14 Automated Grade Control’s Steady Plow Toward Full Autonomy
The same construction equipment manufacturers who brought you automated grade control precision and efficiency anticipate full autonomy as the next leap forward.
FACE OF THE INDUSTRY
24 Making Strong Connections
Cynthia “Cindy” Powell reflects on her career in the industry, how it’s changed, and the room it still has to grow.
JOBSITE INNOVATIONS
30 Taking Your Asphalt Mill To The Next Level
The addition of a large milling machine to your pavement maintenance business can open a lot of new doors for you, but there’s a whole other level of value and power to these machine waiting to be unlocked.
34 Road Engineering Is Climate Engineering
Given the majority of U.S. roads are built using asphalt, in the current climate paradigm is that still the best choice for road construction and replacement?
Published and copyrighted 2025 by IRONMARKETS. 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 by IRONMARKETS, 201 N. Main St. Ste 350, Fort Atkinson, Wisconsin 53538. Periodicals postage paid at Fort Atkinson, Wisconsin and additional entry offices.
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With over a century of innovation to its credit, Blaw-Knox® pavers have earned a reputation for quality, durability, and performance unmatched in the industry. Our continued focus on innovation is what drives our product engineering with designs that improve performance while maintaining user-friendly, ergonomic comfort and reliability for the operator.
BLAW-KNOX, THE LEGACY LIVES ON. For more information contact your Blaw-Knox dealer or visit www.blawknox.com
Propane Means Efficiency for Asphalt Business Owners
This clean-energy could be the game-changer you need to get ahead of the competition.
Watch the video at: https://asph.link/np4atf8b
Best Contractors to Work For in Construction for 2024 Announced
The program honors the top construction companies that provide a positive workplace environment, competitive compensation, training and opportunities for advancement.
Read more at: https://asph. link/0qeuj47e
The Corporate Transparency Act and Beneficial Ownership Reporting
The CTA created a new requirement for all businesses to disclose certain ownership information. You need to be sure you understand the requirements.
Read more at: https://asph. link/qj7psx4p
Cat Announces Latest Global Operator Challenge
Heavy equipment operators from more than 40 countries compete to claim worldwide title in largest challenge to date.
Read more at: https://asph.link/ p2xd9sul
Li-ion Battery Shipments to Exceed 3.5 TWh in 2029
Li-ion battery shipments will have strong growth in the future, registering a 21.4% compound annual growth rate (CAGR) by 2029.
Read more at: https://asph.link/ oll0rd6f
NEW IntelliPac ™ Moisture System
Astec paves the way for sustainable, innovative asphalt plants. The new IntelliPac Moisture System is a revolutionary solution that integrates seamlessly with Astec control systems. This provides unparalleled, real-time visibility into virgin aggregate moisture content. IntelliPac empowers operators to optimize mix design, minimize energy consumption, and reduce environmental impact. With Astec, you get superior asphalt production – better for the environment, better for your business.
BUILT TO CONNECT
Brandon Noel, Editor
bNoel@iron.markets
234-600-8983
The Possible Impacts Of Policy On Labor
The construction industry has a labor shortfall of about a half-million workers. How will deportation further impact the industry?
According to the Bureau of Labor Statistics’ most recent Census Bureau data, the construction workforce in the United States hovers around 7.8 million people. Everyone working in or adjacent to construction has seen the same hiring horror stories for more than a few years now. The labor shortage has been a key talking point not just for politicians but for economists and for people working the asphalt industry, too.
The shortage in labor has been used to explain everything from higher prices, rising wages, inflation, shorter service hours for businesses, and longer wait times for projects. Some experts have expressed concern about is a promise from the incoming president.
In the days after his election win, incoming President Donald Trump declared his intent to use the military to carry out the largest deportation plan in American history. This would have a profound impact on the construction, and the asphalt industry by extension, without a doubt. In theory, you can see what the intention is, but the question is whether or not employers are ready to accept the collateral.
The positive result here is that by removing those working without proper documentation, you reduce the likelihood of workers being the victims of labor exploitation. Undocumented immigrant workers cannot seek out the same protections that documented migrant workers and U.S. citizens can.
They are almost always being underpaid, overworked, and left to fend for themselves if
they get injured on the job. When they work on a crew, they do so at their own risk, with no leverage to protect themselves at all.
The negative side effect is that employers will almost certainly face an exacerbated labor shortage, worse than we’ve already experienced.
According to a 2022 survey conducted by the independent nonprofit group American Immigration Council, 1.5 million members of the construction workforce are undocumented laborers. If the new administration makes good on its plans, mass deportation could potentially push the labor shortfall for this sector in excess of 2 million workers. Construction would be one of the hardest hit industries, but it wouldn’t be the only impacted U.S. industry by far.
For citizens and those with documented status, it could mean even better compensation, as the competition for skilled workers could potentially double or triple. It’s hard to really nail down exact impacts, because there are some documented immigrants who may inevitably, though mistakenly, be deported.
It could also mean that the conditions for the legal U.S. workers could become strained if they face more understaffed jobsites. The completion times for projects may get longer as the number of available crews is reduced. Longer lead times combined with slower production could result in smaller profits for contractors.
Ultimately, it’s not an simple problem with an easy solution, but what we do know is that any possible decision doesn’t take place in a vacuum. Whatever happens will have ripple effects on every business owner in our industry. See you on the road!
Chief Executive Officer.................................................. Ron Spink
Chief Revenue Officer Amy Schwandt VP, Finance Greta Teter VP, Operations & IT .................................................... Nick Raether VP, Demand Generation & Education Jim Bagan Corporate Director of Sales Jason DeSarle
Brand Director, Construction, OEM & IRONPROS Sean Dunphy
Published and copyrighted 2025 by IRONMARKETS. 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.
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NEW PRODUCTS
LeeBoy 8680 Paver
Features:
• 210 hp (157 kW) Kubota Tier 4 Final diesel engine
• Legend HD PRO screed
• Paving widths variable up to 15 ft., 6 in. with PRO screed
• 12-½ ton capacity material hopper
• Dual electronic steering and adjustable operator platforms
• Two 18-in. feeding conveyors
• Hydraulic extending power tunnels
• Automatic temperature control (ATC) standard
• Smooth rubber tracks with oscillating bogeys
Bobcat New Machine IQ Telematics Features
Available on select compact track loaders and skid-steer loaders, the technology can now be used for select Bobcat compact excavator, compact wheel loader and Toolcat utility work machines. The new Remote Engine Disable/Enable feature allows users to remotely enable or disable their machine’s engine through the Owner Portal or Machine IQ app. Machine IQ, launched in 2019 in North America, allows connected-machine owners to monitor the health of Bobcat machines and remotely track information related to maintenance, security and performance. Remote Engine Disable/ Enable represents the first two-way update to the telematics system.
Generac offers the SLT-D CUBE Stationary Hypercube Light Tower for jobsite illumination in remote areas, construction sites, public locations and more. This portable light tower is powered by a Kubota Z482 twocyl. diesel engine and equipped with four 320W LED lights. The solidstate LED lights generate up to 184,000 lumens of output during use (46,000 lumens per LED light), resulting in wide-area illumination. An included dusk-to-dawn sensor and timer controller automates light operation. The lights are elevated by a galvanized mast with six sections. Operators can manually rotate the mast up to 340 degrees when fully extended. An optional diffuser kit is available for expanding light distribution. A center lifting point and forklift pockets enable transportation around work areas.
Wolverine and Metallica Scholars are back for year two with an all-new collaboration. This year’s special edition collection features boots, a hoody, a t-shirt, and a beanie, inspired by the legendary rock band. 50% of sales from each item will support the Metallica Scholars Initiative Performance Features:
• Also Available in Soft Toe
• Gold rated premium waterproof full-grain leather upper with Metallica Scholars guitar detail and metallic accents
Blue Diamond Attachments Land Grader
Blue Diamond Attachments has announced the launch of an all-new land grader to its full line of skid steer attachments. The new Blue Diamond land grader offers front and rear cutting edges – allowing users to push or pull material for precise placement. Both bolt-on cutting edges are ½ in. thick with adjustable side edges and the blade attachment articulates up to 8 in. independently of the machine on either side.
