my surprise when we drove up to this thing.....

to inspect the plant for him with the thoughts of buying it. I gave him a price to go there, but never heard back from him. He apparently figured the price was too high. After all, most people figure it IS just iron. Six months later, he calls and wants me to come set-up what he bought.

My first question was, “Who took the plant down for you?”

He gave me the name of a company I’d had dealings with in the past that I

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considered to be “fly-by-night” since I mostly had to clean up their messes.

“Why not have the guy that took it down put it back up?” I asked.

"He charged us $80,000 to take the plant down and now we can’t find him.

I am told he filed bankruptcy.”

Needless to say, I felt sorry for the client, so I said I would look it over. I flew down to Texas and went to the jobsite. When I drove up to the asphalt plant I was simply astonished at what I saw. The disassembler’s crew had used a cutting torch and a Sawzall to get the plant down. Haphazardly. The duct work was ruined. The feeder and baghouse legs were cut off at random angles as were most of the rest of the supporting structures. All the rubber belting for the conveyors was simply gone. The electrical wiring was cut at random lengths and just heaped into a shipping container. There was NO possibility of ever using any of it again.

But the Drag Conveyor was the worst. The conveyor had about a 15° twist in it where they had apparently dropped it. To say the plant was a disaster would be an understatement. It was very nearly scrap iron. All of these issues turned a two week job into a two MONTH job that cost the client over $160,000 when it was all over. This didn’t include the $80,000 he paid to get the plant down. He was almost $250,000 into a plant he only paid $300,000 for to start with. Not a very economically feasible project.

ASK FOR HELP INSTEAD There are companies out and about like mine who offer assistance in assessing and moving asphalt plants. If you are

the slightest bit uncomfortable, get help. I don’t know about others, but at my company what we do is take a client’s personnel and teach them how to tear down, move and reset their own plant. When we are finished, the client’s personnel understand their plant and know how to work on it. This is invaluable training. And it also helps us weed out personnel who are simply not suited to the stresses of an asphalt plant.

In worst case scenarios, my guys will move plants alone, but I think this is a huge missed opportunity for the client.

We are a training company first and foremost. If we can leave a client in a better place than when we met them, I always feel good about that.

However there are times when the client simply doesn’t have the time or personnel to invest in moving the plant and my guys are tied up. In these instances I have been hired to supervise the move by lesser known companies.

As long as things are done correctly, this is a viable option.

My advice is simple: If you are not 100% comfortable with every aspect of moving and resetting an asphalt plant, GET HELP. Even if it is only in a supervisory capacity. My Texas client could have saved at least $150,000 on his move if someone had just supervised the people doing the work.

Please remember, if you have a problem and need some advice, e-mail or call me. I don’t charge for phone/email consultations. Keep in mind, I will be happy to help. Now and anytime in the future.

Cliff Mansfield operates C.M. Consulting, an asphalt repairing, upgrading and operational training company. He has 40 years of experience in the industry.

Visit hotplantconsulting.com for more information.

For more information on getting your plant ready for 2019, visit ForConstructionPros. com/12294511

JANUARY 2019 ASPHALT CONTRACTOR

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12/20/18 12:46 PM

PRODUCTION NOTES ADM Storage Silos Asphalt Drum Mixers offers crane-set and self-erect asphalt storage silos, which are compatible with both the company’s own and similar competitive models of asphalt plants.

• Stationary and self-erect designs can be used in various plant configurations • Self-erect silo capacities ranges from 30 to 300 tons and stationary silo models hold between 100 and 300 tons • All models equipped with alarms to alert operators when asphalt levels are high • Available drag conveyors from 150 to 500 tph help deliver the freshly mixed asphalt to the storage silos Search: 10082676

Astec Warm Mix Systems The benefits of warm mix asphalt, such as reduced energy consumption, lowered emissions, and elimination of visible smoke, are well-known in the asphalt paving industry and the latest generation of the Astec warm mix system simplifies production of warm mix asphalt.

• The Astec warm mix system achieves a lower temperature at a lower cost by eliminating the need for additives or special asphalt cement • Instead, the Astec warm mix system injects a small amount of water into the liquid AC to create microscopic steam bubbles Search: 20989627

Gencor Giraffe Recycle System The Gencor Giraffe RAP unit combines a bin and feeder, lump breaker, vibrating screen and scale conveyor into a single easily transportable unit.

• Unique bin design eliminates material bridging, with steep-sided tapered walls, self-relieving throat and welded beater plates on the sides of the bins • Rack and pinion adjustments allow the bin gates to be easily raised or lowered to maintain the correct amount of RAP being fed for precise material flow • Double-drum RAP lump breaker can easily reduce RAP material size without crushing the aggregate Search: 10091574

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ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES Heatec Rubber Blending System

CMI Magnum Series Drum Mixers The CMI Magnum series is designed for both large stationary installations as well as highly mobile paving companies running CMI Super Portable series of asphalt plants.

• Part of the family of counter-flow drum mixers that incorporates the latest in counter-flow technology and is capable of meeting the most stringent air quality regulations, providing improved mix quality and lower cost per ton • Available as portable drums in capacities from 225 to 500 tph and as relocatable and stationary drums in capacities from 225 to 600 tph, Magnum drums move virgin aggregates and RAP materials counter to the flow of the exhaust gas inside the drum Search: 12320485

Ammann ABP HRT Asphalt-Mixing Plant The ABP HRT (high recycling technology) plant is an ideal fit for asphalt manufacturers who need to incorporate large proportions of RAP without sacrificing capacity and quality.

• The HRT is a “two-in-one” plant featuring both warm and cold recycling systems that can be used simultaneously • There are two warm recycling systems to choose from; One is the conventional concurrent flow dryer for RAP additions of up to 60% and the second is Ammann’s latest development in warm recycling, the RAH100, which can utilize 100% RAP • Vertical stacking of the RAP-bearing components reduces wear and sticking and shortens the travel distance of hot RAP material • Production capacity of 440 U.S. short tons per hour Search: 20988239

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The Heatec rubber blending system is a self-contained trailer-mounted unit that's powered by a motorgenerator set.

