Asphalt Contractor February 2016 by ForConstructionPros.com

Latest Technologies for Production, Paving & Preservation FEBRUARY 2016

Asphalt gets SALTY Page 74

How to rejuvenate HIGH-RAP MIXES for heavy traffic Page 20

Portable Plant Selection

Best practices for emulsified bond coats Page 42

101 The top three things to consider when selecting a portable asphalt recycling plant Page 58

www.ForConstructionPros.com/Asphalt

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STAY INFORMED RECON™ monitor keeps you informed about the status of asphalt storage tanks and hot oil heaters at your HMA plant. It is a web-based system that uses your smart phone, tablet computer or PC. Your display screen shows real-time status of the hot oil heater that heats your asphalt tanks. The status of asphalt stored in tanks is also shown. Other screens show trend data that enables you to better manage usage. H E AT E C , I N C .

Other options are also available. The system can be easily retrofitted to many existing plants without upgrading existing equipment. Please contact Heatec at 800-235-5200 for more information. Visit our website heatec.com RECON™ is a trademark of Heatec, Inc

Search: 10073245

an Astec Industries Company

5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com

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Upcycle:

(verb) \uhp-sahy-kuh l\:

To reuse material in such a way as to create a product of higher quality than the original:

Ultradrum A.R.E. 50%

UltraRAP 70%

MegaRAP 100%

It seems any plant these days can recycle, but have you ever asked about the quality of the mix produced? With higher RAP percentages comes the problems of degradation of the mix. That’s why Gencor developed the innovative UltraRAP and MegaRAP concepts, which can process 70% and 100% recycle without superheating and degrading the quality of the mix. The result is a noticeably superior and consistent mix. So if you want superior high RAP capability, don’t just recycle ... Upcycle. Call Gencor today and learn how you can “Upcycle”. 407.290.6000 or visit www. gencor.com Search: 10073090

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› TABLE OF CONTENTS FEBRUARY 2016

COVER STORY

DEPARTMENTS PAVING INNOVATIONS

20 PAVEMENT PRESERVATION

42 PLANT MATTERS

PLANT MATTERS

58 Portable Plant Selection 101

The top three things to consider when selecting a portable asphalt recycling plant.

62 PAVING INNOVATIONS

PAVEMENT PRESERVATION

PLANT MATTERS

20 Town Rejuvenates

42 New Research Drives

62 Cliff’s Notes

High-RAP Mix For Heavy-Traffic Pavement

Wellesley, MA, milland-fill project at busy recycling area uses 40% RAP mix treated with new sustainable asphalt rejuvenator.

30 Machine Control

Technology Cuts Road Prep Time in Half Valley General Construction uses machine control on subdivision in southern Alaska.

34 Paving Products

Pavers, rollers, screeds, material transfer vehicles & more.

Emulsified Asphalt Bond Coat Best Practice

As new evidence of their usefulness unfolds, fresh attention is being paid to the use of emulsified asphalt tack or bond coats in bituminous paving.

Some advice on how to properly maintain the baghouse.

63 Plant Products

Plants, baghouses, mixers, dryers, silos, automation systems.

50 Three Training

Resources to Get the Most from the Preservation Associations Educational resources to help you get the job done.

52 Preservation Products

Milling machines, reclaimers, infrared equipment & more.

4 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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UNBEATABLE TEAM.

The Wirtgen Group owes its strength to the excellence of its three road technology product brands – Wirtgen, Vögele and Hamm – with their unique wealth of experience. Put your trust in the Wirtgen Group team.

WIRTGEN AMERICA . 6030 Dana Way . Antioch, TN 37013 Tel.: (615) 501-0600 . www.wirtgenamerica.com

ROAD TECHNOLOGIES

Search: 10075240

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TABLE OF CONTENTS IN EVERY ISSUE

8 Editor’s

Perspective What’s a state to do?

10 New Products

A look at the latest equipment and technology available for the asphalt industry.

18 Technology Update

MultiCool aids compaction calculations in the field.

67 Finance Forum

73 Advertising Index 74 The Last Exit

The family office: an alternative capital solution.

Scientists have developed a new salt-filled asphalt that prevents ice from forming on roads.

WHAT’S ONLINE www.ForConstructionPros.com/Asphalt

CONSTRUCTION-FOCUSED MEDIA COMPANY DONATES $10,000 TO CHARITY

GEORGIA GOVERNOR ANNOUNCES 10-YEAR, $10B TRANSPORTATION INVESTMENT PLAN

AC Business Media, Fort

Georgia Governor Nathan Deal has announced a $10 billion, 10-year

Atkinson, WI, fulfilled

transportation investment plan that would be financed through a $900

holiday wishes this

million transportation funding bill passed in 2015. The plan includes an

season with a donation

18-month list of road resurfacing and bridge repair and replacement

of $10,000 to charities

projects.

chosen by and in the

Search: 12158157

name of its employees. AC Business Media’s Reconstruction magazines and digital properties including ForConstruc-

VIDEO: CONSTRUCTION EXPECTED TO GROW IN 2016

tionPros.com. Search: 12155875

The U.S. economy

portfolio includes Asphalt Contractor and Pavement Maintenance &

STATES ASSESS EFFECTS OF FEDERAL SURFACE TRANSPORTATION BILL

is in growth mode with little chance of recession or

Both Missouri and Arkansas expressed concerns that their states

runaway inflation.

will not be able to provide the required matching funds in order to

That bodes well for

receive federal highway money as laid out in the FAST Act. Other

the construction

states, including Tennessee and Rhode Island, warned that the

industry as evidenced

increased federal funds will still not be sufficient to cover all of their

by Ken Simonson,

transportation revenue needs.

chief economist at

Search: 12149614

Associated General Contractors. Search: 12158391

February 2016 Vol. 30, No. 2

Published by AC Business Media Inc.

201 N. Main Street Fort Atkinson, WI 53538 (800) 538-5544 • www.ACBusinessMedia.com www.ForConstructionPros.com/Asphalt

Published and copyrighted 2014 by AC Business Media Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage or retrieval system, without written permission from the publisher. Asphalt Contractor (ISSN 1055-9205, USPS 0020-688): is published ten times per year: January, February, March/April, May, June/July, August, September, October, November, December, with an additional Buyer’s Guide issue published in August by AC Business Media Inc., 201 N. Main Street, Fort Atkinson, Wisconsin 53538. Periodicals postage paid at Fort Atkinson, Wisconsin and additional entry offices. POSTMASTER: Please send change of address to ASPHALT CONTRACTOR, PO Box 3605, Northbrook, Illinois 60065-3605. Printed in the U.S.A. Canada Post PM40612608. Return Undeliverable Canadian Addresses to: Asphalt Contractor, PO Box 25542, London, ON N6C 6B2. SUBSCRIPTION POLICY: Individual subscriptions are available without charge only in the USA. The Publisher reserves the right to reject nonqualifying subscribers. One-year subscription to nonqualifying individuals: U.S. $45.00, Canada & Mexico $65.00, and $95.00 all other countries (payable in U.S. funds, drawn on U.S. bank). Single copies available (prepaid only) $10.00 each (U.S., Canada & Mexico), $15.00 each (International).

6 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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Track DENSITY IN REAL TIME. PA SS:

PA S S :

TEM P ER ATU R E:

250°

D EN S I TY:

TEM PERATURE:

220°

DE NS ITY:

95.1%

94.2%

PA SS:

TE M PE RATURE :

270°

DENS IT Y:

92.6%

Volvo Intelligent Compaction (IC) with Density Direct. Volvo has changed the game. Density Direct provides actual density calculations in real time — eliminating guesswork and reducing core sampling. Improve mat quality, do it in less time, get your bonus, and win more contracts with Volvo Density Direct. Learn more at volvoce.com/DensityDirect.