Key features of the new Blue Diamond land grader include:
• Rear-Positioned Wheels:
Compact design allows the operator to get into corners, up against structures, and around pillars with ease while also improving travel and stability on graded surfaces.
• Front and Rear Cutting Edges: Bolt-on, front and rear cutting edges
Topnet Live
Topcon Positioning Systems has announced a major addition to its reference station service, Topnet Live. New service areas are available through expansion within California, Hawaii, Oregon, Nevada, Utah, and Washington, with 180 full-wave geodetic reference stations added to the network. Simplifying the workflows for many different devices in many different industries, network corrections offer centimeter accuracy for high-end engineering, surveying, construction and agriculture measurement and guidance systems.
NEW PRODUCTS
Tenna Enhanced Reporting Engine
TENNA announced the enhancement of its reporting engine. This enhancement is designed to better solves contractors’ common obstacle of identifying actionable information when observing large quantities of equipment management data and helps to easily spot trends across the fleet. Tenna’s enhanced reporting engine includes new data visualizations as well as configurable construction report building capabilities. These visualizations provide a faster way for construction businesses to identify historical and forecasted trends across projects and sites and pinpoint and address issues across equipment fleet operations. Users can filter, sort and configure construction reports to drill into the precise data their business needs, manipulate visualizations in a variety of ways to suit their analysis, and scale reports with operations.
Tenna’s construction reports can also be distributed to additional users as well as saved, rerun and disseminated on a preset schedule.
Masaba SelfContained Conveyor Line
Masaba, based in Vermillion, S.D., introduces its new line of SelfContained Hydraulic Radial Stacking Conveyors. Fully designed and built by Masaba, these road- and pit-portable stackers operate under their own power via a 72 hp Yanmar onboard diesel hydraulic power unit for remote operations and job sites. Masaba self-contained stackers are available in a standard belt width of 36-in. and in standard lengths of 80-ft. and 100ft. The company will offer additional lengths in the future, and will work with customers who desire custom widths and lengths.
Hyundai HD130 Tracked Dozer
The HD130 dozer is a 15-ton-class machine equipped with a 4-cyl. Tier 4 Perkins 1204J engine. The HD130 can be ordered as either an LGP (low ground pressure) model or in an XL configuration. The LGP model has an operational weight of 33,730 lbs. (15,300 kg) and ground pressure of 4.98 psi (34.3 kPa), while the XL configuration weighs 31,907 lbs. (14,500 kg) with a ground pressure of 6.16 psi (42.2 kPa). Both feature a track length of 8 ft., 11 in. (2,720 mm). The HD130 comes standard with a 2D grading system that simplifies precision grading for novice operators. The system controls the blade functions, for more accurate grading.
Cat Command for Loading for Cat Medium Wheel Loaders
EarthCam Mobile StreamCam IoT with Air Health
The Mobile StreamCam IoT with Air Health is an all-in-one service combining advanced air quality monitoring with high-resolution live video streaming. The health and safety of employees on the jobsite and future building occupants is a key concern for the construction industry, and indoor air quality plays a pivotal role. EarthCam’s Air Health analysis delivers 10 real-time metrics to report on environmental conditions and pollutants in interior construction, providing early warning if air quality falls below safe thresholds. Air Health combines high quality images with a RESET Air Index certified sensor to report on particulates and gases.
Blue Diamond Brush Cutter Line
Blue Diamond skid steer, compact track loader, mini skid steer, excavator and mini excavator Brush Cutters are designed to handle site prep and clearing. The company has grown its offering – now providing Heavy, Extreme and Severe Duty models. Blue Diamond provides 13 different models of brush cutters for use with mini skid, skid and track loaders:
• 36, 42 and 50 in. mini skid steer closed and open front
• 60 and 72 in. heavy duty models
Cat Command for Loading now supports Cat 950, 962, 966, 966 XE, 972, 972 XE, 980, 980 XE, 982, and 982 XE next-generation wheel loaders. Command maintains high machine productivity in operating environments like demolition, environmental remediation, stevedoring and the handling of fertilizer, chips, and sawdust. Available in both lineof-sight and non-line-of-sight configurations. Cat Command for Loading is expanding to all medium wheel loaders, excluding the GC models. Removing the operator from the machine, Command for Loading offers semiautonomous remote control of next generation Cat 950 – 982 wheel loaders designed to increase operating safety in hazardous environments.
• 60 and 72 in. extreme duty models
• 72 in. severe duty model
• 44 in. swing arm cutter
• 84 in. dual motor brush cutter
Seven mini excavator and excavator brush cutter models are available.
Our UL asphalt tanks have properly sized normal and emergency venting as standard.
All structural attachments are OSHA approved and are af xed to our tanks per code.
All tanks are tested to UL142 Section 42.2.1a 10th Edition.
All weld joints are per UL142 standards.
Your asphalt tanks will be properly labeled and registered with UL142.
Automated Grade Control’s Steady Plow Toward Full
IAUTONOMY
The same construction equipment manufacturers who brought you automated grade control precision and efficiency anticipate full autonomy as the next leap forward
t’s a bit of a stretch to realize zero human interaction in the operation of heavy construction equipment. However, make no mistake. The move is on to make it happen.
Caterpillar started its research on autonomous trucks in the 1990s, leading to the production of its first autonomous vehicles for mining operations in 1994. These vehicles operate without a driver in the cab, hauling stone from quarries safely, productively and efficiently. But Caterpillar is not the only manufacturer in the space. CASE Construction Equipment (CE) also sells autonomous trucks and tractors, allowing contractors and farmers to operate multiple vehicles for high efficiency output on large-scale jobs. Other manufacturers are in the space, but none yet have introduced a fully autonomous grade control solution.
“Part of the problem involves the environmental context,” said Scott Hagemann, senior market professional for Caterpillar. “Autonomous trucks work in a mine, where the location is isolated; there’s no traffic or people in harm’s way during the operation. But with grade control, you’re usually operating in a densely populated area, where there are too many factors to trust safe operations to pure robotics.”
So, for now, automated grade control is the best way to improve precision, safety and efficiency on a construction site. That is...for now.
ON THE ROAD TO FULL AUTONOMY
The Society of Automotive Engineers identified six stages of automation, starting at Stage zero and progressing to
Stage 5, the yet-to-be-realized holy grail of vehicular automation. These stages progress as follows:
• Stage 2 – Dual automated driver assist (for example, cruise plus braking control)
• Stage 3 – Human monitoring and interdiction of autonomous operation
• Stage 4 – Full autonomy within set boundaries (for example, driverless taxis inside geofenced areas)
• Stage 5 – Fully self-driving vehicles without drivers or boundaries
Where haul trucks might operate at a Stage 4 level of autonomy in a mining environment, Stage 3 bulldozers and excavators are equipped to support automated grade control on construction
“Technically, you could perform the operation from your living room, oceans away,” said Cameron Clark, earthmoving industry director for Trimble. “The idea would be to ensure safety in a diverse work environment, such as along a steep dam or embankment or provide convenience where travel or labor shortages might inhibit job progress.”
ADVANCEMENTS IN GRADE CONTROL
Over the years, automated grade control has progressed from 2D to 3D, following a technology continuum from basic valve controllers and lasers to onboard sensors and software programs capable of directing a machine’s position. Harnesses and brackets on many machines make adding basic controls for screeds, buckets or blades easy. And when it’s all connected on the equipment, WiFi and cellular connections to the cloud enable global positioning systems and global navigation satellite systems to triangulate movements coordinated with a digital site plan for complex grading at virtually any depth or angle.