• Booster heater raises the temperature of virgin asphalt prior to mixing • Its hopper feeds ground rubber into its pre-wet mix tank where it is mixed with the virgin asphalt • The mixture is piped to its two reaction tanks and held for usage • Its hot oil heater heats all tanks Search: 20865502

ADM Call Box A tank heater that fails on a cold evening and goes undiscovered until the next morning can lead to significant downtime, between repairs and waiting for the asphalt to reheat. ADM’s call box notifies operators of an event at the plant.

• Can be tied to most plant systems, but it is most often used to monitor asphalt tank temperature • Custom automated alerts via text message or phone call allow operators to be in the know when they are away from the plant • Operations choose from landline or cell phone configurations

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 temperature control • Dual fuel capacity (bolt-on facility for natural gas) • Fault diagnostics, with history log

Search: 21026258

Superior Industries Tracked Conveyors Superior Industries has added a 75-ft. tracked stacker and an 8- by 16-ft. tracked feed hopper to its portable conveying solutions.

• Weighing in at 34,000 lb., each stacker can handle up to 1,000 tph • Hydraulic power controls the tracks, folds and discharge height • Tracked portable feed hopper processes up to 800 tph from a reinforced, 8-cu.-yd. hopper Search: 21030219

Rotochopper B-66 L-Series Grinder The B-66 L-Series horizontal grinder is designed to meet the needs of grinding larger, more abrasive feedstock materials and engineered to increase overall production rates with efficiency.

• Lower, longer infeed hopper has less drag and tackles the toughest grinding jobs with ease • Aggressive powerfeed pulls materials into grinding chamber and 38-in. throat opening accommodates tough material such as large logs, whole trees and brushy feedstock Search: 21028316

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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AND YOU KNOW WE DO THIS...

You know Astec for durable, reliable equipment with proven performance. A pioneering team with decades of experience and a culture committed to putting the customer first has culminated in a range of options including drum styles, baghouse styles, and silo styles which allow you to configure the precise plant for your needs. Only Astec offers a complete line of portable, relocatable and stationary asphalt plants from 80tph to 600tph. Astec manufactures both Astec and Dillman brand equipment.

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JOBSITE INNOVATIONS |

BY JESSICA LOMBARDO, EDITOR

Maintain your MTV for Optimal

PERFORMAN

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ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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ANCE I

Preventative maintenance on a material transfer vehicle can help prevent costly breakdowns n the road building industry, we don’t just believe in Benjamin Franklin’s phrase “an ounce of prevention is worth a pound of cure,” we swear by it.

That’s because the product we rely on, asphalt, is extremely perishable and if we don’t get it put down in a timely manner, everyone is in trouble.

To help contractors put asphalt down faster, the use of Material Transfer Vehicles (MTVs) has been increasing as a way to use less trucks while reducing both material and thermal segregation. Many states are also starting to require the use of these machines during paving so any breakdown in this equipment would be detrimental to the success of a job.

“An MTV breakdown on a jobsite can bring the entire operation to a stop, from the plant to trucking to the paver,” Donny Smith, senior product specialist at Weiler says. “Proper and preventative maintenance will increase the life of critical components, in turn, reducing operating costs. Proper cleanout of the machine along with regular scheduled greasing, oil and fluid changes, along with inspections help ensure the machine is running at optimal performance.”

Vijay Palanisamy, product marketing manager at Dynapac agrees.

“Due to the high investment cost nature of purchasing a MTV, every hour a machine is parked for maintenance directly impacts the top line and bottom line of the contractor,” he says.

“Both preventive maintenance that can be done at job site

www.ForConstructionPros.com/Asphalt

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and annual maintenance at the shop to go over wear parts is suggested to help keep these machines running in prime condition.”

CLEAN MACHINE Manufacturers of MTVs say the number one thing you can do to keep your machine running properly is to make sure it’s clean.

“Cleaning is everything about wear life,” Kyle Neisen, product manager, pavers & MTVs for Roadtec, Inc. says.

“It is one part of maintenance that can dramatically increase the life of wear parts. It saves money and time, and increases efficiency.”

Smith adds that contractors who are diligent about cleanout typically see significant improvement in wear life.

“We continually stress the importance of following recommended daily and weekly cleanout procedures,” he says.

“It is easy to see the correlation between machine cleanliness and wear life.”

The daily cleanout process includes the following: 1. Ensure all excess material is out of the hopper and conveyors. You can do this by leaving it run for 10 minute prior to completing cleanout to loosen any material.

2. Spray down the machine including dump hopper, augers, chains and hopper.

3. Open front dump hopper cleanout door and remove excess material from hopper, especially material buildup at the corners of the outer augers.

4. Raise the front dump hopper and clean excess material around.

5. Open storage hopper cleanout doors and remove excess material from hopper, especially material buildup at the corners of the outer augers.

6. Close all doors and spray down machine including dump hopper, augers, chains and hopper.

Contractors should also follow the recommended maintenance schedule

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JOBSITE INNOVATIONS Open storage hopper cleanout doors and remove excess material from hopper, especially material buildup at the corners of the outer augers.

Maintenance issues at the asphalt plant can cause significant damage to the machine . Make sure you are working with a clean and reputable asphalt plant to avoid any unnecessary damage.

with weekly cleanout of conveyors that includes opening all conveyor doors for inspection and cleaning. While doing this, maintain proper and even chain tension, spray down conveyors before and after operation daily with either the internal spray down system or manually.

In addition to cleaning out the machine, contractors should be sure they are working with a clean and reputable asphalt plant as machine wear can be directly related to the plant.

“As the first piece of equipment on the jobsite, the MTV is the first to get a part of the plant through the machine,” Smith says. “If there have been maintenance issues there, the damage a piece of plant can have on an MTV can be very significant, in addition to causing the entire paving operation to stop for repairs. When a company looks back at the operating costs of an MTV, many times it is not noted that a piece of the plant caused the damage that may have included replacement of chains and/or augers prior to normal wear life.”

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Aggregate also has a significant impact on wear life. Depending on the type of rock being used, some components will wear faster regardless of the level of cleanout.

MAINTAIN WEAR PARTS In addition to keeping the machine clean, maintenance should be completed regularly to help increase uptime.

“Maintenance should be performed daily, on the jobsite,” Neisen says. “This will prevent a majority of issues that could cause work to halt. These are simply checks and procedures that only take minutes. If a crew

gets into the habit of performing daily maintenance, it’s quick and easy and the payoff, in terms of productivity, is exponential.”