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February 2016 • Vol. 30, No. 2

EDITOR'S PERSPECTIVE

Lisa Cleaver, Editor

What’s a State to Do?

Published by AC Business Media Inc.

lcleaver@ ACBusinessMedia.com

hile we all breathed a sigh of relief to have a highway bill signed into law last December, we can all be honest and say that the five-year, $305 billion FAST Act is far from perfect. The FAST Act formally reauthorized the collection of the 18.4 cents per gallon gas tax, which is typically used to pay for transportation projects. It also includes $70 billion in “pay-fors” to close a $16 billion deficit in annual transportation funding. These offsets include changes to custom fees and passport rules for applicants who have delinquent taxes. The federal gas tax has been frozen since 1993, and Congress has been struggling for years to come up with a way to pay for a long-term transportation funding extension without raising the gas tax. According to a recent report in The Hill, a pair of House Democrats is now pushing the Obama administration to allow states to search for alternatives to the 18.4 cents per gallon gas tax. Rep. Peter DeFazio (D-Ore.) and Del. Eleanor Holmes Norton (D-D.C.) said in a letter to Transportation Secretary Anthony Foxx that states should begin experimenting with new infrastructure funding mechanisms now, despite the fact that Congress just passed a bill. “The FAST Act … does not resolve the long-term solvency challenges of the Highway Trust Fund,” the lawmakers wrote. “To ensure that we are not in the same position four years from now, we must immediately begin to identify real, workable funding solutions to carry our surface transportation programs through the 21st century.”

201 N. Main Street | Fort Atkinson, WI 53538 800.538-5544 • www.ACBusinessMedia.com www.ForConstructionPros.com/Asphalt

So, really, what are you trying to say? “Congress is sending the states a clear message,” says Patrick D. Jones, executive director of IBTTA (International Bridge, Tunnel, and Turnpike Assoociation). “The federal government is gradually moving away from providing a dedicated source of funding to support state transportation programs.” Many state governments have already begun searching for other funding sources to keep their highway programs whole. Several states have raised their own gas taxes in the last year. Public private partnerships (PPPs) are being implemented in others. Some states have raised the sales tax on fuel and cigarettes or have increased vehicle fees. California's Governor Jerry Brown is investigating a $65 annual vehicle fee that would raise about $2 billion a year for that state's crumbling roads. Another alternative states can consider: tolling. One benefit of tolling is the money you pay goes directly to maintain and improve the highways on which you travel. With less help from the federal government, it's going to be a challenge for states to find a dependable, sustainable stream of revenue to keep their highways and bridges modern, well-maintained, safe and efficient. And it’s clear states will have to take this problem by the horns and solve it themselves. What is your state doing to maintain its transportation network? Drop me a line at LCleaver@acbusinessmedia. com to discuss. Thanks for reading!

Publication Staff Publisher

Amy Schwandt

aschwandt@ACBusinessMedia.com Editor

Lisa Cleaver

lcleaver@ACBusinessMedia.com

Associate Editor

Jessica Stoikes

jstoikes@ACBusinessMedia.com

Ad Production Manager

Patti Brown

Art Director

April Van Etten

Sr. Audience Development Mgr

Wendy Chady

Audience Development Mgr

Angela Kelty

Advertising Sales (800) 538-5544 Sean Dunphy sdunphy@ACBusinessMedia.com Jill Draeger jdraeger@ACBusinessMedia.com Erica Finger efinger@ACBusinessMedia.com Tom Lutzke tlutzke@ACBusinessMedia.com Amy Schwandt aschwandt@ACBusinessMedia.com Eric Servais eservais@ACBusinessMedia.com Denise Singsime dsingsime@ACBusinessMedia.com

ForConstructionPros.com Digital Operations Manager

Nick Raether

Digital Sales Manager

Monique Terrazas

Editor

Larry Stewart

Managing Editor

Kimberly Hegeman

Change of Address & Subscriptions PO Box 3605, Northbrook, IL 60065-3605, Phone: (877) 201-3915 • Fax: (800) 543-5055 circ.AsphaltContractor@omeda.com

Reprint Services For reprints and licensing please contact Denise Singsime at (800) 538-5544 ext. 1245 dsingsime@ACBusinessMedia.com

List Rental Elizabeth Jackson, Account Executive, Merit Direct LLC, Phone: (847) 492-1350 ext. 18 Fax: (847) 492-0085 • ejackson@meritdirect.com

AC Business Media Inc. Chairman

Anil Narang

President and CEO

Carl Wistreich

Executive Vice President

Kris Flitcroft

CFO

JoAnn Breuchel

Vice President, Content

Greg Udelhofen

Vice President, Marketing

Debbie George

8 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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THE UNIFIED “UF” SERIES DRUM

SINGLE DRUM COUNTERFLOW

PROS: RUGGED! SKID MOUNTED or PORTABLE Built to last WARPAGE Resistant

SACRIFICES COMPROMISES

CONS:

YOU DON’T OWN ONE YET 13333 Highway 24 West Fort Wayne, IN 46814 Tel. (260) 672-3004 Fax. (260) 672-3020 www.almix.com Search: 10071910

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NEW PRODUCTS

Evoflex CA Maximizes Recycled Binder Performance Ingevity’s latest product allows the use of up to 50% recycled content in mixes

tate transportation agencies and private road owners view increased use of recycled materials as an environmentally responsible way to stretch limited transportation funding dollars. The Federal Highway Administration (FHWA) is also encouraging the use of recycled materials in the construction of highways to the maximum economical and practical extent possible with equal or improved performance. FHWA promotes the use of RAP because its utilization can have the greatest economic, environmental and engineering impact in pavement recycling. To meet these objectives, Ingevity has developed Evoflex CA, an engineered family of additives that allow for greater use of reclaimed asphalt materials. Designed to work with Evotherm warm mix asphalt (WMA)

technology, Evoflex CA is said to more effectively mobilizes the bituminous content of reclaimed asphalt pavement (RAP) and recycled asphalt shingles (RAS), even when using WMA production temperatures less than 275°F.

How it works Ingevity derives Evoflex CA additives from forestry products, providing an environmentally friendly, non-toxic solution to increasing the amount of RAP/RAS incorporated into mixes. Evoflex CA accomplishes this by effectively solubilizing the asphalt in recycled materials, increasing the blending of the virgin and the oxidized binders. High recycle-content mixes made with Evoflex CA have improved coating and workability with a wide variety of paving materials. When oxidized binders are fully incorporated into mixes, producers can maximize the full value of

their reclaimed materials. As more RAP/RAS is used, the difficulty of effectively blending the recycled binder with virgin materials also increases. This is where Evoflex CA comes in. Evoflex CA additives are designed to improve the contribution yield of binder from recycled materials. Evoflex CA additives also function as rejuvenators and offset the potential negative impact of increasing the use of highly oxidized materials. Greater amounts of reclaimed products can be added while Evoflex CA maintains flexibility and low temperature crack resistance. Evoflex CA allows you to: • Solubilize RAP/RAS to increase recyclebinder contribution • Facilitate blending of both virgin and oxidized asphalts • Improve low temperature mix performance • Maintain the intermediate temperature of the original binder

grade • Reduce the need to alter binder grades when using recycled materials For more information, visit ingevity.com. Search: 12092637

Evoflex CA Case Study Ideker: Route 78 in Jackson County, MO This thin lift re-surfacing project provided an opportunity to evaluate the benefits of cost savings and longevity of a high RAP/RAS mix utilizing Evoflex CA. Commonly, the binder contributed by RAP and RAS increases the stiffness of the mix. This leads to mixes that can be difficult to construct and roads that are prone to premature aging. The Missouri Department of Transportation's goal was to increase the use of RAP and RAS while also creating a quality mix that would be easier to place without compromising the agencies performance expectations. Evoflex CA successfully improved the low temperature properties of the mix while increasing the effective binder contribution from the recycled materials. Upon completion, the project received the “Excellence in Asphalt Paving and Quality Construction” award from the Missouri Asphalt Pavement Association. Ultimately, the use of RAP, RAS and Evoflex CA resulted in a high quality project at a great value for MoDOT.