“The last mile in the journey to fully autonomous will come when we can consistently and accurately read and react to dynamic elements in the immediate environment around a fully equipped machine in motion,” Hagemann said. “When we can fully know the position of everything on the machine, not just the blade but every corner, elevation, from the top of the machine to the bottom of the tread, we’ll at last be into Stage 5 autonomy.”
intelligence gets added to grade control systems, we get closer to autonomous grade control and the goal of getting the operator out of the cab.”
GET INTO THE GAME
As tight labor markets continue to press contractors to do more with less, the adoption of automated grade control in construction continues to rise. According to “Work Smarter, Not Harder: How Advanced Grade Control Tech Brings Efficiencies,” a recent For Construction Pros article on the topic, “automated grade control technologies are becoming an integral part of compact machines and attachments, as they create a noticeable reduction in downtime on jobsites.”
Operators can use control pads on smart phones to connect to a system wirelessly and update plan changes or troubleshooting information. Simple 2D technology that integrates onboard inertial measurement sensors with an in-cab monitor can produce highly accurate single or dual angle slopes efficiently, potentially paying off a technology investment on a single large project.
sites. Common operator assists might include blade and bucket controls, monitored by an in-cab operator who reads grading progress on an output display and can override or refine the operation using onboard commands.
Remote control is also possible when performing grading operations under Stage 3 conditions. In this instance, the operator is not on board the vehicle but operating it from a separate location using a joystick or belly box.
In the meantime, automated grade control is continuing to advance. The ability to make data-driven design decisions and push a button to automate them has been enhanced by evermore sophisticated software used on earthworks systems. As geo-sensors send data from the extremities of the machine to the operating system, onboard software steers and controls the blade to execute the grade accordingly.
“Data fusion is the enabler behind any automated grading system,” said Clark, who helps product managers and developers push the envelope toward improving grade control. “As more
“Starting small, with a 2D system and basic laser technology, is usually the easiest way to see results and get familiar with the technology,” said Bob Flynn, construction precision sales manager for CASE CE. “For more experienced users, I’d recommend investing in off-board solutions that help with data management. These are typically under-utilized but can offer valuable insights into jobsite productivity.”
Automated grade control is the best way to improve precision, safety and efficiency on a construction site.
The key is to make sure the system matches the application and not to overspend. Most solutions are upgradable and evolve over time, so the best advice would be to visit a dealer, discuss your situation, and demo a few products.
“Just as you wouldn’t use a 20-pound sledgehammer to nail a picture into
Remote control is also used when performing grading operations under Stage 3 conditions. In this instance, the operator is not on board the vehicle but operating it from a separate location using a joystick or belly box.
Caterpillar
Caterpillar
a wall, you never want to purchase technology simply for technology’s sake.” said Hagemann. “Go in with a few use cases and solve those first. The rest will fall into place.”
NOTEWORTHY CONCERNS
Until automated grade control makes the leap to autonomous, contractors would do well to pay attention to basic best practices when using automated technology, such as training.
Most manufacturers offer excellent training materials and support to get new operators up to speed quickly on the technology. Some even provide remote or onboard training by way of downloadable videos for instant playback in the cab. An operator can simply punch up a help topic and watch a how-to instructional video to correct on-the-job issues without contacting an expert or leaving the site. This is critical for the safe use of automated systems and for accelerating the contractor’s return on investment (ROI).
One project may be all it takes.”
Also, be wary of how reliable your technology really is. Ask around and do your homework before you buy.
“It can be easy to fall in love with technology just because it’s technology,” said Trimble’s Clark. “If a cable breaks or a sensor gets damaged on site, suddenly your machine can’t be used. So, from entry level to premier offerings, work with reputable dealers and make sure to keep quality and reliability high on your list of solution priorities.”
ENJOY THE BENEFITS ALONG THE WAY
While the journey to full autonomy may not be complete yet, the benefits provided by positioning yourself for the breakthrough are many. Within the confines of automated grade control, consider these benefits:
• The safety afforded by not having to position surveyors on the site
• Reduced rework, material usage, fuel cost, environmental impact, and need for skilled labor
• Increased job completion
• Enhanced productivity
• Competitive stance that accompanies lower costs and improved margins
By adopting existing technology as it moves toward the holy grail, you set yourself up as a front runner in the quest. When full autonomy becomes available, you will have a jump on the competition. Your people will already be familiar with autonomous technology by virtue of their understanding of automated grade control.
LOOKING AHEAD
“Be careful how you measure ROI,” said Flynn, who helps CASE CE customers determine what technology fits best with their given applications. “ROI can be very job dependent. You may find enough savings on material alone to justify a purchase. On the other hand, an accurate grade down to within one-tenth of a foot may save you the cost of a single laborer checking grade with a grade rod.
In the march toward Stage 5 autonomy, remember, everyone is still learning. Haul trucks, compactors and other heavy equipment in mining and farming merely point the way to greater economies in construction and related industries. Where mundane and repetitive tasks are replaced by machines today, finesse work, such as grading, will likewise be managed using advanced technology.
“The ability to coordinate whole fleets from a remote site is coming
soon,” said Flynn. “No one wants to work onsite in 100°F weather.”
Clark reports that Trimble is already adding features and functions that will minimize operator involvement in the grade control process to a point where the operator may be the only safety mechanism onboard.
“Once we figure out how to get the operator out of the machine altogether, it will be game over,” he said. “Jobsite safety and productivity will make a quantum leap, making construction in even the most hazardous locations practical.”
Trials are underway at research and development labs across the globe, in pilot projects designed to take semiautonomous, human-directed operations to full autonomy with artificial intelligence and machine learning. As these pilots prove out, new options will become available, leading to cost reductions on the very technology designed to lower overall job costs.
For early movers, renting autonomous equipment may be the economical way to sample its effectiveness without incurring steep, upfront costs. As well, retrofit kits for many existing machines will become available that preserve existing investments, allowing full autonomous operation without replacing manual operations altogether.
KEEP YOUR EYES ON THE PRIZE
While autonomy looms on the horizon today, automation is available, here and now. Automated grade control can produce huge returns on investment by way of improved grading accuracy, lower cost and enhanced productivity.
“Autonomous control is already making inroads in unsafe conditions where a task is reliably repeatable,” said Hagemann. “Keep your eyes on the ‘secret squirrel’ stuff that’s happening now behind the curtains. You’ll be seeing more of it online, in showrooms and at tradeshows very soon.”
Joe Zagorski is a freelance writer.
For more information visit https://asph.link/b5xdw5
2D machine control systems add semiautonomous operation to the process, with the operator only controlling the arm when desired
Link-Belt Excavators
LIQUID ROAD
By Brandon Noel, Editor
Asphalt Plant Maintenance Fixes On A Tight Budget
Sometimes you have to get creative.
It should go without saying that asphalt plants are a complex, interconnected system. After speaking with experts from several top asphalt plant manufacturers, one of the biggest takeaways I had from the information they shared is the importance of comprehensive, regular maintenance.
Each and every part of the machine has some impact on the others, and, while some maintenance points can mean the difference between being able to turn it on and produce mix, in order to produce at the highest quality and at the safest levels. You can’t cut corners.
“Running an asphalt mixing plant on a tight budget and with a short offseason requires a strategic focus on maintenance to ensure long-term reliability and profitability,” Ryder Harman, sales manager for ALmix, told me. “If you are not lucky enough to shut down for longer periods of time to work on, or catch up with your plant maintenance, you’re dealing with an additional layer of difficulty in keeping your facility running,
especially on a tight budget.”
However, there is a difference between being on a tight budget and cutting corners.
“It should go without saying that all maintenance on any equipment is critical to some degree,” noted Carlos Cardenas, Midwest area sales manager for the Ammann Group. “But some are more important when it comes to simply keeping the plant running. The rest are important to maintain efficiency, limit the environmental impact, and most importantly, to keep everyone involved safe.”