Wear parts on an MTV include: bearings, sprockets, augers, chains and conveyor floor liners.

Wear on a sprocket is easily visible.

When a sprocket is worn or cupped, it causes damage to chain rollers. Replacing a chain is much more expensive and time consuming than replacing a sprocket.

That’s why it is so important to perform sprocket inspections daily. Proper maintenance and replacing of sprockets will increase the life of the chain rollers and the entire chain.

Manufacturers will specify a maintenance schedule in their operation and maintenance manuals and maintenance is to be performed at what machine hour intervals they need to take place. See sidebar on page 40 for general hours of service details.

“Following the recommended maintenance schedule, whether in the field or in the shop, will lead to best results for the contractor,” Smith says. “A complete machine audit and “deep” cleaning in the off-season is another great way to inspect the machine and perform preventive maintenance and repairs.”

After cleanout is complete, close all doors and spray down machine including dump hopper, augers, chains and hopper.

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During daily cleanout, raise the front dump hopper and clean excess material around.

JOBSITE INNOVATIONS

Service Intervals With any maintenance program, always follow the schedule recommend by the manufacturer in your manual.

Still, here are some general*, though not all inclusive, maintenance guidelines to follow for your MTV. 10 Hours or Daily Maintenance: • Air cleaner inspection • Auger inspection • Fluid level checks • Daily grease locations • Spray down tank fill 50 Hours or Weekly Maintenance: • Chain tension check and adjustment • Weekly grease locations • Spray down filter cleaning Every 100 Hours: • Auger inspection • Cooling system clean • Hydraulic system check • Overall machine inspection • Tire inspection • Switches inspection Every 150 Hours: • Chain tension check and adjustment Every 250 Hours: • Brake system check • Conveyor floor plate inspection • Fume extraction inspection and cleaning • Ground fault test • Sprocket inspection • Lug nut torque • Planetary oil check Every 1,000 Hours or Annually: • Hydraulic filter/fluid replacement • Pump drive gearbox oil replacement • Spray down filters replacement • Wheel planetary oil replacement *Example of services, not complete listing

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IMPROVE UPTIME BY DECREASING OPERATING COSTS Uptime is a huge buzz word in the industry. The less time you spend repairing your equipment, the more time you can spend working. In response to that, manufacturers are developing equipment that increases uptime while reducing operating costs.

There are three main operating costs of owning a MTV: 1. Wearparts & preventive maintenance costs (50%) 2. Fuel and transport costs (25%) 3. Labor costs (25%) “Beyond completing proper maintenance, contractors should choose a MTV that reduces the above three important operating cost drivers,” Palanisamy says. “This means that from the beginning of machine ownership, the maintenance requirements are reduced. Reduced maintenance not only helps in operating costs, it also helps contractors increase uptime so that additional production is gained.”

And reducing maintenance starts with the machine you purchase. Newer equipment is being developed with

Following theses and other recommended maintenance schedules for your MTV, both in the field and back in the shop during the off-season, will lead to the best results for contractors who operate these machines.

increased fuel efficiency, fewer wear parts and a smaller footprint which can reduce transportation costs.

“Traditional MTVs are huge consumers of wear parts,” Palanisamy says. “The frequency of changing the wear parts every season with less than 1,000 operating hours adds huge rebuild costs for the contractor at the end of every season.

“And even though machine manufacturers can’t change labor costs, they could influence the efficiency of the crew by increasing operating comfort and reducing the clean-up time needed at the end of the day with a newer machine.”

For more information on MTVs, visit ForConstructionPros. com/12244883

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JOBSITE INNOVATIONS BOMAG BW190ADO-5 Tandem Vibratory Roller

Roadtec SB-2500e Shuttle Buggy Material Transfer Vehicle The SB-2500e Shuttle Buggy is powered by a Tier 4 Final-compliant engine.

• Autotracking option automatically adjusts speed to keep a constant distance from the paver • Bindicator option indicates to the operating crew when the hopper is getting full or empty • Sliding platform on operator’s station contributes to greater visibility • Full-width cleanout door included on C-1 conveyor and bomb bay-style cleanout doors on C-2 conveyor • Upgraded sprockets include 38% more wear surface Search: 12055690

Volvo CR30B and CR35B Combination Rollers The CR30B and CR35B combination rollers include a high-frequency front drum and four pneumatic rear tires.

• Features 47.2- and 52-in. drum widths, 4,100 and 4,140 vpm and 7,460 and 8,050 lbs. of centrifugal force • Auto-vibration feature automatically engages vibration when machine reaches 1.5 mph and disengages when speed drops below 1.2 mph • 49.6-hp Kubota Tier 4 Final engines with optional auto-idle feature • Pressurized, 79-gal. water spraying system and separate emulsion tank • Include a side console and display, laterally sliding operator seat and sloped engine hood Search: 20995716

The BW190ADO-5 tandem vibratory roller offers traditional front-drum vibration and TanGO rear-drum tangential oscillation, increasing the machine’s flexibility.

• Mainline 78.3-in. rolling width • Front drum offers dual vibration frequencies (3,000/4,200 vpm) and dual amplitudes (0.036/0.013 in.)

• Rear drum boasts a highly wear-resistant drum wrapper surface • 114-hp Kubota liquid-cooled diesel engine Search: 12056912

Caterpillar CB54 XW Tandem Vibratory Roller The CB54 XW Tandem Vibratory Roller offers compaction performance, application versatility and operator comfort to maximize productivity while providing exceptional product quality.

• Standard compaction width: 79-in.

• Max travel speed: 8-mph • 137.0 hp Cat C4.4 engine with ACERT • Machines are capable of performing effectively on a variety of mix types, while keeping pace with the paver Search: 12176975

InstroTek 3500 Xplorer Nuclear Density Gauge InstroTek Model 3500 Xplorer is a highly advanced but very intuitive moisture density gauge with straightforward and uncomplicated operation.

• Menu options are easy to read and navigate • A backlit LCD screen and special scroll functions allow operators to easily read the Xplorer’s two-line display during day or nighttime work • The simple keypad layout and program design will permit technicians to quickly move from other moisture density gauges to the Xplorer 3500 • This unit has been thoroughly tested for ruggedness and accuracy Search: 21010109

Vögele MT 3000-2i Material Transfer Vehicle The MT 3000-2i material transfer vehicle from Vögele offers optimal performance in a new-design MTV for asphalt paving.