10 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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roadtec.com 1.800.272.7100 423.265.0600

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NEW PRODUCTS Midland Machinery SPF-8 Road Widener The SPF-8 Road Widener is a foldable machine that transforms to 98.5 in. for transport without permits. • Capable of spreading material from 1 to 8 ft. from a 3-cu.-yd. fold-up hopper by way of a movable, variablespeed, 500-tph conveyor • Quickly transforms from right to left hand discharge of material depending on job requirements • 74-hp John Deere engine provides the power to push a fully loaded 18-wheeler Search: 12057765

Chicago Pneumatic SR 140 Soil Compactor The SR 140 soil compactor is suitable for all types of supporting and reinforcement courses, including gravel, sand, silt, clay and sub-base and base materials. • Operating weight of just over 14,000 lbs. • Features dual speed and dual amplitude with a drum width of 66 in. and a drum diameter of 48 in. • Kubota Tier 4 Final engine cross-mounted for easy service access • Standard ECO-mode maintains low engine rpm and noise levels and helps reduce fuel consumption by up to 15% • Spacious operator platform with vibration insulation, ergonomically positioned steps, an adjustable seat, battery disconnector and lockable storage compartment Search: 12156049

Level Assist from Superior Industries Superior Industries offers its new Level Assist option that automatically levels a plant once the machinery is raised to a desired height. • Once the plant is in its operating location, the operator hydraulically lifts the machinery to a desired height then engages the Level Assist by switching the control panel from manual to auto mode • Designed to reduce labor force required for setup from two or more to one • Available option for new or can be retrofitted to existing portable crushing, screening and washing plants Search: 12157015

Sakai SA33L-2 Trench Roller

Rhino RWL Loaders Rhino’s RWL wheel loaders feature repeatable fine modulation for superior bucket control with less spillage. • Electro-hydraulic implement controls and load-sensing hydraulic system with simultaneous lift and tilt capabilities for better control with less effort • 240-hp Cummins engine • Closed cab with ergonomic seat, air conditioner and radio • Models range from 6 to 31 tons; Rhino RTL Track Loaders also available • Bucket Capacity: 4.6 to 8 cu.yd. • Operational Weight: 41,006 lb. • Rated Load: 13,228 lb. • Breakout Force: 41,814 lb. Search: 12146985

The 24.6-hp SA33L-2 trench roller offers a tight turn radius that cuts in half the time spent on manholes, and a solid frame capable of withstanding severe conditions. • Standard infrared remote control system, or infrared remote and manual controls on the Dual Control model • Split-style drums enable easy 24- to 33-in. conversion • 19,460 lbs. of centrifugal force • Vibration frequency of 1,950 vpm and amplitude of .083 in. • Heavy-duty yet simple layout of the engine compartment along with marine-grade wiring, accessible sectional hydraulic hoses and a metal engine compartment hood with heavy-duty self-adjusting hood latches ensure durability and ease of maintenance and service • Molded polyurethane battery includes cast dynamic shock absorbers for shock mounting and added stability Search: 12146273

WHAT DOES SEARCH: 10000000 MEAN? Each product and advertisement found in Asphalt Contractor’s pages has a unique 8-digit code that can be entered into the search bar found at the top of www.ForConstructionPros.com/ASPHALT. By searching for the unique number, you will be instantly taken to the specific piece of online content where you can find more images, online exclusive information, related products and videos, and more!

12 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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THE FACES OF ASTEC PARTS

SHE’S ALWAYS YOUR PARTS PERSON When parts tech DONNA FLOYD is not helping her customers, you’ll find her camping in a matador red replica 1961 Shasta Airflyte. And when she gets back to the office and takes your call, she takes as much care to find the part you need as she does to find the perfect campsite, because she’s always your parts person.

An ASTEC parts tech knows that being successful in her job means that you count on her to deliver when needed. So when she takes your call she takes care to find exactly the part you need and then gets it to you as fast as possible. She’s always your parts person.

Anyone can stock parts and ASTEC stocks the world’s largest inventory of parts for asphalt plants. But ASTEC doesn’t just stock parts. With a team of 35 parts professionals, ASTEC delivers the industry’s best customer service.

Any part, any brand. We can help.

Search: 10072061

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NEW PRODUCTS Allmand Night-Lite NL5000 Light Tower

Spaulding RMV Hot Patcher The RMV Dump Patcher is designed to unload large amounts of asphalt in a short amount of time, giving a crew more time to finish their work. • Powered by two hydraulic cylinders that lift the hopper with ease and fluidity • Includes a 105,000-btu burner for diesel and automatic temperature controller • Heavy-duty steel construction with continuous welds • Comes with an adjustable 12-position hitch, tandem axles, surge/electric brakes and commercial-rated tires Search: 12131778

The compact Night-Lite NL5000 60-Hz light tower includes Allmand’s 1,250-watt metal halide light system and a vertical manual winch tower deployed from the rear to keep the operator away from the tower cables. • A stepping pad enables easy fixture adjustment and mast rotation from the ground • Genset Protect system is designed to protect the engine and generator from starting and stopping with AC power and ensures the lighting system is turned off at startup and shutdown • Kubota 1005 liquidcooled, Tier 4 Final/ CARB-certified diesel engine • 45-gal. steel fuel tank provides approximately 90 hours of runtime • Exterior operating controls and fuel fill neck allow for quick operation and refueling Search: 12146968

Caterpillar CB64B, CB66B and CB68B Tandem Rollers The 12- to 14-metric-ton CB64B, CB66B and CB68B feature 79- (CB64B) and 84-in. drum widths, a high-flow water spray system, increased operator comfort and enhanced technology via Cat Compaction Control. • Auto-Adjustable Compaction adjusts through the full range of amplitudes in as little as four seconds for uniform compaction throughout the mat • Pass-Count and Temperature Mapping systems provide real-time visual references of the passes made and asphalt mat temperatures • Machine to Machine Communication shares coverage and pass-count maps between the operating displays of multiple machines • 142-hp Cat C4.4 ACERT Tier 4 Final engine with standard Eco-mode and automatic speed control Search: 12140335

Wacker Neuson RD7 Walk-Behind Rollers The RD7 roller series has a compact design with dual smooth, beveled edge drums that allow for tight side clearance for compaction of asphalt and granular materials in confined areas. • 1,624-lb. RD7He includes an 8.2-hp Hatz diesel engine with electric start, while the 1,512-lb. RD7A has a 9.7-hp Honda gasoline engine • Feature a drum width of 25.6 in. and a high/low centrifugal force of 4,998/2,935 lbs. • Total hydrostatic drive with all hydraulic hoses and cables protected from damage • Shock-mounted, low-vibration handle offers multiple gripping points a center handle for fine control while finishing asphalt and a foot-operated handle lock

Bobcat S595 Skid-steer Loader This 74-hp 500-frame size skid-steer loader boasts a 2,200lb. rated operating capacity (ROC), making it suited for those who need to lift and carry more material without moving up to a larger machine size. • The 6,800-lb. vertical lift path model offers a 119-in. lift height to hinge pin • M-Series features include optimal operator comfort, machine performance and enhanced visibility • Standard two-speed travel allows operators to choose between low and high speeds to match jobsite conditions and tasks • Pressurized cab minimizes dirt and dust and keeps operators comfortable Search: 12154465

Search: 12156071

14 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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TURN GREEN INTO BLACK. USE LESS FUEL.