Lots of owners and managers of plants have experienced working with a tight budget, and it means that all sorts of decisions must go through a process of prioritization. That’s different than cutting corners, because when someone is cutting corners, they primarily approach maintenance from a cost perspective, regardless of how critical the procedure or replacement part.
This list is for those of you out there with limited time and a budget to keep in mind, who also need to operate at a high level.
UNDERSTANDING MAINTENANCE GOALS
Every part and operation that can be fixed, reconditioned, or replaced can be placed into four different pillars of plant maintenance:
• Keeping the plant running
• Efficiency and quality
• Environmental impacts
• Safety
This list is not ordered by level of importance, because they are all equally important. If you twisted a plant manager’s arm, hopefully their answer would be that plant safety rises above all other aspects of maintenance. However, our maintenance goals can be categorized and understood as falling into one of them.
“The truth is there is no such thing as a short list for maintenance,” noted Cardenas. “It is all important to maintain a balance between performance, efficiency, environmental impact and safety. If you are truly limited on time and budget, there are steps you can take without sacrificing on maintenance.”
Since we are working from a framework with a limited budget and limited time, let’s focus on the first pillar: keeping the plant running.
1. DRUM, BURNER, AND PUMP
The task of prioritizing your asphalt plant maintenance begins with understanding its basic, core function: drying the aggregates and mixing it with the liquid binder. This would mean the burner and the drum are the absolute first step in plant maintenance.
“The drum and burner are the heart of the plant,” said Harman. “Any inefficiency here directly affects asphalt quality, expected production rates, and production costs. Any issues with the drum or burner mid-production can lead to timely delays.”
Key Tasks:
• Inspect and clean the drum for buildup or wear.
• Check the drum shell for holes or thin areas that require patching.
• Have your burner tuned by a professional. You should be doing this at least once a year.
• Repair or replace worn-out drum flights to maintain material flow and heat distribution. Make any necessary flighting adjustments.
• Check your trunnions and their alignment, make adjustments as necessary.
• If timing allows, insulate the drum shell for increased efficiency and prolonged hot stop ability. A short winter maintenance period is perfect for having this work completed.
• Ensure burner fuel and air flow is uninterrupted. Inspect filters, valves and pressures.
• Regularly clean strainers in your asphalt pump.
• Check for leaks or visible damage.
• Calibrate the asphalt meter as needed.
These tasks are low-cost on the front end, but can end up costing you a lot more in downtime later. Taking care to check these boxes first can save you a lot of headaches down the line.
“To keep your burner running you simply need to keep the fuel and air flowing,” said Cardenas. “Check fuel pressure, and air pressure regularly. If these are not correct check fuel filters, valves, and check for obstructions in the air supply which includes the exhaust gas system.”
And that takes us to our next maintenance on a budget point.
2. BAGHOUSE, DUST CONTROL, AND EXHAUST
Once you’ve checked all your incoming lines for the burner, you must follow it through to the outbound exhaust systems, because if it is faulty it will cause your burners to malfunction. While these maintenance checks certainly pertain to keeping the plant running, you can cross off another item on your list because these systems impact our pillars of efficiency and environmental impact and plant safety, as well.
“Airflow is the key to production, so you want to ensure your baghouse is in top operational condition,” added Harman. “Proper dust control system functionality [also] ensures environmental compliance and prevents damage to sensitive equipment from excessive buildup.”
Key Tasks:
• Inspect and replace worn-out or torn bags.
• Inspect and replace cages.
• Clean ductwork and check for blockages.
• Check for and work to seal off any air leaks throughout the baghouse and ductwork.
• Verify that fans and blowers are operational and efficient.
• Inspect fan bearings and blades for wear and vibration
• Check the damper for proper operation.
• For pulse jet systems: Test air diaphragm valves, solenoid valves, pulse timer board, and differential pressure switches.
• For reverse air systems: Inspect rotor function and differential pressure switches.
• Consider upgrading exhausters using a damper to adjust airflow to exhauster systems driven by VFD (variable frequency drive) to increase efficiency and reducer wear on your exhauster.
“Check the bag cleaning system, air diaphragm valves, solenoid valves pulse timer board, and differential pressure switch for a pulse jet system,” adds Cardenas. “For a reverse air system check to make sure all the rotors are functioning correctly, and check the differential pressure switch. Check bags for holes or blindness. [However], if you can’t get the aggregate or the liquid asphalt in the drum then nothing else matters.”
3. COLD FEED BINS, RAP FEED, AND CONVEYOR INSPECTION
Being able to efficiently and accurately move your aggregates is the name of the game. If these transportation systems become faulty and break down during your busy production schedule, it’s going to be a huge headache. Not only that, but it’s going to cost you money that you can save now by properly inspecting and conditioning the gear now.
Provided by Ammann
Additional Maintenance For Tight Budgets from ALmix
• Focus on Preventive Maintenance: Remember, regular small repairs are less expensive than major breakdowns during the production season. Don’t wait until it breaks.
• Dive into Documentation: If you don’t already have a system for documenting plant issues, repairs, and improvements. Get started this offseason. This costs nothing but your time mostly, but having detailed documentation of your plant’s performance and maintenance needs will keep you prepared for what to focus on during your short offseason.
• Create Efficiency at the Tank Farm: New hot oil heaters are far more efficient than older models and can quickly add efficiency to your tank farm setup that pays for itself quickly in fuel savings. Additionally, modern Hot Oil Heaters like the ALmix HC Heater utilize internet-connected, remote controls that allow plant personnel to manage the heater remotely from any internet-connected device. Consider adding insulation to your AC lines to create fuel cost savings over future seasons.
• Bring out a Pro: Most plant manufacturers have teams of plant service professionals who travel around the country helping producers get the most out of their plants. Tap your plant manufacturer to have a service professional come to your plant and weigh in on any issues, these guys are trained to handle a multitude of different problems quickly and efficiently.
“These systems are required to move a large amount of material reliably; malfunctions can halt production and lead to a waste of materials,” explained Harman. “Consistent feeding of aggregates and recycled materials is essential for smooth operations and mix consistency.”
Key Tasks:
• Inspect belts for wear, tears, or misalignment.
• Lubricate and adjust pulleys, sprockets, bearings, and rollers. Replace worn pulleys.
• Replace damaged belts to prevent costly mid-season breakdowns.
• Inspect and repair cold feed bins and RAP feed bins for wear or damage.
• Consider adding liners in your bins for better material flow and enhanced wear protection.
• Check vibrators and bin gates for proper function.
Provided by Ammann
• Inspect conveyors and drag chains for wear and alignment.
• Calibrate belt scales.
The backbone of the production cycle, your feed systems cannot afford to be overlooked.
“If you do have the time and money to do a scheduled shut down to replace a drag chain how then can you afford to replace the chain if it breaks mid production?” asked Cardenas. “If you don’t have enough time to do it right the first time, you will always find the time to do it right a second time.”
4. BUILD OR REPLENISH SPARE PARTS INVENTORY
If you’re keeping your plant running on a tight budget this year, and, after checking off the key tasks on your list, you have some wiggle room left over, then you need to be thinking about what you have on hand just in case something unforeseen happens. There are all the things you can plan for, and then there are the things you never see coming. The best case scenario when those happen, is that you have, on hand, things to get you back to operational as fast as possible.
Harman. “The offseason is the perfect time to inventory your spare parts and stock up on what you need to be prepared for the start of next season.”
Key Tasks:
• Contact your plant manufacturer for a recommended spare parts list for your plant, or the specific plant unit from that manufacturer.
• Ensure that you have spares of heavily used wear parts, electrical components and sensors, and parts that typically require longer lead times from the supplier.
• Utilize a clean, dry, and dedicated location for storing the parts, as well as a system for replacing spares once they are used on your plant.
Not having an essential part on-hand can be a devastating situation when you’re in the heart of your busy season. Downtime is the dirtiest word in the industry, and no one wants to pass along that downtime to their customers who depend on their supply.