• Weighs 56,000 lbs. and has an 18-ton storage capacity, making it heavy enough to get the job done but portable enough to haul with minimal hassles • Low profile gives it a low center of gravity, and it can move 1,300 tph • Active remixing is achieved by two 16-in.-diameter conical augers in the receiving hopper • Auto feed function automatically slows or shuts down feeding when the hopper insert is filled • Both the primary and secondary conveyor belts are 43 in. wide, and are heated to keep material from sticking, and eliminate “warm-up” loads • Propel system with auto distance control keeps the feeder at a preset distance from the paver • Power is provided by a 215-hp Deutz water-cooled, Tier 4i-compliant engine Search: 12113037

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RD-1200XT Truck-Mounted Road Dryer The RD-1200XT pavement-drying unit from Road Dryer, LLC, quickly dries asphalt and concrete pavement, allowing crews to pave or apply surface treatments or striping after just one pass.

• The unit, which blows heated air up to 300° F directly downward through multiple nozzles, eliminates the risk of “flying objects” and allows traffic to flow in nearby lanes — reducing congestion caused by traffic restrictions • Available as a simple-to-operate trailer- or truck-mounted unit, the RD-1200XT can be adjusted for 8-ft to 12-ft drying widths Search: 21032471

VT LeeBoy 8515E Asphalt Paver The 8515E asphalt paver has a height of 68-in. for improved operator visibility to the front of the machine.

• 74-hp Kubota Tier 4 final engine • Enhance hydraulic system optimizes system performance • Paving width: 8-ft.to 15-ft.

• Legend 815 or Legend 815 heavy-duty electric screed • Poly pad tracks or continuous rubber tracks • Under auger material cut-off gates

Lincoln Paving 770 Series Windrow Elevator The 770 Series is equipped with a 60-in.-wide high-capacity slat conveyor and has a 94-in. discharge height for a full hopper load.

• Smooth running, Tier 4i, six-cylinder diesel engine • Two high-torque hydraulic motors drive an upgraded high-demand duty cycle gear reducer on both sides to provide balanced power to the conveyor drive shaft • Hydraulic telescoping paver attachment for ease of hookup • Easily operates attachments such as the pugmill, remix auger or a material modifier for rubberized hotmix asphalt Search: 20866393

Search: 12313462

DESIGN. ENGINEERING. M A N U FA C T U R I N G .

SERVICE. If you store liquid asphalt, blend asphalt emulsions or polymer modified asphalt, Heatec is your one source for everything from tank farms to asphalt terminals. Heatec will design and build a system for you that is efficient, durable and easy to use and provide world class parts and service support 24/7. Learn more at www.heatec.com.

Search: 10073245

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JOBSITE INNOVATIONS Dynapac MF2500CS Material Transfer Vehicle The MF2500CS and MF2500CS with SwingApp boast a capacity of up to 4,000 tph and are able to handle a variety of material applications, including asphalt, concrete, sand and base material.

• The conveyor belt system can empty a standard 35-ton truckload in as little as 35 seconds • SwingApp functionality can transform the unit to an offset feeder by swinging the conveyor belt up to 55° in either direction • The units are fully automated through the integration of distance control and feeding sensors • A Cummins QSB 6.7-C220 diesel engine enables operating speeds of over 80 fpm Search:20995073

SAFETY A PRIORITY? Not if you don't have a Silo Safety System

Libra Silo Safety System Blocks attempts to open a silo above the cab Independent of, and compatible with, existing automation and manual switches No operator interaction needed -it's always on guard

Carlson CP85 Commercial Paver The CP85 features a high-torque, 74-hp Cat 3.4B Tier 4 Final engine that requires no DEF, a heavy-duty chassis, highway-class wear components and leading operator controls.

• Wear components including stronger chains and slats, fully replaceable Hardox floor plates, 12-in. replaceable auger flights and fully sealed highway-class auger bearings • Dual control consoles pivot down 30° and outwards 40° and control stations can be adjusted to the comfort and visibility needs of the operator • 8- to 15-ft. EZC815 electrically heated screed includes a 2% screed taper, fulllength element hold downs for efficient heat transfer, adjustable slide track system and spring-loaded endgates Search: 20987451

Get fast, relevant product information in the Buyers Guide at ForConstructionPros.com Search: 10073668

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PRESERVATION UPDATE

How to Prepare Pavement for

SURFACE TREAT M

Proper surface preparation can extend the life of your surface treatment

S

urface treatment is a broad term used to describe a number of asphalt/aggregate systems applied to the entire surface of a pavement, usually for a sealing effect against the intrusion of water and air. Since this sealing effect keeps base materials dry and slows the oxidation (hardening) of the asphalt pavement, it can usually extend the service life of a pavement.

Because of this benefit, surface treatments are used as part of an overall pavement preservation program. In this

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role, they‘re often applied to pavements that are still in good to very good condition in accordance with Pavement Management System guidelines.

Typical surface treatments include: • Fog seals • Chip seals (hot & cold) • Scrub seals • Slurry seals • Parking area sealcoats • Cape seals • Microsurfacing • Thin-bonded wearing course • Slurry Most of these treatments involve the use of asphalt emulsions, which are waterbased forms of asphalt, requiring a cure or “break” period for the water to evaporate,

leaving the asphalt particles to perform their sealing and bonding action. Because they rely on evaporation of water, they are warm weather, low humidity operations.

Therefore, a requirement for a good job is warmer, dry weather! As an example, most chip seal operations require an air temperature of 70° F or warmer.

So the first element of preparation is to plan to do the work only when it’s warm enough. Perhaps the only exceptions to this are: • Hot-applied chip seals, which do not involve emulsions but rather use a hot asphalt rubber or polymer-asphalt binder • Microsurfacing, which contains polymers and cement and relies on more of a “chemical break”

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The first element of preparation is to plan the work when the weather cooperates. Most chip seal operations, for example, require an air temperature of 70° F or warmer.

T MENTS • Thin-bonded wearing courses, a hot mix process This article will focus on preparation work necessary for effective surface treatments. It should be noted that even though public agencies usually contract-out surface treatment work to specialty contractors, it’s not uncommon for many of the preparation tasks to be done in-house by agency crews. Of course, prep work can also be included in a contract, and in the current economy with agencies downsizing, there may be a trend in this direction.