GENERAL COMBUSTION OFFERS A FULL LINE OF HY-WAY HEATERS HY SERIES · HYT SERIES · MKVO SERIES · ELECTRIC TANKS · SA ELECTRIC SERIES HEATERS · PI ELECTRIC SERIES HEATERS

All Hy-Way heaters deliver the highest efficiency by way of their unique turbocoil design. In fact, it’s the most energy efficient heater in the market with lower stack temperatures than competitive units. Which means your profit isn’t being wasted up the stack. With over five decades of unrivaled experience in efficient heat transfer, General Combustion helps you make more black. No other system saves you more. 5201 N. Orange Blossom Trail ∙ Orlando, FL 32810 ∙ 407.290.6000 ∙ GeneralCombustion.com Search: 10073093

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Long Drying Time Plus Long Mixing Time Equals

High Quality

MIX

DILLMAN UNIDRUM The robust, hard-wearing Dillman Unidrum takes full advantage of its long drum to produce a consistent, high-quality mix with up to 50%* RAP content. Add the optional V-Pack stack temperature control system to operate in the most efficient way possible. Only available on the ASTEC family of asphalt plants. *at 3% moisture

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DILLMAN UNIDRUM Features

• • • • •

Easily Retrofitted 200-700 Tons Per Hour Optional Astec Warm Mix System Optional V-Pack Stack Temperature System Backed by 24/7 Parts and Service Support TM

Search: 10073061

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TECHNOLOGY UPDATE

MultiCool Aids Compaction Calculations in the Field MultiCool can help in the planning process and in-field decision making. The app has been recently updated to make time-to-compaction calculations in the field easier. Depending upon mix temperature and air temperature, the time a roller operator has to achieve the desired density can vary significantly from day to day or job to job. MultiCool V2.0 was developed by Dr. David Timm and Ben Peters of Auburn University with funding from the National Asphalt Pavement Association (NAPA). It can be downloaded for Android devices through the Google Play app store or visit goaspha.lt/multicoolv2 to access the desktop or mobile web version. MultiCool has been validated in cold (Minnesota) and warm (California and Alabama) climates for typical Superpave mixtures, stone matrix asphalt (SMA) mixes, warm mix asphalt (WMA), reclaimed asphalt pavement (RAP), recycled asphalt shingle (RAS) and ground tire rubber (GTR) mixtures.

ultiCool is a user-friendly application that calculates the rate of cooling in an HMA mat during construction and was developed to help accurately predict asphalt pavement cooling time. It requires that the user input such items as the time of day (entered automatically according to the computer’s clock), latitude, air temperature, wind speed, mix information and lift thickness for each HMA lift, type of material being paved over, its temperature and whether or not the soil or base are frozen. The program then computes how quickly each lift of HMA will cool and when the next lift may be placed. This cooling rate prediction can help contractors better plan rolling operations to more efficiently achieve target mat density. This allows field personnel to make decisions concerning cold weather paving and the scheduling of HMA deliveries to the paving site. While it is no substitute for good judgement and on-the-job observations,

This cooling rate prediction can help contractors better plan rolling operations to more efficiently achieve target mat density.

While not a substitute for good judgement, Multicool can help in the planning process and with in-field decision making.

18 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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Search: 10074983

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PAVING INNOVATIONS

Town Rejuvenates

High-RAP Mix

For Heavy-Traffic Pavement 20 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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The Wellesley, MA, mill-and-fill project at a busy recycling area uses 40% RAP mix treated with new sustainable asphalt rejuvenator By Paul Fournier, Contributing Editor

mill-and-fill paving project employing hot mix with high recycled asphalt pavement (RAP) content was recently carried out at a busy recycling/transfer center in Wellesley, MA, to demonstrate the effectiveness of a new asphalt rejuvenator. Town officials and others are monitoring the performance of the 40% RAP mix that was dosed with Delta S, an asphalt rejuvenator product of Collaborative Aggregates. The Wilmington, MA, company sponsored the project and served as general contractor. The area chosen for the Wellesley demonstration lies within the town’s busy recycling and transfer center, where asphalt pavement has deteriorated due to the high volume of traffic, especially from heavily loaded trucks. The center experiences anywhere between 800 and 1,500 residents’ vehicles each day and about 4,000 on Saturdays. In addition, it undergoes continual traffic from the DPW’s regular 6-wheel, 35,000-pound trash collector trucks plus six to eight tractor-trailers that periodically pick up compacted refuse. Due to resulting pavement damage, the site was a good candidate for mill-and-fill and ideal for testing the new rejuvenator. The demonstration was authorized by the Wellesley Department of Public Works, headed by Director Mike Pakstis, who has indicated they are willing to try new things if they offer cost-effective alternatives that prolong pavement service life. Recycling asphalt pavement and asphalt shingles (RAS) falls within this category, since it reduces the amounts of expensive virgin materials required for pavement construction, freeing up funds for additional roadway improvement projects.

Limits to RAP/RAS share

A mill-and-fill paving demonstration sponsored by Collaborative Aggregates in Wellesley, MA, uses HMA containing 40% RAP and Delta S asphalt rejuvenator.

Despite the industry trend to increase asphalt recycling, there is a practical limit to the total amount of RAP and RAS that can be used in making hot mix asphalt for pavements due to the nature of the materials. As the percentages of RAP or RAS in mix designs increase, the higher viscosity and lower ductility of the embedded asphalt due to long-term aging in the field stiffens the mix and thus diminishes new pavement resistance to rutting and cracking. A remedy for this is the use of asphalt rejuvenators. Generally, rejuvenators can restore the original properties of asphalt binder such as viscosity and ductility. But traditional rejuvenators may contain lubricating oil extracts and extender oils, which may be derivatives of benzene, a substance toxic to humans and the environment. What’s more, some rejuvenators simply soften the binder but do not chemically reverse the oxidation of the aged binder in the RAP and RAS.

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVING INNOVATIONS The project began with the milling and removal of two inches of existing pavement on some 3,000 square yards of entry road, parking and trash recycling area. The hot mix asphalt, made to Massachusetts DOT specifications and manufactured by Rochester Bituminuous, was a dense-graded top course containing 6% asphalt binder, with 95% of the aggregate passing a ½-inch sieve.

In contrast, Delta S is a sustainable, or “green” non-toxic product that is safe for workers and the environment, according to Collaborative Aggregates, an affiliate of Warner Babcock Institute for Green Chemistry (WBI), the research firm that invented the asphalt rejuvenator. Derived from non-toxic renewable feedstocks, the new rejuvenator is designed to chemically reverse aging of existing asphalt binder and retard future aging and oxidation. This in turn helps minimize asphalt pavement rutting and cracking. Since Delta S also has warm mix additive capabilities, the company is marketing it as a sustainable, dual-action WMA/asphalt rejuvenator product.