“Having an inventory of manufacturer-recommended spare parts for your plant helps eliminate downtime during the production season and avoid costly delays in receiving parts,” emphasized
“The time to remove the old chain and install a new one would be same in both occasions but if you planned it ahead of time the chain might cost less because you had already punched it and it is now on your lot. So, you don’t have to pay expedited shipping cost or deal with long lead times,” explained Cardenas. “You won’t be down an extra day because you now have to clean out the drag and waste the mix, before removing the failed chain. You will not have a line of trucks just sitting idle. It they are your trucks it’s expensive, but if they are your customer’s, that can cost you even more, especially if these unplanned stops are a frequent occurrence.”
This year, you can really look smart and frugal by approaching your annual plant maintenance with this twopronged approach: be economical with your maintenance goals and make efficient use of your time.
Contributions from Asphalt Drum Mixers Inc., ALmix, and Amman made this article possible. For additional resources use the QR code below.
For more information visit http://asphalt.com/kk3fi1
BIGGER PROFITS!
By Brandon Noel, Editor
CONNECTIONS Making Strong
Cynthia “Cindy” Powell reflects on her career in the industry, how it’s changed, and the room it still has to grow.
Share a little bit about yourself. In what field do you currently work in the asphalt industry, and how would you describe what you do on a day-to-day basis?
I am a wife, a mom, and a Pippa (grandmom), and I have been part of the asphalt industry for nearly two decades. I’m currently serving in a dual role as Vice President of Mix Technology for Aztec Asphalt Technology and Vice President of the Southeastern Region for Total Asphalt Rejuvenation. In these roles, I focus on innovation and sustainability, particularly using Veritas Green, a patented asphalt surface rejuvenator.
My work involves collaborating with industry partners to optimize the use of rejuvenators, developing application strategies, and building relationships with municipalities, DOTs, and private contractors to ensure that our solutions meet their specific roadway preservation needs. I also spend time educating others about the benefits of incorporating rejuvenation technology into their pavement preservation strategies through presentations and one-on-one consultations.
What do you personally see as the part you play in the industry?
I see my role as a connector – bridging the gap between innovation and real-world application. I’m passionate about promoting sustainable practices and helping others understand how technologies like Veritas Green can transform pavement preservation. By sharing knowledge, building relationships, and encouraging collaboration, I aim to empower others in industry to embrace solutions that extend pavement life, improve recyclability, and reduce environmental impact.
I also view my work as an opportunity to inspire a broader vision of what the asphalt industry can achieve. By highlighting the importance of innovation and showcasing the leadership of women in the field, I hope to encourage a more inclusive, forwardthinking industry that is prepared to meet the challenges of tomorrow.
How did you get started in the asphalt industry in the first place?
My start in the asphalt industry came not from what I knew, but from who I knew. In 2006, I was a single mother looking for a stable job when I was introduced to East Alabama Paving through a family connection. I joined the company with no prior knowledge of asphalt or construction, but I was determined to succeed. What started as a job quickly turned into something much more – I made the decision to treat it as a career, not just a paycheck.
That mindset changed everything. I immerse myself in learning every aspect of asphalt production, testing, and mix design. Over time, I realized that this industry offered endless opportunities for growth and innovation, and I wanted to be a part of it. That decision to commit fully to my work laid the foundation for the career I have today, and it’s a choice I am grateful for every day.
Early on in your career, did you face any unique challenges or roadblocks that you had to overcome in order to keep progressing?
Early in my career, one of the biggest challenges I faced was proving myself in a predominantly male industry. For women to succeed in this field, it’s essential to demonstrate early on that we can pull our own weight and win our own battles. I had to show my coworkers that I was just as capable, dedicated, and resilient as they were. Once I did that, everything changed.
What began as a challenge turned into one of my greatest blessings. I earned the respect of my coworkers, and in return, I gained some of the best friends and champions I could have ever asked for. We built mutual respect and trust, and I knew they were in my corner cheering me on.
Another key to overcoming challenges was finding a mentor. While it’s wonderful to connect with another woman as a mentor, it doesn’t have to be. Some of the most influential women I know in the industry were mentored by men who believed in their potential. For me,
mentorship has been invaluable, and it’s something I encourage everyone to seek out as they navigate their careers.
How would you describe the nature of your experience over the years?
The challenges women face in the construction field are no secret, and my experience has been no exception. There were moments when I had to work harder and push further to show that I belonged and could contribute just as much as anyone else. Many of my coworkers, both men and women, have become my biggest advocates and lifelong friends.
What stands out most in my journey is the balance of challenges and opportunities. Yes, I’ve faced hurdles, but I’ve also been blessed to work in a field that values results and innovation. The asphalt industry, in particular, is evolving, and more doors are opening for women to step into leadership and make a lasting impact. I’m proud to be part of that progress, and I hope my story encourages other women to pursue careers in construction.
What about your perspective as a woman do you believe has helped you or given you insights over the years?
Women often have a natural ability to focus on details while also seeing the bigger picture, which is crucial in an industry where precision and longterm planning are key. I’ve found that this perspective allows me to approach challenges with creativity and balance –whether it’s problem-solving in the lab
or strategizing for a large-scale project. Another aspect of my perspective as a woman is the emphasis on building relationships. I’ve always valued collaboration and clear communication, which has helped me connect with coworkers, clients, and partners on a deeper level. Those connections have been the foundation of my success, allowing me to foster teamwork and mutual respect in what is traditionally a male-dominated field.
Finally, I think women often bring resilience and adaptability to the table. These traits have been invaluable as I’ve navigated challenges and changes in my career. They’ve allowed me to turn obstacles into opportunities and to continuously grow, not just as a professional but as a person.
Everyone is looking for good workers, and recruiting more women into the workforce is one possible solution. What barriers do you think exist that sometimes stand in the way and make recruitment difficult?
If you don’t know, then you don’t know – and that’s one of the biggest barriers to recruiting women into the asphalt workforce. Many women simply aren’t aware of the opportunities available in this industry or that they can earn the same wages as the man working next to them. That lack of knowledge can create hesitation or prevent women from considering asphalt as a viable career path.
Organizations like Women of Asphalt are excellent tools for breaking down these barriers by providing mentorship, education, and networking opportunities. But as an industry, we must do more to actively reach out to
women and share the message that, while jobs in asphalt construction require hard work, they also offer incredible rewards – financial stability, career growth, and the satisfaction of contributing to critical infrastructure.
I believe starting recruitment efforts in high schools and technical colleges would be a game-changer. By engaging young women early, we can show them the pathways available in this field, whether it’s in project management, technical roles, or handson construction. With a targeted campaign, we can demonstrate that the asphalt industry is not only inclusive but also provides meaningful, well-paying careers that women can thrive in.
From when you began your career to now, how has the industry changed most and improved?
I’ve noticed an increased focus on safety – not just physical safety on the jobsite, but also mental health. Suicide rates in the construction industry are alarmingly high, and it’s encouraging to see our industry taking steps to address this issue through awareness and support initiatives.
Mental health is an integral part of safety, and as an industry, we’re beginning to recognize that protecting workers goes beyond physical measures. This heightened focus on both physical and mental well-being ensures that everyone on the team is cared for in a more holistic way.
For me, safety is deeply personal –it’s about making sure that everyone on the team goes home at the end of the day. This not only protects workers but also reinforces the professionalism and care that define our industry.
While there’s still progress to be made, I’m proud of the steps we’ve taken as an industry to evolve and improve over the years.
What would you consider to be your “passion” topic in the industry?
My passion in the asphalt industry is simple: to make asphalt better. This includes improving the safety and longevity of our roads, particularly through innovations in materials and
design. One area I’m especially passionate about is open-graded friction course (OGFC) pavements. While OGFC is great for improving road safety by reducing hydroplaning and increasing visibility during rain, it has to be made more durable and longer lasting to justify the cost for state DOTs. That’s where my work comes in – I truly believe that products like Veritas Green can help extend the life of OGFC pavements, making them more cost-effective and sustainable.