TYPICAL PREPARATIONS Typical preparation tasks for a surface treatment include;

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• Cleaning the old pavement surface • Removal of pavement markings (raised markers, thermoplastic striping) • Masking of street iron (manhole covers, utility boxes, drain inlet grates) • Sealing of cracks • Digouts & patching (of localized problem areas)

Surface treatments, such as microsurfacing, are important workhorse strategies to extend pavement life. But like many operations, their success depends highly on the degree of preparation that’s done on the old pavement.

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PRESERVATION UPDATE

Localized pavement problems such as alligator cracking or disintegration in a wheel path of the lane, indicate a load-related, structural failure. The usual approach to repair these types of defects is to dig out the bad material and replace it with new hot mix asphalt (HMA).

• Leveling & rut-filling • Key (wedge) cuts at gutters Of course administrative preparations must also be made – things like press releases and news articles, notifying the neighborhood, posting ‘no parking’ signs, arranging for tow-away service, ensuring access for equipment and haul trucks and arranging for staging areas, if necessary.

Let’s look more closely at the jobsite preparation tasks.

CLEANING THE OLD PAVEMENT The success of any surface treatment depends on the asphalt binder sticking to the old surface. Perhaps the single

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biggest deterrent to good adhesion is dust.

Therefore, the old surface must be clean.

As a minimum, power brooms or street sweepers should be used shortly before the surface treatment. Where necessary, water flushing should also be used. Pay special attention to any areas that have been milled as these tend to be dusty surfaces.

Parking areas may exhibit oil drip spots.

Depending on severity, these may need to be burned off, dug out and patched or sealed with a special oil spot primer.

Removal of pavement markings (raised markers, thermoplastic striping): It’s usually not necessary to remove painted striping, but raised markers and thermoplastic stripes (e.g. crosswalks) and legends (e.g. arrows) should be removed – usually by grinding. In some cases, the surface treatment can be placed so as to avoid (and preserve) existing special markings. Temporary markers – usually the peel-and-stick, stand-up reflector type – should be installed to serve until the permanent lane striping is applied.

Masking of street iron: Street iron

such as manhole covers and valve box covers should be protected by masking them with paper or special plastic sheeting. Small peel-and-stick markers should be attached to the metal to reference the location of the iron to facilitate removal of the masking material after the surface treatment is applied. Reference staking or GPS logging may also be used for this.

Sealing of cracks: Existing cracks wider than 1/4-in. should be sealed with specialty crack sealer material. Both hot and cold applied products can be used.

The sealant supplier should be consulted as to the proper product for your location and climate. Different products may be necessary depending on the time of year you’re doing the crack sealing.

In climates that experience extreme fluctuations in temperature (e.g. mountains, desert), pre-routing of transverse cracks should be considered.

When sealing cracks, care should be taken to: • Try to place the sealant only into the crack

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PRESERVATION UPDATE • Not leave excessive smearing of sealant on the surface of the pavement • Not leave sealant high so as to form a ridge or bump that motorists would feel. A squeegee tool should be used only where needed to knock down high spots Crack sealing may be done days or weeks ahead of the surface treatment.

Cold-applied sealants should be fully cured prior to covering them with any surface treatment.

If sand is used to prevent tracking of sealant, a thorough sweeping must be done prior to placing surface treatment.

Digouts & Patching: Although surface treatments are intended for roads still in good condition, there may be some localized pavement problems.

These usually take the form of alligator cracking or disintegration in a wheelpath of the lane, indicating a load-related, structural failure. These areas should be repaired before placing a surface treatment. The usual approach is to dig out the bad material and replace it with

new hot mix asphalt (HMA). Cold mix or proprietary pothole patch materials should not be used for patching prior to a surface treatment. They contain volatile elements that would be sealed in by the surface treatment, keeping them from hardening and an unstable, soft spot could result.

Digout & patching operations are also sometimes referred to as mill & fill, plugging or R&R. Guidelines for proper digout & patch work include:

• Layout a perimeter cutline at least 1-ft. beyond any visible cracking • Use straight lines and square corners to create the cut lines • Try to keep longitudinal cutlines out of the wheelpath • For patches thicker than 4 in., make the cut wide enough for a small roller to fit into the trench for compacting the base material and lower lifts • Excavate deep enough to permit the new HMA patch to be at least 50% When sealing cracks, try to place the sealant only into the crack, try not to leave excessive smearing of sealant on the surface of the pavement and don't leave the sealant high so as to form a ridge or bump. Use a squeegee tool if necessary to smooth out high spots.

Cracks wider than 1/4-in. should be sealed with either hot- or cold-applied specialty crack sealer material.

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PRESERVATION UPDATE thicker than the old pavement that failed. This will mean removing some of the aggregate base layer • After excavating, always level and compact the remaining base material • Use an HMA mix type appropriate for the traffic loading • If the HMA in the new patch will be more than 4- in. thick, place it in two lifts, if practical.

• Each lift thickness should be at least three times the size of the large aggregate in the HMA. • Make at least four passes of the roller on each lift while the mix is above 175° F. • Place enough loose HMA so that after four roller passes the surface will be flush with the old pavement

The surface of a new HMA patch will be more open (porous) compared to the surrounding old pavement that has been under traffic for years, so an important final step is to apply a tack coat of asphalt emulsion to the surface of the new patch. This will help seal the surface so it won’t absorb the binder in the future surface treatment.

Leveling: Some surface treatments (e.g. chip seals, slurry seals) should not be placed on surfaces with rutting in the wheelpaths. In the case of chip seals, the watery emulsion that’s spray-applied will simply pond in any ruts and result in the chips being fully imbedded or “drowned’ in asphalt, resulting in an asphalt-rich, slick wheelpath. In the case of slurry seals, excess slurry mixture

larger aggregate. This is followed by rolling.

In more severe ruts, say deeper than 1/2 in., rolling should be done with a rubber-tired (pneumatic) roller. Care should be taken to minimize any edge ridges as they will reflect through and be visible after the surface treatment.

As with digouts & patching, a leveling patch should also be fog sealed with asphalt emulsion and allowed to cure prior to placing any surface treatment.

A rutted pavement may also be leveled by filling the ruts with microsurfacing or by grinding it down with either a diamond grinder or a milling machine. These operations often involve subcontractors with special equipment and may not be cost effective.