Demonstration formulation Steve Viviano, the company’s vice president of business development, served as project manager for the Wellesley demonstration. Principal subcontractors were Mathias Corp. of Boston, for milling; Riverside Asphalt Services of Boston, for asphalt tack coat; and Cooper Bros. Paving of Saugus, MA. The hot mix producer was Rochester Bituminous Products of West Wareham, MA. The demonstration began with the milling and removal of two inches of existing pavement on some 3,000 square yards of entry road, parking and trash recycling area. Mathias Corp. used a Bomag BM 2000/60 for the milling and a Bobcat S750 skid-steer loader for cleanup and sweeping. After the area was swept, Cooper Bros. hand-applied packaged

RS-1 rapid-setting asphalt provided by Riverside Asphalt Services to the area in a ribbon pattern. Meanwhile, Rochester Bituminous used its Gencor drum mix asphalt plant to manufacture the approximately 340 tons of bituminous concrete required for the demonstration project. The hot mix asphalt, made to Massachusetts DOT specifications, was a dense-graded top course containing 6% asphalt binder, with 95% of the aggregate passing a ½-inch sieve. “The HMA was designed to have 6% total asphalt binder, so each ton contained 120 pounds of asphalt binder and 1,880 pounds of aggregate," Viviano says. “The RAP was previously analyzed and determined to contain 5% binder. Since each ton of hot mix contained 40% RAP, the sum of RAP aggregate and RAP binder equaled 800 pounds. Five percent of 800 pounds equals 40 pounds,

the weight of RAP binder. Thus the weight of virgin binder, a PG64-28, was 80 pounds, and the weight of virgin aggregate was 1,120 pounds,” Viviano says.

Dosing, and a WMA trait It was determined that the stiffer RAP asphalt binder would require dosing it with 4%, or 1.6 pounds, of Delta S per 40 pounds of binder, but in practice the liquid rejuvenator was decanted directly into the virgin asphalt tank at the rate of 1.6 pounds per 80 pounds of virgin binder. The effect of the rejuvenator on each ton of mix would be the same. “We could have added the rejuvenator to the mix in a number of ways,” Viviano noted. “For example, we could have sprayed it over the belt or bin for the RAP, or blended it in-line with the liquid asphalt using an injection system. “But it was easier in this case to pour it directly into the virgin asphalt tank,” he continues. “Delta S is a light liquid

22 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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PAVING INNOVATIONS

A Bobcat S750 used for cleanup loads excess material on a Peterbilt dump truck.

How to Make Sustainable Products for the Asphalt Industry Sustainable, or “green” non-toxic products, like Delta S are being developed by a staff of more than 35 scientists under scientist/entrepreneur John C. Warner, Ph.D., the president and chief technology officer for Warner Babcock Institute (WBI) for Green Chemistry. WBI is essentially an invention factory where sustainable technologies are created for all industries that employ chemicals including general construction and asphalt production. About 85% of the research at WBI is performed under contract with companies needing or wanting new sustainable products for their own operations. The other 15% of research is spent on finding new technologies for WBI’s proprietary purposes. WBI affiliate, Collaborative Aggregates LLC, was founded in 2014 to manufacture, market and sell engineered construction products developed by WBI. Delta S is one of those products.

Research is also underway on other construction-related products. One in late-stage development is a non-toxic, formaldehyde- and isocyanate-free thermosetting resin that is effective as an adhesive in engineered wood products. A different kind of scientist, Dr. Warner is both a researcher employing green chemistry to invent environmentally beneficial products, and a businessman making profits while fulfilling customers’ product needs. A pioneer in green chemistry, Dr. Warner in 1998 co-authored "Green Chemistry: Theory and Practice,” with Paul T. Anastas, Ph.D., which established the 12 Principles of Green Chemistry. The textbook was written to make budding chemists aware of the need to study toxicology and consider the effect that the manufacture and utilization of existing and new substances could have on the environment. In recognition of his work with green chemistry, Dr. Warner was awarded the 2014 Perkin Medal by the American Section of the Society of Chemical Industry for “innovation in applied chemistry resulting in outstanding commercial development.”

resembling vegetable oil, and when you pour it into the asphalt binder, you see it going into solution immediately.” Rochester Bituminous stored the HMA in its 50-ton silos at 325°F until the material was hauled to the Wellesley recycling center. The mix producer’s own trucks transported the material for the 50-mile trip to the Wellesley site. At the job, Cooper Bros. Paving first applied a levelling course of HMA over the site then followed this with the placement of the 2-inch top course in a single lift using a LeeBoy 8500 paver. The mix laydown temperature was approximately 305°F. When the contractor’s 5-ton Galion roller finished breakdown rolling, the mat temperature was about 250°F. A 2-ton Beuthling B200 static roller was used to provide finish compaction, with the HMA still exhibiting workability even though the mat temperature was only registering about 200°F.

NCAT’s tough testing The 40% RAP composition for the Wellesley demonstration mix is the highest ratio tested to date by Collaborative Aggregates for an asphalt pavement project on this scale. A somewhat smaller installation of asphalt pavement mix treated with Delta S rejuvenator was placed at the test track of the National Center for Asphalt Technology (NCAT) in Opelika, AL, to document the rejuvenator’s performance. However, the NCAT installation involved a much more aggressive mix design, and is being subjected to far greater vehicle loads, than the Wellesley project. NCAT’s 1.7-mile oval pavement test

Final compaction was accomplished using a 2-ton Beuthling B2000 static roller, with mat still exhibiting workability at 200°F.

24 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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PAVING INNOVATIONS track is designed for accelerated pavement testing of up to 46, 200-foot-long sections of track in two-year trafficking cycles with loading that simulates 10- to 15 years of heavy interstate truck traffic. The Delta S test section was installed at the track in August 2015 for NCAT’s sixth research cycle, at the same time as a group of sections sponsored by nine state DOTs and the FHWA were placed

to study thin overlay pavement cracking. Although Collaborative Aggregates’ NCAT section has 20% RAP content — just half that of the Wellesley project — it also contains 5% RAS. The RAP used for this section has an upper failure temperature of 110°C, and the RAS failure temperature is 189°C — both temperatures being substantially higher than usual for such applications.

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Furthermore, while shingles embed about four to five times as much asphalt as RAP, the recoverable asphalt is considerably stiffer and more costly to incorporate in HMA. Five percent RAS is the upper limit currently being employed by most asphalt producers for commercial operations. The cracking group sections at the NCAT track have mixes containing varying combinations of RAP and RAS. Even though the Delta S section is not part of the cracking group, NCAT officials are going to compare the performance of Collaborative Aggregates’ stand-alone section to one of the group sections that is similar in design and construction but doesn’t contain a rejuvenator. NCAT believes the results of that comparison will provide them with additional data points to study while they look for ways to accurately predict the crack resistance performance of pavements containing large amounts of recycled asphalt products.

More to come

WHAT’S BEHIND YOUR DASHBOARD? 1 0 2 8 5

Cooper Bros. Paving first applied a levelling course of HMA over the site then followed this with the placement of the 2-inch top course in a single lift using a LeeBoy 8500 paver.

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The documentation of Delta S performance at NCAT, with its warm Alabama climate, will be supplemented in the near future with similar documentation of a test section in a colder area of the U.S., according to Collaborative Aggregate’s Viviano. In addition, he indicated there will be more projects like Wellesley taking place elsewhere throughout the U.S. to demonstrate the effectiveness of the company’s new sustainable asphalt rejuvenator.