My passion for road safety became deeply personal the day I watched my teenage son drive off alone for the first time. In that moment, I realized just how much trust we place in the roads we build. It’s a responsibility I take to heart, knowing that the work we do has the potential to save lives. Whether it’s through promoting innovative solutions, enhancing pavement designs, or advocating for better maintenance practices, I’m excited to contribute to safer, longer-lasting roads every chance I get.
What would you like other women to know from your experiences who are new to the industry?
I want you to know that the sky is truly the limit. This is an industry where your work ethic, determination, and willingness to learn matter more than any stereotypes or preconceived notions. The work is undoubtedly hard, but it is also incredibly rewarding –both in the sense of accomplishment and the opportunities for growth.
Don’t let outdated stereotypes hold you back. This industry is for everyone who is willing to put in the effort and take pride in what they do. You’ll find that your contributions are valued and that there are countless opportunities to build a meaningful and successful career. With a good work ethic and a commitment to learning, you can achieve more than you ever thought possible in the asphalt industry.
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By Brandon Noel, Editor
Taking Your Asphalt Mill To The
NEXT LEVEL
The addition of a large milling machine to your pavement maintenance business can open a lot of new doors for you, but there’s a whole other level of value and power to these machine waiting to be unlocked.
Ayear ago, the Buck Brothers were in a different place. They were pretty sure that they wanted to add a milling machine to their yard, but they hadn’t pulled the trigger just yet. All the math looked good, and they had become far too busy to keep subcontracting out for their future milling needs. That didn’t make the enormous investment any easier, or smaller, to swallow.
During a panel discussion at the 2023 IGNITE conference, Chad Buck had mentioned his two son’s desire to make the move. “I’m trying to get retired,” he told the crowd of other pavement professionals in attendance. “They want to spend a million dollars or something, and get this milling machine, and we’ve never done that before.”
It’s never a decision to be taken lightly. After plenty of research, shopping around, and some training with other experienced contractors, they bit bullet. They acquired a Caterpillar PM820, which can mill up to 13 inches deep, and has 815 hp which puts it into a high enough class to be above the emissions level, not requiring DEF testing.
Throwing down for their new highway class milling machine wasn’t the end of their vision, or ambition, because the plan was always to push the mill’s capabilities to the next level.
3D MILLING: THE BASICS
Earlier this summer, I received some very limited training on a Wirtgen 200 Fi, and when I say, “limited training,” I mean that I was allowed to do a single pass in a straight line for about twenty-five feet. I was grateful for that experience, and, in all honesty, that’s about as much as I would have let me do too. But I was definitely anxious to get some more time at the controls when I could. That’s when Jacob Buck reached out to me, and asked if I knew anything about 3D milling.
I decided that I should go and see for myself what the Buck Brothers were getting into. They were as new to the process as I was, having just got into milling in general, the addition of a totally new layer of complexity seemed
like a gamble. The day I joined them on the jobsite, was the first time they were giving the 3D milling set up a go.
“It’s our first year doing it,” said Jacob Buck, vice president of Buck Brothers standing next to their new behemoth. “So far, we’re really satisfied with it.”
The components they purchased in order to perform 3D milling with Trimble can all be acquired separately, but they need to work in concert to produce the desired machine grade control:
• Total Station Tripod
• Data Collector and Target on a rod with Trimble SiteWorks
• Machine Display on the mill with Trimble RoadWorkds 3D
• Machine Target ECM and Radio
• Trimble Business Center (to build the 3D model)
That might seem like a lot of different pieces of the puzzle, not counting the mill itself, but the benefits of 3D can be quickly understood. While everyone is familiar with a tool like
the global positioning system (GPS), machine grade controls for 3D milling require something much more refined and accurate. Universal Total Station (UTS) provides a much more refined level of specificaiton.
“GPS is not nearly as accurate as UTS. GPS has roughly golf-ball sized accuracy, versus UTS which has millimeter-level accuracy,” said Buck. “So whenever we’re fine grading something, whether it be with our greater blend on skid steer or this, we know that it has to be UTS.”
What does the process look like? It begins on the site before any of your heavy iron gets there.
“What we do before the job starts is we’ll come out here, survey it using the total station and a rod with a data collector, and then bring that back to the office. We’ll make a model of the job, optimize it, smooth it out, and make sure there’s no water holding anywhere. After we’re done, then we come out here and we put that model into the machine. Basically, the goal is that we
want to mill this to grade, so that when we come to pave it, we can shoot sonics off of it and there will be no water.”
Once the 3D model is in the machine, and the automatics are set, the operators can focus on driving the mill and directing the conveyor system, and the mill will automatically direct itself according to the pre-designed model.
3D milling is especially effective at fixing and repairing the liabilities of preexisting pavements, a big benefit and selling point to potential clients. When trying to remove areas where potholes developed or water pooled in large sections, it is almost always an issue with what is underneath the asphalt.
To properly deal with this issue when you’ve been hired to resurface means getting down below and regrading the base material to prevent a repeat scenario when you repave fresh wear-layer overtop. It’s not usually a matter of inches, however, that’s why the UTS accuracy is so vital, because a contractor using 3D can make the careful adjustment and get a big result and a happy customer.
BOOM IN BUSINESS
The Buck Brothers knew there was demand for milling services beyond their own needs, but they didn’t exactly know just how big the demand was going to be. The result has been a serious expansion of their business, more than they had even anticipated.
“We are getting like 500 calls a week,” said Buck. “People think I’m bull-shitting them, but I’m not. We’ve adopted a new software so that everything in the background is running a lot smoother. It’s been the biggest game changer.”
While demand for their services was scaling up, it was vital that they realized
Operators can focus on driving the mill and directing the conveyor system, and the mill will automatically direct itself according to the pre-designed model.
their need to scale up the behind-thescenes workflow to help them manage everything. The Buck Brothers utilize HubSpot for their customer relationship manager (CRM) needs, and OneCrew for everything else. It didn’t just help them scale up their capabilities, but it helped them quantify what kind of scaling and where they needed it most.
“If I didn’t have it, we’d just be guessing, right? The office might just tell me they were really busy, but what would that really mean? How many calls? What were they calling about? What are people calling the most about,” explained Buck. “Now, we can look at all that data and make educated decisions, which is really important.”
SOFTWARE SOLUTIONS
While the Buck Brothers use two different pieces of software for their backend management, and that works really well for them, I was curious about a possible solution that might do the job of both on a single platform.
The software created by PROcru just so happens to combine the needs for job costing, scheduling, CRM, and more all in one place.
“Right from the initial call you’ll pull three things: the contact who you spoke
Jacob Buck
Jacob Buck
Buck Brothers acquired a Caterpillar PM820, which can mill up to 13 inches deep.
with, the company they are associated with that needs the potential pavement work done, and you will have the site or services they need completed,” said Tom Hastings, technical director of software at PROcru.
This generates a new lead for your sales team, from there, someone on your team can be assigned to it, and then it continually and automatically track all the data associated with it for years to come. Whether or not the bid was accepted, the entirety of the client’s work-performed history, the performance efficiencies, and all costs associated with them.
After the lead is created and handed off to a sales team member, it continues its job tracking any and all proposals and communications between sales and the client. Even after initial proposals go out, if resolution isn’t reached, the platform will track and encourage follow-up communication until a definitive outcome is recorded.
“That information never goes away as it moves through the process,” said Hastings. “Sales can always see what needs to be done next from their
dashboard, and automatic reminders can be sent to unresponsive clients if it’s still in an open status. Once it is sold, all the information about the job goes to project management and their own dashboard.”
However, PROcru can do more than just individual client and/or project management, the platform also works as a scheduling tool for your different teams and crews on the ground. It acts as their very own time-clock right on their phones, which, in turn, generates labor cost and efficiency reports, all of which are aggregated into larger job costing reports.