Remember also that after any milling or grinding it’s important to thoroughly clean the surface to remove the dust created by the operation.

SUMMARY Surface treatments are important workhorse strategies used by pavement managers nationwide. Like many operations their success depends highly on the degree of preparation that’s done on the old pavement. When applied to pavements still in good condition, with an effort on pre-cleaning and the proper repair of major defects in the old pavement, these pavement preservation procedures will fulfill their mission of extending the life of a pavement, and protecting this important investment.

The success of any surface treatment, including sealcoating, depends on the asphalt binder or sealer sticking to the old surface. Perhaps the single biggest deterrent to good adhesion is dust, so at a minimum power brooms or street sweepers should be used shortly before the surface treatment.

• Don’t use vibratory rolling when the roller drum is touching old (cold) pavement • Check the final patch with a straight edge

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will be deposited in the rutted area and will later be unstable under traffic – especially in hot weather. It’s important that the pavement be checked with a straight edge and excessive rutting be corrected via leveling work.

So how is leveling accomplished?

The most common approach is to simply blade lay an HMA leveling course – usually with aggregate no larger than 1/2 in. – and feathering the edges by careful hand raking to remove

Roger D. Smith is a pavement consultant/trainer in California and editor of the California Pavement Preservation Center Newsletter, visit www.csuchico. edu/cp2c/ to learn more.

To learn more about matching the preservation treatment to the surface distress type, visit ForConstructionPros. com/21014840

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PRESERVATION UPDATE Cimline DuraPatcher DuraTruck

Asphalt Transports

The DuraPatcher Truck mount is the solution for ready to work patching. The spray patcher removes the pothole in one quick and cost effective 4 step process.

1. Clean the area with compressed air 2. Apply an emulsion tack coat 3. Fill the hole with coated aggregate 4. Cover with dry aggregate so traffic can resume immediately • Vent-Flo nozzle • Ergonomic no-stress Boom • 6 yd. aggregate hopper Search: 12270445

Live Bottom Trailers Star Inc. Road-Guard Rubberized Asphalt Emulsion for Road Surfaces

Heavy Duty Trailers

ChipSpreaders

Etnyre FWD and QUAD Chip Spreaders Etnyre's FWD and QUAD Chip Spreaders are designed to spread aggregate in the chip seal process.

• Computer-controlled application rates • Front-wheel or four-wheel drive • Fixed spread hoppers from 10 to 15 feet • 148- to 230-hp engines Search: 10078188

Road-Guard Rubberized Asphalt Emulsion for Road Surfaces finishes with a uniform rugged surface and improves driving conditions on an existing road surface.

• Tough, rubberized AE based pavement soating • Excellent cost savings compared to conventional road surface treatments • Formulated with select asphalt grades

and hot blended with rubber • Useful for housing subdivisions, commercial parking lots, city and county roads, ring roads and approaches Search: 12278274

Wirtgen W 35 Ri Milling Machine

Asphalt Distributors

E. D. Etnyre & Co.

www.etnyre.com 800-995-2116 email: sales@etnyre.com

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The 10,141-lb. W 35 Ri compact milling machine is designed for tight or restricted areas for the partial rehabilitation of pavement, milling around manhole covers, placing and removing road markings, or interior applications.

• It has a 14-in. cutting width, expandable to 20 in., with a maximum 4-in. cutting depth as well as an 82-fpm top operating speed • Three variably selectable milling drum speeds suit a wide range of applications.

• The standardized operating concept permits operators to save up to three milling depths using the standard ergonomic multifunctional armrests • The WIDRIVE machine management system centrally manages engine control, travel drive, milling drum drive, water system and Level Pro Plus • The unit is powered by a 60-hp four-cylinder Deutz TCD 2.9 L4 Tier 4 Final engine Search: 12228882

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PRESERVATION UPDATE Crafco Patcher The diesel Crafco Patcher is a double boiler that is digitally controlled to assure that material temperatures are held within specification ranges at all times.

• A swivel material delivery chute makes placing material fast and easy • To clean out, load the machine with dry aggregate - run agitator and empty - it's that easy.

• All machines are equipped with a safety shutoff on the lid to prevent injury during operation • Available in a one ton (Patcher I) and two ton (Patcher II) configuration • These machine are specifically designed to heat and apply TechCrete and PolyPatch patching material Search: 11487582

Roadtec SX-8e/ex Soil StabilizerReclaimer The 82,000-lb. SX-8e/ex is capable of cutting up to 20 in. deep and 100 in. wide and is designed for road rehabilitation, cold recycling, or soil stabilization.

• Rotor designed for milling and mixing the most resistant soils completely and homogeneously • Variable geometry cutter housing enables the unit to achieve material gradation with each pass • 755-hp Caterpillar C18 Tier 4i (SX-8e) or 700-hp Caterpillar C18 Tier 3 (SX-8ex) engine • Air-shift four-speed transmission • Includes joystick controls and four different steering modes Search: 20973546

KM 8000T Hotbox with KM 2-18X Infrared Recycler KM 8000T Hotbox with KM 2-18X Infrared features a 4-ton trailermounted hotbox reclaimer and a 3.5-in. by 6.5-in. infrared recycler.

• Triple wall construction with high efficiency insulation for heat retention • Thermostatically controlled heating system for better fuel efficiency • Maintain HMA for up to 48 hours or reclaim bulk stored virgin HMA • Burner and key components mounted above frame and in steel enclosure • Front to back loading doors with cantilevered handles • Diesel or propane fired (two 30-lb. propane cylinders included with propane units) Search: 20978622

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Search: 10074819

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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Search: 10074806

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PRESERVATION UPDATE GSB-88 Gilsonite-Based Emulsified Asphalt Seal Coat

Rosco RA-400 Spray Patcher

Gilsonite-based, environmentallyfriendly and versatile emulsion enhances, seals and extends the life of asphalt at a low cost per square yard on pavements ranging from high-speed state highways to parking lots, city streets, county roads and more.

• GSB-88 undergoes rigorous independent third-party environmental testing • After an intensive 2011 Life Cycle Assessment by the Institute for Environmental Research & Education (IERE), GSB-88 earned an Environmental Product Declaration (EPD) attesting to the significant environmental benefits of its use in preserving pavement • GSB-88 has also been honored with a GreenCircle/LEED Certification, recognizing that one application every five years can significantly extend the life of asphalt and help reduce global warming, acidification and eutrophication by nearly 50% when compared to reconstruction

One RA-400 Spray Patcher is capable of repairing more than 200 potholes in a single day.