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26 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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PAVING INNOVATIONS

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Valley General Construction uses machine control technology during a project that covers approximately one-mile total of roadwork on the five streets in the JSCCR Subdivision in the Matanuska-Susitna Borough in southern Alaska

or most people the acronym, JSCCR, is a definite puzzler. What it stands for is Juniper, Spruce, Cranberry, Cottonwood, and Rose, which are the names of the roads in a heavily-wooded

residential subdivision located in the Matanuska-Susitna Borough in southern Alaska, not far from Palmer, AK. In 2014, the Matanuska-Susitna Borough committed to fund an upgrade of the JSCCR Subdivision roads. The

This was the first project the Valley General Construction used machine control technology on an excavator.

Subdivision is roughly square shaped and encompasses approximately 200 square acres. The country dirt roads within the JSCCR Subdivision are laid out in a grid pattern. The Borough’s plan is to have the roads brought up to the Borough standard of asphalt-paved roads. The JSCCR Subdivision upgrade is on a two-year plan. The objective for year one is to raise the embedded dirt roads to grade and then let them winter over so that in year two they can be paved. Valley General Construction LLC, based in Palmer, won the $350,000 contract for the first phase work. Valley

30 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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PAVING INNOVATIONS

The objective of the first phase was to raise the embedded dirt roads to grade in order to get them ready to pave with asphalt after the winter.

General was founded in 2007 and is considered a small-size excavating and grading union contractor with its six to eight employees. The company owners have more than 80 years combined experience in the construction industry. Roadwork and commercial projects are the bulk of the business Valley General engages in within its local radius, although with Anchorage being a mere 40 miles or so away via the Glenn Highway, the company does complete projects in the big city area. “Since the roads are embedded below grade, there have been major drainage problems,” stated Brian Hooks, project manager and co-owner for Valley General Construction. “We needed to not only bring the road up to gradem, but build in a culvert to address the water run off.” The network of roads within the subdivision became an engineered project. The Borough’s engineers produced

CAD drawings with the 12-footwide roads, three-foot-wide culverts, and cut-ins for 50 driveway approaches. “I took the engineers’ drawings and used Topcon MAGNET Office Site to create a site model and files that could control the excavator and dozer we used on the project.” Hooks says. “We knew the project would benefit from our use of GPS machine control.”

Technology training Hooks is no stranger to machine control technology. “About six years ago, I took an introductory class on GPS machine control through my local union hall,” he says. “A couple weeks after that I bought a simple system on Craig’s List.” With the machine control system purchased online, Valley General was able

to see tangible benefits of improved productivity. There were also frustrations because the system was not capable of accessing the GLONASS satellite system, which meant it was restricted to the available GPS coverage or the L1 C/A signal. Hooks partnered with GPS Alaska Inc. based in Anchorage and received additional training and help selecting a more robust system for the company’s CAT dozer. Valley General purchased the Topcon 3D-MC2 machine control, which is designed to access all satellites and provide position updates up to 100 times per second. The 3D-MC2 sensor combines a gyro, compass and inertial sensor to measure the X, Y and Z position as well as the roll, pitch, yaw and acceleration of the dozer. The Topcon system can access both GPS and GLONASS satellites, which meant that Valley General has access to more than double the number of satellites. Additionally, Valley General purchased a Topcon X62 excavator grade control system for its Hitachi ZX210-6 hydraulic excavator with operating weight of 47,245-48,238 lbs. and Bucket Force (ISO) of 35,520 lbs. This was the first project the contractor used machine control technology on an excavator.

The project The machines were used on the approximate one-mile total of roadwork on the five streets in the JSCCR Subdivision. The embedded roads were already several inches below grade. Excavation will

Excavation brought each road to a uniform 10-inches below grade before lifts of fill soil, crushed stone and a binder-layer of reclaimed asphalt pavement (RAP) were added.

32 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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bring each road to a uniform 10-inches below grade before lifts of fill soil, crushed stone and a binder-layer of reclaimed asphalt pavement (RAP) are added. Once completed, the roads will winter over until next spring. Alaskan winters are long, so the Borough wants to adjust the roads after several freeze-thaw cycles can occur during the winter season before a finished asphalt surface is paved. The JSCCR Subdivision project required 4,000 cubic yards of fill dirt and 8,000 cubic yards of #5 crushed stone. Additionally, 250 feet of culvert pipe was placed. “We completed in two weeks,” Hooks says. “It went well because we have machine control technology. Our accuracy is spot on, so we’ve eliminated wasted time with rework. “Our machine operators can literally go out onto the job and know, by

looking at their monitors, what needs to be done,” Hooks continues. “The project is stakeless, so we don’t need surveyors or have delays when a stake is run over. Plus, we also eliminated the need for a worker to walk along with the excavator for spotting and checks.”

“We’ve been using the technology for so long, it’s hard to imagine running a project without it.”

Saving time It’s been estimated that the JSCCR Subdivision project would have taken twice as long to complete without the use of machine control technology. “We’ve been using the technology for so long, it’s hard to imagine running a project without it,” Hooks says. “In fact, if someone took it away, people would walk out the door ... probably, following me. It’s that important.” Valley General’s work in the JSCCR

Subdivision has successfully been completed. Officials with the MatanuskaSusitna Borough are happy with the results. When asked what he remembers most about the project, Brian Hooks said: “I’ll always remember this being our first project using machine control on an excavator and how easy it was, and how it saved us on needing a walk along worker. And I’ll remember how good the roads looked when we left the subdivision ... we did nice work there.”

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PAVING INNOVATIONS Weiler P385A Asphalt Paver

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Atlas Copco Dynapac CP2700 Pneumatic-Tired Roller The Dynapac CP2700 pneumatic-tired roller for soil compaction as well as asphalt finishing and sealing applications features a spacious platform, ergonomic controls and a rotating, sideway-sliding seat and steering assembly. • Tier 4i-compliant engine • Dual-circuit braking system maintains full braking effect even if one circuit is disabled • Compacting width of 7.55 ft. and a maximum operating weight of 59,000 lbs. • Optional temperature sensor and DCA-A analyzer can play back the rolling pattern and produce a printout of all relevant information Search: 12051951

Carlson CP75 Commercial Class Paver The CP75 commercial class paver features a 74-hp Cummins Tier 4i engine delivering more power, improved fuel economy and high torque. • Electrically heated EZC813 screed with an 8- to 13-ft. standard paving width or optional 8- to 15-ft. EZC815 screed • Screed-mounted controls provide an intuitive platform that keeps the controls relative to the operator • One-piece forward tilting hood and forward access panel over the hopper for easy maintenance and serviceability • Built with heavy-duty replaceable floor plates, hardened steel auger flights and a rebuildable platform Search: 12087872

Chicago Pneumatic Ride-on Asphalt Rollers This complete line of compact tandem asphalt rollers includes articulated models in both gasoline and diesel versions. • AR90G gasoline version features vibration on the front drum, with drive on both the front and rear drums, while the diesel-driven AR100 comes with vibration and drive standard on both front and rear drums • AR120 features noise-reduction technology and is equipped with a Kubota watercooled diesel engine • Models feature spacious platforms, ergonomically positioned steps, shock mounts and a sliding operator seat • Sleek, legible instrument panel includes a warning panel and a fuel gauge Search: 12043363 Search: 10074819

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVING INNOVATIONS Sakai GW750-2 Pneumatic Roller