It can, in real-time, compare the projected use of labor-hours and materials to what is actually happen on a given day. This type of data can show where things might be falling through the cracks, like the phantom phone calls Jacob Buck talked about. You can’t fix what you don’t know you’re missing.
QUALITY Widener
Jacob Buck
Several Trimble components work together to provide precision milling.
Capturing and quantifying what’s happening is essential.
“We can schedule by either serviceline or by crews,” said Hastings.
“Through it, you can schedule each different phase of the job. The employees, having the app installed on their phones, can then see on a daily basis where and to what they’ve been assigned to get done. If they go out to multiple jobs a day, it records times and expenditures of assets on all those different jobs.”
You can see clearly what’s going on, because it takes the information from your proposed job, its materials and manhours, and then records the actual. For instance, if you propose a three-day project, and after one day the project is less than a third of the way completed, then you know right away you have a problem.
“I think the most beneficial portion of PROcru for contractors is the instantaneous job costing every
The Buck Brothers knew there was demand for milling services beyond their own needs, but they didn’t exactly know just how big the demand was going to be.
day. Every day, the management team will see exactly how the crews are performing, right down to the margin percent. That’s powerful information to have,” said Hastings.
For those paving companies looking to truly breakthrough the invisible ceilings they’ve hit over the past few
seasons, it might be worth taking a look at different technological offerings to either expand their service offerings or to improve their backend management, or, perhaps, even both.
For more information visit https://asph.link/tech
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Jacob Buck
Road Engineering Is Climate ENGINEERING
Given the majority of U.S. roads are built using asphalt, in the current climate paradigm is that still the best choice for road construction and replacement?
The Cornell Program in Infrastructure Policy (CPIP) explores policy aspects of infrastructure deployment: design, construction, operation, maintenance, procurement, funding, financing, and recycling of assets to ensure efficiency, cost-effectiveness, equity, and inclusion.
CPIP encourages the incorporation of the latest technologies – sensors, robotics, artificial intelligence, cybersecurity, low‐carbon materials, and data analytics – into new infrastructure projects.
The program’s scope includes heavy civil infrastructure such as roads, bridges, tunnels, airports, seaports, drinking water systems, wastewater treatment facilities and energy systems.
Professor Rick Geddes is the founder and academic director of CPIP, which started in 2012 and focuses on peerreviewed research, teaching, and public engagement and outreach. Its 40-member industry advisory board represents, “some of the most distinguished people in the infrastructure world,” he said.
Among CPIP teachings is, ‘climate engineering,’ a term Geddes said Cornell University developed to emphasize the new technologies that have been developed in the infrastructure world.
“I call it a quiet technological revolution, because we hear a lot about driverless cars and electric cars. But there’s a whole set of other technologies that includes sensors embedded in concrete and elastic asphalt,” he said.
Geddes noted the work of Cornell University Materials Science and
Engineering Professor Emmanuel P. Giannelis who was instrumental in developing new materials for roads and highways to decrease the rutting and cracking that typically takes place especially during freeze-thaw cycles.
“We developed a new family of surfacing materials by incorporating clay nanoparticles into asphalt,” Giannelis said. “These particles are chemically similar to those found in soils except for their size, which is much finer. Specifically, they have at least one of their dimensions in the nanometer range and they can mix with the other ingredients at the nanoscale.”
As a result, adding a small amount of nanoclays leads to significant improvements in mechanical and thermo-cycling performance, Giannelis explained.
“In addition, the nanoclays allow replacement of more expensive copolymers and other polymer additives with the lower cost crumb rubber. The technology offers significantly improved
performance compared to traditional surfacing materials leading to roads with longer-lasting surfaces, even under extreme weather conditions.”
The technology is being scaled up and tested in real applications and is a good example of a new type of partnership where academia works with private, government, and corporate partners to develop critical next-generation technologies, Giannelis explained.
“I believe there’s a lot of other innovations in asphalt and these materials that needs to be studied more and tested,” he said. “They key is adoption at scale, where you try to figure out new materials to get more with less or more with the same, so you don’t have to resurface as often. It’s more environmentally friendly. That’s the climate engineering we’re trying to get across.”
MAKING THE CASE FOR TOMORROW
Another policy topic CPIP investigates is ‘future-proofing.’
“It’s a bit of a misnomer, because we can’t protect ourselves from the future,” Geddes noted. “But the idea of futureproofing is if you have a procurement contract with a private partner to do operation and maintenance, that contract includes clauses in it such that the private partner has a duty to utilize the latest technologies in their operation and maintenance of the infrastructure.”
Geddes said that as a professor of economics, one factor on his radar is the lack of proper pricing of the use of the transportation infrastructure, creating challenges in building and rebuilding roads.
“It’s very difficult to price all roads immediately, but we have seen a lot of incremental steps like congestion pricing in New York City,” he said. The program, which had been postponed, is rolling out in a modified version beginning Jan. 5.
“One of the things that bothers me is that the economics and technology now is available to do that properly, but we seem to fail on the political side,” Geddes said. “How political a lot of the policies become in transportation is disconcerting.”
Additionally, Geddes said he understands the encouragement of using electricity rather than fossil fuels, but EV drivers aren’t paying anything for the use of the roads under the current way they are funded at the state and federal level. He points out many people – particularly younger people – have equity concerns associated with the gas tax.
“It was greatly increased in 1956 at the federal level by President Eisenhower to pay for the construction of the interstate highway system,” said Geddes. “In those days, any four-door family car got about the same mileage per gallon. If you bought a gallon of gas, you would use the roads about the same amount.
“Today, that’s no longer true. A wealthier person who has a Tesla pays zero in the gas tax. But a poorer family with a less energy-efficient old pickup truck pays a heck of a lot.”
Geddes noted federal taxes on fossil fuels per gallon stand at 18.4 cents for gas and 24.4 cents for diesel.
“The uptake of electric vehicles means there’s less use of fossil fuel and
The Cornell Program in Infrastructure Policy exists to “educate the next generation of infrastructure leaders”. Here a class celebrates the completion of an intensive seven day bootcamp in designing spreadsheet models for infrastructure finance in January 2024.
less tax revenue is going to be more correlated with this inequity problem,” explained Geddes. “The Department of Transportation has to fund itself somehow and you’re pushing that cost onto the gasoline drivers who tend to be lower income. Gas tax is regressive in the sense that it hits poor families more than rich families.
“They are not indexed to inflation, so inflation, over time, erodes the purchasing power of those fossil fuel taxes,” he said. “That’s also true at the state level.”
Geddes said that the cost of construction materials has gone up faster than the consumer price index against the backdrop of declining revenue. He added that he understood the reason for the shift away from the use of fossil fuels for environmental and other reasons, but calls it a paradox, “because you’re trying to fund your transportation network based on the consumption of fossil fuels at the same time you’re trying to discourage the use of fossil fuels.”
The Corporate Average Fuel Economy standards that were increased at the end of the George W. Bush administration and the beginning of the Obama administration have been tightened over time, Geddes said.
Rick Geddes
Rick Geddes
“The idea is to encourage more efficient vehicles and discourage use of fossil fuels and the car companies complied. They figured out more efficient engines,” he added. “But the effect of that on the tax revenue for transportation at the state and federal level declines as a result.”
Geddes backs the idea of switching to a road usage charge, such as used in Oregon.
“You pay a flat fee per mile of road use. You separate the use of the road from whatever fuel you use,” he said. “There is a solution to this, but it’s the political will that’s lacking.”
TRANSPORTATION REFORMATION
Geddes talked of the reform of the National Environmental Policy Act, dating to Jan. 1, 1970, requiring federal agencies to assess the environmental effects of their proposed actions prior to making decisions.
“It was thought to be a modest bill, but it’s become a giant barrier to the efficient delivery of infrastructure in the United States,” he argued. “The effect of delaying projects is to make them more costly. It slows them down enormously. I think it slows the adoption of new technologies.”