• Requires a single operator to make pothole repairs, and the employee never has to leave the safety of the truck cab • Powered by a Kubota Tier 4 Final 65-hp diesel auxiliary engine • The RA-400’s telescoping delivery boom extends and retracts to perform a four-step spray injection process that the operator controls with a joystick • First, a hydraulically driven, high-volume blower cleans the pothole • Second, a tack coat of emulsion is applied to the area • Third, a mixture of aggregate and hot emulsion fills the pothole • Fourth, a finish coat of dry aggregate is applied • The whole process takes about a minute, so arterial road or residential street closures aren’t necessary.

The patch is immediately ready for traffic flow

Search: 20864153

Search: 20861979

NEW ON THE MARKET - 275 tph portable parallel flow drum plant w/Self Erect Silo. Combination of New/Used Components $1,350,000.

Call if interested CMC Remote Infrared Thermometer Package.

Self-Contained.

Caterpillar PM820, PM822 and PM825 Cold Planers The PM820, PM822 and PM825 have operating weights from 79,630 to 82,650 lb. and cutting widths from 79 to 98.6 in.

• Three electronically controlled cutting settings to match rotor speed/torque with operating conditions • 755-hp Cat C18 ACERT Tier 4 Final engines isomounted to reduce vibration • Hydrostatic drive with two variable-displacement propel pumps supplying a variable-displacement motor at each track • Automatic traction control system minimizes track slip in extreme conditions • Standard four-mode steering with electronic control module • Hydraulically controlled front loading conveyor Search: 20980992

Search: 10072464

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CLASSIFIEDS

Reliable Asphalt Products provides EVERYTHING for an asphalt plant!

THE RELIABLE WORLD OF ASPHALT PLANT PRODUCTS

www.ReliableAsphalt.com

DID YOU KNOW?

Reliable Asphalt Products keeps completely rebuilt Hot Oil Heaters in stock for any emergency!

THE RELIABLE WORLD OF ASPHALT PLANT PRODUCTS

www.ReliableAsphalt.com

DID YOU KNOW?

Reliable Asphalt Products provides parts and components for every type of asphalt production plant!

“I call Jim. He’s super knowledgeable, gets stuff to me quick and is most times cheaper.”

- Manor Jones, MO

“We needed it, we got it FAST, and it works GREAT!”

- John Odum, Texas

Great value with expert customer service!

New, Used and Refurbished Asphalt Plant Equipment 521 Old 7 Mile Pike • Shelbyville, KY 40065 • Office Toll Free (866) 647.1782

Call Jim Watson.

Over 30 years experience!

Great value with expert customer service!

New, Used and Refurbished Asphalt Plant Equipment 521 Old 7 Mile Pike • Shelbyville, KY 40065 • Office Toll Free (866) 647.1782

INC. 521 Old 7 Mile Pike • Shelbyville, KY 40065 Toll Free (866) 647.1782 • Fax (502) 647-1786

www.ForConstructionPros.com/Asphalt

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CLASSIFIEDS ASPHALT PLANT TRAINING! Online: Anytime, Anywhere Classroom: Des Moines, Iowa Feb 19-20, 21 2019 Plant Operation • Plant Quality Assurance Plant Safety • Electro-Mechanical Systems and Troubleshooting

CALL NOW TO REGISTER! Phone: 952 939 6000 or carrie@clarencerichard.com www.clarencerichard.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

DRUM PROBLEMS? BREAKING THRUST IDLERS AND BEARINGS TRUNNION BEARING FAILURE ■ TIRE WEAR AND FLAKING

HIGH AND UNEVEN AMPERAGE TRUNNION SLIDING ■ VIBRATION AND WASHBOARD

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■

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WE CAN HELP! TIRE / TRUNNION RESURFACING AND ALIGNMENT SPECIALISTS

570-779-1982 www.evansanddaniels.com 62

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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CLASSIFIEDS

E

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

World of Asphalt in Indianapolis, IN Feb 12-14, 2019 Booth 21138





   

      

   







  

                                

AV

                       

       

       

www.ForConstructionPros.com/Asphalt

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MORE CHOICES MORE FLEXIBILITY

CLASSIFIEDS

Rolling Stock Parts

Plant Parts

Shaker Decks

RAPwranglers

 PAVER WEAR PARTS  LIVE BOTTOM TRAILER PARTS

 MATERIAL TRANSFER DEVICE PARTS  PLANT EQUIPMENT & PARTS  WINDROW ELEVATOR CHAINS  PICK UP MACHINE PARTS  SHUTTLEBUGGY ® MTV PARTS

www.asphaltace.com

1-888-878-0898

sales@asphaltace.com

ASPHALT PLANTS · Gencor 400 tph stationary counterflow plant · Astec 350 tph Relo Double Barrel plant w/4 silos · Astec 150 TPH Portable Drum Mix Plant with SEB & Baghouse · ADM 100 tph stationary drum plant with 2 silos & recycle · 100 tph portable drum mix plant with baghouse · ADM 110 tph portable drum plant · Etnyre 150 TPH Drum Mix Plant · H&B 10,000# tower and dryer · Astec 5000# Asphalt Batch Plant · H&B 4000# asphalt batch plant · Astec 89’X32” slat conveyor · Astec 58,000 CFM portable · Stansteel 44,000 CFM Baghouse · CMI 51,000 CFM baghouse · Almix 30,000 CFM baghouse

· Astec 500 tph Double Barrel only · Two bin rap system · Stansteel 8’X36’ aggregate dryer with burner · 7’X30’ portable drum mixer · Astec 750 barrel self-erect lime silo · Astec portable five bin cold feed with conveyor & screen · 2-200 Ton Asphalt silos and slat conveyor · Burke 2 mil btu hot oil heater

Please Call For Complete Inventory

Plant for sale? Call Clancy!