Vögele MT 3000-2i Material Transfer Vehicle The 56,000-lb. MT 3000-2i is powered by a 215-hp Deutz water-cooled, Tier 4i-compliant engine, has an 18-ton storage capacity and can move 1,300 tph. • Active remixing achieved by two 16-in.-diameter conical augers in the receiving hopper, and passive remixing achieved via a 17- or 22-ton “receiving insert” in the paver hopper • Receiving hopper empties in advance of the next dump, while the rear-tilting front of the hopper moves stray material toward the conical augers • Auto feed function automatically slows or shuts down feeding when the paver hopper insert is filled • Propel system with auto distance control keeps the feeder at a pre-set distance from the paver

The 20,370-lb. GW750-2 develops a dynamic gyratory action that combines the kneading action of a pneumatic tire roller with the high forces generated by a vibratory roller. • Seven 16-in.-wide pneumatic tires include three vibrating tires positioned on the front axle and interspersed with four on the rear for a 77-in. total overlap coverage and rolling width • Five force settings ranging from 20,580 lbs. of static force to over 55,000 lbs. of total applied force are switchable from the operator’s station • Features 38% gradeability and delivers a vibration frequency of 2,400 vpm • 123-hp Isuzu 4jj1XDIA water-cooled, turbocharged engine and hydrostatically driven axles • Rubber-isolated operator’s station includes dual seats and instrumentation Search: 12113133

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Caterpillar AP600F and AP655F Asphalt Pavers The 8-ft. AP600F wheeled paver and AP655F rubber track paver with Mobil-Trac undercarriage come with a standard Eco-mode or an Advanced Eco-mode with automatic engine speed control. • 173-hp C4.4 ACERT Tier 4 Final engine • Available with SE50 V and SE60 V vibratory screeds or SE50 VT screed with vibration and tamper bars • Maximum paving widths from 21.3 to 26.3 ft. • Refined heat distribution of screeds combines with the 70-kW integrated generator bring the screed to the proper temperature in approximately 15 minutes • Feature intuitive touch screen operation, single-button feeder system activation, auto fill feeder system, quickchange heating elements and front wheel assist Search: 12140296

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40 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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PAVEMENT PRESERVATION

New Research

DRIVES

Emulsified Asphalt Bond Coat

BEST PRACTICE By Tom Kuennen, Contributing Editor

s new evidence of their usefulness unfolds, fresh attention is being paid to use of emulsified asphalt tack or bond coats in bituminous

paving. They’re commonly called “tack” coats, but as their purpose is to bond one layer of asphalt to another layer of

pavement, industry is beginning to dub them “bond” coats. The same way that fragile, thin veneers of wood are glued to each other to form a robust sheet of plywood, research shows layers of asphalt pavement perform better when bonded to each other. “An emulsified asphalt tack coat produces a strong adhesive bond without

slippage between an existing pavement and a new overlay,” reports the Colorado Asphalt Pavement Association in its 2013 report, Best Practices for Applying Undiluted Emulsified Asphalt Tack Coats. But the performance of this adhesive bond can be endangered by poor placements. • Underscoring this new attention to

42 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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Successful bond or tack coat application will cover complete paving width and will have double or triple overlap by nozzles that are aligned the same way. Photo Credit: Colorado Asphalt Pavement Association

emulsified tack or bond coats was the recent release of National Cooperative Highway Research Council (NCHRP) Report 712, Optimization of Tack Coat for HMA Placement (for your copy, search “NCHRP Report 712”). • In cooperation with the Federal Highway Administration, since January 2015, the Asphalt Institute has been

presenting workshops on the rationale for and proper placement of bond coats. They’ve been conducted for state DOTs from coast to coast, and a summary presentation was conducted at the October Pavement Preservation & Recycling Alliance (PPRA) conference in Niagara Falls, ON. • In a widely distributed spring 2015

report, the National Center for Asphalt Technology (NCAT) reiterated the importance of bond coats, and the need for correct placement. • New value-added bond coat products have come into the market which enhance performance, and reduce undesirable tracking of emulsion onto adjacent roadways, curb cuts, parking

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVEMENT PRESERVATION lots and sidewalks. • Computerized distributor trucks – replacing the old driver-controlled tachometer-based systems – are taking the guesswork out of onthe-job emulsion placement. In the meantime, “spray pavers” – which apply bond coats immediately in front of the screed – are getting new attention for use for thin and ultrathin bonded overlays.

Scherocman. In the past, application of tack or bond coats mostly has been a “seat of the pants” operation, but this is changing, the report says. “Selection of an optimum tack coat material and application rate are crucial in the development of proper bond strength between pavement layers, says NCHRP 712. “In general, selection of tack coats has been mainly based on experience, convenience and empirical judgment. In addition, quality-control and qualityassurance testing of the tack coat construction process is rarely conducted, resulting in the possibility of unacceptable performance at the interface and even premature pavement failure.” To this end, the report articulates optimum application methods, equipment type and calibration procedures, application rates and asphalt binder materials for the application of bond coats, and recommends revisions to AASHTO methods and practices. A significant driver in this report is the development of two new devices for testing of bond coats, the Louisiana Tack Coat Quality Tester (LTCQT) and the Louisiana Interlayer Shear Strength Tester NCHRP Report 712 gives snapshot of tack (LISST), the former for field use or bond coat usage as it is today, and can be and the latter for lab use. downloaded at no charge. T he LTCQT ev aluate s the quality of the adhesive strength of bond coat on the jobsite, and adds a new NCHRP sets stage dimension of quantification of field NCHRP 712 set the stage for the current testing of bond coat applications. To excitement in emulsified asphalt tack or complement this device, the LISST was bond coats. This practical study – develdeveloped for the characterization of oped by the Louisiana Transportation interface shear strength of cylindrical Research Council (LTRC) of Louisiana specimens in the laboratory State University for the Transportation “The LTCQT is a small test unit that Research Board – looks at the existing can measure the bond strength of a state of bond coat application and sets tack coat in the field,” said Edward Harout guidelines for best practice. rigan, TRB staff officer. “The LISST is a The study was developed by LTRC test fixture fitted into a universal testing researchers Louay N. Mohammad, Momachine to measure the interface shear stafa A. Elseifi, Abraham Bae, and Nastrength of a tack coat in a field or labchiketa Patel; Joe Button of Texas A&M oratory specimen. With the LISST, the University; and consulting engineer Jim effects of pavement surface types and

SPRAY conditions, tack coat material types and tack coat application rates and methods on tack coat performance can be assessed.” LTRC’s research for this project also resulted in the development of a training manual, presented as an appendix in the report. The training manual provides a comprehensive presentation of the recommended construction and testing procedures for tack coat materials.

Need for bond coats The need for bond coats is clear, but their application is inconsistent and varies widely among both contractors and road agencies. Some local road agencies don’t provide detailed bond coat specs. In its own way, at least one DOT doesn’t require them on milled surfaces. If tack coats are not a contract pay item, their application may be at the mercy of the contractor, who might consider bond coats an additional expense that is not specified.

44 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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AY PAVER “If the overlay can’t stick it’s not going to bond,” and if we don’t get the bond, we’re wasting our money.” Nonetheless, best practices are established. For example, for maximum service, bond coats should be evenly distributed across the full width of clean pavement, not just as the commonly seen narrow spritzes on the substrate. Spray bar nozzles must overlap, ideally in multiples of three; triple overlap is recommended for higher application rates such as chip seal, but may not be achievable for lower rates of bond coats.