Another consideration is examining the way the U.S. has delivered infrastructure for about a century –particularly with taxes on municipal bonds, which tends to discourage partnerships between the public and private sectors, Geddes said.
“A lot of times, private partners are the ones who have they do these projects globally,” he said. “They understand the technologies. They’re willing to take risk. I’ve urged policymakers to undertake reforms of the way we deliver and procure infrastructure in the United States in order to encourage more public private partnerships.”
Geddes noted the Infrastructure Investment and Jobs Act (IIJA) increased the cap on tax-exempt highway or surface freight transfer facility bonds to $30 billion and that it’s his understanding the U.S. will hit that cap soon.
“I would urge no cap as long as it’s a qualified project,” he added. “The Treasury claims it would lose revenue, but we can debate how much that would be.”
Geddes added that the U.S. infrastructure is owned and controlled in a, “very balkanized fashion. There’s a lot of very small owners of infrastructure. They’re used to doing procurement in a certain way and are a bit concerned about innovative techniques like public private partnerships that are regularly used in many other countries.
“My hope would be that the public sector could be trained. We call it public sector capacity – capacity is like the comfort level with innovative contracting, the knowledge, and the skills, so they protect the contract with
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the private sector more but also protect the public interest in the process of doing that.”
Through CPIP, Geddes advocates innovative procurement contracts where the private sector assumes some of that risk through future proofing and insurance that tries to speed up adoption of those technologies by the public sector owners.
“The primary thing is to protect the public interest, but at the same time, we can’t be stuck forever in a certain way of doing things,” Geddes said. “This quiet technological revolution in infrastructure offers us this chance to really leap forward.”
RESILIENCY WILL ONLY BECOME MORE IMPORTANT
The issue of road reconstruction as a result of climate change is a global concern.
“We are seeing, primarily due to recent events, that future infrastructure and adaptation, resilience, and risk for climate change is rapidly rising up in the discussions of governments, municipal authorities, and industry,” noted Professor Sean Smith, chair of Future Construction, School of Engineering at the University of Edinburgh.
Transport infrastructure – along with buildings and housing – has taken some of the biggest hits from climate change, he added.
“Recent events both in Europe with Storm Boris and Hurricane Helene in the U.S. showed the catastrophic damage to highways, country and mountain roads – many of the key arteries for communities, business and inter-city movement of people and goods which have been so badly damaged,” he said.
“Many transport routes such as roads or rail have become the new rivers of climate change as they are the primary route map for the channelling of heavy intense storm rains prior to reaching rivers and deltas.”
Fifty years ago, no designer or engineer foresaw the extent of intense rainfall many countries now face. All local and national governments need to make greater headway in ensuring infrastructure resilience and adaptation is integral to annual spending plans, noted Smith.
“Learn from some of these key events and undertake infrastructure risk assessments and modeling to then focus funds to maximize resilience on key communities and industry areas,” he said.
Smith noted there is not necessarily any region that is not affected by climate concerns – case in point, Asheville, N.C. Earlier this year, Dubai experienced 18 months of rain in two days.
“Previous modeling needs to shift from the ‘what did we plan and know from before’ to ‘what we need to do to plan for the unknown’,” Smith explained.
Smith believes asphalt is still the best choice for road construction and replacement, “with a greater focus on enhanced reinforcement of roads – boundaries – and embankments and with the opportunity to potentially build in parallel pipework to draw the water away, most likely and easier to be surface mounted awaiting use once such storms arrive.”
“We don’t have much time,” he said. “The sooner we start, the better.”
by Carol Brzozowski, freelance writer for Asphalt Contractor.
For more information visit http://asphalt.com/kk3fi1
5 Tips for More Efficient Operation in Cold Weather
Keeping up with coldseason maintenance and operation practices can help reduce strain on your machine. Here are five tips to warm up winter operations.
Cold weather is one of the harshest conditions for an operating equipment. When temps dip below 0, machine components are
pushed harder. Everyday tasks you performed in the summer now put more wear and tear on equipment.
Keeping up with cold-season maintenance and operation practices can help reduce strain on your machine. Here are five tips to warm up winter operations.
➊ REPLACE FLUIDS WITH COLD WEATHER FORMULAS.
Fluids throughout your machine get thick as temperatures drop. This change in consistency leads to more
friction. The machine is now working harder, which can lead to unexpected downtime. Cold weather can impact systems throughout your machine including the engine and hydraulics. This is especially true for today’s advanced fuel system where diesel fuel gelling up can seriously impact fuel efficiency and overall productivity. To avoid a chilly outcome, replace fluids with cold-weather versions during late fall or early winter maintenance cycles. Look at the specifications on your engine oil, hydraulic fluids,
antifreeze and diesel fuel and replace or use additives as necessary.
It is worth noting that you don’t need to replace fluids for a single cold snap. But if temperatures in your area of operation are averaging below zero for extended periods of time, you will want to make sure to change over to colderrated alternatives before winter.
➋ ALWAYS WARM UP MACHINES BEFORE OPERATION.
Starting your equipment and letting it get up to temperature before starting operations is about more than having a cozy cab. Even if you’ve added coldrated fluids, if the machine has not had a chance to warm up, those compounds are not functioning at 100%. Ensure optimal performance by allowing plenty of warm-up time before taking on a
task. Maybe enjoy a hot cup of coffee or cocoa while you wait. And be sure to build this downtime into your winter timelines.
➌ CHECK TIRES REGULARLY.
Cold air is denser than warm air. This impacts the air in your tires, resulting in fluctuating tire pressure. For equipment such as telehandlers, maintaining proper tire pressures is important for stability and effective operation. Checking tire pressure daily, especially on equipment parked outside, can reduce wear and tear on tires and provide safer, more efficient operation.
It’s also worth noting that cold temperatures make rubber hard and brittle, which can result in a rougher ride and more risk of tire damage in rough terrain.
Finally, adding water or other liquids to tires is not recommended. It can cause issues with tire balance and durability. Today’s high-performance tires are not designed to hold up to this old practice.
➍ KEEP YOUR BATTERY WARM AND MAINTAINED.
Despite great advances in battery technology, there is still no way to counteract the effects of extreme cold on battery life and operation. Store equipment indoors whenever possible, and for larger equipment, make sure you have insulated blankets, block heaters or other systems to keep the area around the battery as warm as possible. Some manufacturers offer Eberspacher heaters standard on larger equipment. This diesel-fuel heater runs
on a timer to keep the engine block, as well as the cab, warm. It’s an ideal solution for heavy equipment sites with no access to power at night and is required in all military equipment.
➎ MAINTAIN DIESEL EXHAUST FLUID SYSTEMS ON LARGER EQUIPMENT.
As with engine oil and hydraulic fluid, DEF fluids are susceptible to freezing. Since DEF contains a significant
amount of water, it freezes at 11°F and -11°C. It expands 7% when frozen. Industry leading manufacturers engineer selective catalytic reduction systems to be as easy on operators as possible, even in cold weather, but there are still things your crew can do to ensure these systems are maintained.
Don’t give your equipment the cold shoulder this winter. Following these tips will help keep your equipment and your crew on the job and out of the shop. Work with your local dealer to secure additional cold weather gear such as fluids and heated blankets before the temperatures drop.
by Lee Tice is senior product manager at JCB North America.
DON’T MISS THE MOST EXCITING EVENT IN THE
AN IMMERSIVE EXPERIENCE | EXCEPTIONAL EDUCATION | UNPARALLELED
PAVE/X: THE PAVEMENT EXPERIENCE, the only national event dedicated exclusively to the paving and pavement maintenance industries for 2025, aims to help contractors and business owners propel their business and expertise forward with live equipment demonstrations, an in-depth education program and deeper connection opportunities on an expansive trade show floor.
January 28 - 30, 2025
Chattanooga Convention Center
SHUTTLE BUGGY ® SB-3000
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