Serving the Asphalt Industry for 50 years

E.T. CLANCY COMPANY 219-879-8231 • 800-348-8553 Email: sales@etclancy.com • www.etclancy.com

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CLASSIFIEDS

LET'S BUILD

YOUR IDEAL

STRUCTURE

for nearly 40 years clearspan

has been helping companies maximize profits with superior building solutions

Energy Efficient

To find out how we can help with your structure needs visit or call www.clearspan.com 1.866.643.1010

Superior Warranties

Expert Project Managers

No Money Down Financing, Terms Up To 7 Yrs and As Low As 5.99% on buildings

INDEX Advertiser Index

PAGE

Advertiser Index

PAGE

Ace Group

64

Meeker

55

Almix

9

National Pavement Expo

26

Asphalt Drum Mixers

14 – 15

Pegasus

21

Astec Inc.

19, 23, 27, 31, 34 – 35

Process Heating Company

30

Carlson Paving Products Inc.

67

R & D Trench Paver

63

ClearSpan Fabric Structures

65

RC Musson Rubber Company

62

C. M. Consulting

60

Reliable Asphalt Products Inc.

61

Dynapac Fayat Group

5

Roadtec an Astec Industries Co.

68

Eager Beaver Trailers

51

SealMaster

47

E. D. Etnyre & Co.

56

Stansteel

13

E. T. Clancy Company

64

Superior Tire & Rubber Corporation

53

Evans & Daniels Inc.

62

Systems Equipment Corporation

59

EZ Road Inc.

63

Tarmac International Inc.

58

Fast Measure By KTP Enterprises

63

Transtech Systems Inc.

57

GEICO

25

Troxler

41

Gencor Industries Inc.

3

Weiler

7

Heatec

45

WEM Automation

39

KPI-JCI Astec Companies

11

Willow Designs

64

LeeBoy

33

Wirtgen America Inc.

2, 42 - 43

Libra Systems

46

www.ForConstructionPros.com/Asphalt

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THE LAST EXIT |

BY JESSICA LOMBARDO, EDITOR

Roller Maintenance Makes a Lasting Impact Scraper bars hold the water in between the scraper and drum to keep the drum lubricated.

Check them regularly for proper adjustment and any excess wear, and replace them as needed.

Maintain vibratory rollers to ensure peak performance on your paving projects

A

sphalt rollers are highly reliable machines, but when one goes down unexpectedly in the middle of paving, it can have costly repercussions for the entire operation. It can affect mat quality, result in lost time and potential risk of fines due to project delays, plus there is the extra expensive associated with any unscheduled service and repair.

Keeping rollers in peak condition throughout the season can help you reduce such risks and maximize the potential to meet both project specs and deadlines. As with any machine, the better it is maintained, the better it can perform its intended task throughout its lifetime in your fleet.

INSPECT AND MAINTAIN Regular service checks are essential to keeping rollers working properly, and a number of them can be completed as part of the daily walkaround inspection.

Review the service manual for specific guidelines, but at minimum: • Check engine oil and hydraulic oil levels and fill as needed.

• Check coolant levels and ensure the cooling system is clean and clear of debris; replace the air filter if needed.

• Inspect engine, hydraulic system and fuel filters and replace as needed.

• Visually inspect external hardware for loose connections or leaks.

• Check controls, brakes, backup alarms, warning beacons, headlights, etc. for proper operation.

• Make sure the drum is clean and there are no dings or scrapes in the drum surface(s) that could mar the mat.

66

• Ensure tires on single-drum rollers are in good condition and are inflated to the recommended pressure.

• Periodically inspect the shock mounts, which isolate the vibration of the drum from the operator; replace as needed.

Maintenance of engine and hydraulic system components is particularly critical. The engine must be able to operate at the specified rpms in order for the vibratory system to achieve the proper compaction output. Follow manufacturer recommendations for scheduled engine and hydraulic system service intervals to ensure optimum performance.

KEEP WATER FLOWING The water system serves as a lubricant to prevent asphalt from sticking to the drum and damaging the mat. As such, it’s important to make sure all aspects of the water system are properly maintained and in working order.

One of the most common problems encountered is clogged spray nozzles, which can lead to pump failure over time. To minimize the risk of debris entering nozzles from the water tank, fill the tank with clean water from a known source whenever possible. If you will be working in an area where water quality is uncertain, make sure the operator checks the water filtration system frequently.

To maintain proper water flow: • Check the filters according to manufacturer recommendations; adjust the frequency of inspection as needed based on water quality.

• Periodically remove and inspect the sprinkler bar nozzles to ensure they’re not clogged or damaged.

• Make sure spray nozzles are properly adjusted so they distribute water evenly across the drum.

• Check the water tank regularly for contaminants.

Scraper bars also play in role in water system performance. Not only do scraper bars keep the drums free of material buildup, they hold the water in between the scraper and drum to keep the drum lubricated; the scraper system needs to be in contact with the drums at all times to spread the water consistently.

If scraper bars are not properly adjusted, or have excessive wear, water may not reach fully to the edges of the drum, causing asphalt to stick and mar the mat.

PROPER OPERATION Operating procedures greatly affect the life cycle of any machine, and rollers are no exception. Jumping curbs, shifting quickly from forward to reverse, rolling over sharp rock or uneven materials, etc., can accelerate wear and/or damage the drums and other components. Make sure operators are trained in what they should, and should not, do during roller use.

Over compaction can have negative repercussions on roller longevity, as well.

As material is compacted, it absorbs less of the energy generated by the drum.

That energy can be transferred back into the machine, potentially damaging the isolators within the drum, or causing premature bearing wear or damage.

To minimize and/or eliminate over compaction, establish a rolling pattern for each job and verify it through testing.

Compaction meters or monitors can further reduce both over and under compaction risk.

Resources: BOMAG, Case Construction Equipment, Caterpillar, Hamm Compaction, Wacker Neuson

For more information on roller maintenance, visit ForConstructionPros. com/20971104

ASPHALT CONTRACTOR JANUARY 2019 www.ForConstructionPros.com/Asphalt

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Search: 10072346

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SM

WE ARE DEDICATED TO YOUR SUCCESS IN EVERYTHING WE DO. IT’S WHO WE ARE. We know that getting the job done safely, correctly, and profitably is a priority. That is why we offer unrivaled service, technology, and knowledge to drive your success. It is why Roadtec provides you with a level of expertise and training not found anywhere else because that is what you need.

Dedicated to Success.

© 2018 ROADTEC, INC. ALL RIGHTS RESERVED Search: 10074458

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