The emulsion must be dispersed with the right spray pattern, at the right temperature and volume. Long after the paving is completed, inadequate adhesion between two layers of bituminous mix may cause problems in the mat above. “For the effect of tack coat coverage, the use of 50% coverage significantly reduced the interface shear strength by a factor ranging from 50% to 70%,” says NCHRP 712. “In addition, the use of 50% tack coat coverage resulted in inconsistent and non-uniform interface bonding behavior for tacked surfaces.” “If the overlay can’t stick, it’s not going to bond,” said consulting engineer Dale Decker, P.E., at a seminar on tack coats during World of Asphalt 2015 in Baltimore. “And if we don’t get the bond, we’re wasting our money.” Moreover, from the owner and contractor point of view, this bonding of layers via asphalt emulsions comes at a relatively small price. “An analysis of bid tabs using 2013

A spray paver has a self-contained emulsion tank and places bond coat directly ahead of asphalt mix.

data shows that the cost of tack coat is relatively minor compared to other components of a typical paving project,” Decker said. “Therefore, the risk of a poor or a compromised bond from not applying tack should be deemed too great when one considers the ramifications of the loss of fatigue life from this condition. Tack is such a cheap component that it makes little sense to shortchange this critical step and introduce so much risk.” As indicated, the possibility of skipping the bond coat arises with milled surfaces. “Some research indicates the skipping of tack on a milled surface will still result in adequate bonding of layers,” Decker said. “The weight of research, however, indicates that the use of tack improves the bond of a milled

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVEMENT PRESERVATION surface that has been properly cleaned. As with the first scenario, the cost of tack is so small relative to the cost of premature pavement failure, it is foolhardy to skip applying tack.” Do new pavements need tack coats? “NCHRP recommends applying tack coat always,” Decker said. “I don’t disagree with that. Tack coat is the cheapest insurance you can possibly buy as a contractor. It just makes a lot of sense.” The Asphalt Institute also recommends tacking between all lifts.

Types of bond coats Bond coats use either straight liquid asphalt, cutback asphalt or asphalt emulsions, but for a number of reasons, asphalt emulsions constitute the lion’s share of bond coat applications by far. “The most widely used tack coat material in the world is emulsified asphalt,” NCHRP reports, adding emulsified asphalt, or asphalt emulsion, is a nonflammable liquid substance that is produced by combining asphalt and water with an emulsifying agent. A survey in the report indicated that worldwide, approximately 92% of tack coat applications used asphalt emulsions. It’s easy to see why asphalt emulsions are preferred for bond coats. Straight or “neat” liquid asphalt must be kept heated to stay liquefied, and that poses burn hazards and other safety problems as

the distributor moves around on the site. Asphalt – what remains after lighter hydrocarbons have been distilled from the crude oil at a refinery – may also be liquefied by reintroducing some of those lighter hydrocarbons, such as kerosene or diesel, as a solvent. These “cutback” asphalts have been widely used in the past for tack coats, but today are discouraged because as the solvents evaporate, volatile organic hydrocarbons are released which contribute to smog and other environmental ills. An asphalt emulsion is a homogeneous mixture of two insoluble substances, oil and water. In it particles of liquid asphalt (the dispersed phase) are surrounded by molecules of water (the continuous phase). Compared to hot liquid asphalt, asphalt emulsions have greatly reduced viscosity, are safe to use at lower temperatures and allow liquid asphalt to be spread more evenly and thinly. Emulsified asphalt is produced by dispersing tiny globules of asphalt cement into water treated with a small quantity of emulsifying agent. The dispersion takes place in a powerful blender, called a colloid mill, where spinning blades break or shear the liquid asphalt into suspended microscopic particles. The water, or soap solution, is immediately introduced to form the emulsion. The emulsifier — an engineered

surfactant (detergent) or surface-active agent — maintains the microscopic asphalt droplets in a stable suspension, keeping them from recombining. The amount and type of surfactant used, along with other variables, controls properties of the emulsion critical to performance in the field application. For example, emulsifiers affect the “break” time following placement on a road, in which the water evaporates, leaving the residual asphalt behind. Asphalt emulsions partially are categorized as rapid setting (RS), medium setting (MS), slow setting (SS) and quick setting (QS) emulsions. Today, the most common types of emulsions used for bond coats include slow-setting grades of emulsion such as SS-1, SS-1h, CSS-1, and CSS-1h and the rapid-setting grades of emulsion such as RS-1, RS-2 and CRS-1.

Tips for successful bonding The correct placement of asphalt emulsion as a bond coat is important for longlived asphalt pavements. Here are some tips for a successful bond coat: • The correct application depends on four variables, according to manufacturer E.D. Etnyre & Co. They are the desired application rate, in fractions of a gallon per square yard; the forward ground speed, in feet per minute; the asphalt pump output, in

A bond coat placed full lane width, but tire tracking is evident as emulsion is picked up from roadway and placed onto adjacent pavements.

46 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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PAVEMENT PRESERVATION gallons per minute; and the width of the spray in feet. The onboard metering system gives the operator precise control of the application of asphalt, with either manual or computer control. • The spray temperature of the emulsion is important. If it’s too cold, the asphalt emulsion may not flow properly and can cause issues with the distributor pumps. If it’s too hot, the emulsion may separate or “break” in the tank. The temperature depends on the particular emulsion used, consult with the emulsion manufacturer for specific reccommendations. Document the details in case you have to reconstruct what you did. • Keep the storage and distributor tanks clean, especially when changing from one emulsion to another, for example, emulsion for a bond coat to emulsion for a chip seal. “Empty that tank and clean it,” Decker urges. • Nozzle alignment is an important part of the process; get all nozzles at the same angle. If not, a nonuniform spray pattern will result. “Try to achieve a triple overlap,” Decker said. “A double overlap can work too, but triple is the most common and a little more forgiving. A triple overlap ensures uniform placement of material, and that’s what we want.” • Not only do the nozzles have to be aligned the same way, all nozzles need to be the same size and type. Understand what kind of nozzle you have, and make sure they are designed for the intended application rate. Nozzles used for chip seal operations typically will not perform well in a bond coat application. • Height of the spray bar is important. In the old tachometer-based system, as the amount and weight of emulsion in the tank decreased, the spray bar rose. The operator had to account for the rising height of the spray bar, but

“Try to achieve a triple overlap; a double overlap can work too, but triple is the most common and a little more forgiving.” today’s computer-driven systems do that automatically, Decker said. • Calibrate your distributor to confirm what’s being put down. “This is not rocket science,” Decker said. “Before you spray, weigh some pads that are flat and absorbent. Cotton diapers are a good option. Lay them down flat on the roadway, drive over them with the distributor, and pick them up and weigh them again. That will indicate whether the distributor is working at the right distribution rate.” ASTM D2995-14: Standard Practice for Estimating Application Rate and Residual Application Rate of

Four variables affect application rate of asphalt emulsion bond coat. Photo Credit: E.D. Etnyre & Co.

Bituminous Distributors is a test standard that describes this process. • Clean or sweep the pavement before application. Adjust the application rate as you need to, depending on the age and condition of the pavement. • The amount of the bond coat material applied is important. “If we don’t use enough tack, we will get sliding between layers,” Decker said. “If we use too much tack, we can get a slip plane that will cause the same problem.” • If a fine milled surface texture is present, less tack will be required than a standard texture. A really rugged surface will use more tack coat to cover as it presents more surface area. Don’t use tack coats over open graded mixes. For more information about bond or tack coats, or about asphalt emulsions, visit the Asphalt Emulsion Manufacturers Association at www.aema.org.

48 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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PAVEMENT PRESERVATION

Three Training Resources to Get the Most from the Preservation Associations By Michael Dougherty, Online & Social Media Marketing Manager for AEMA-ARRA-ISSA

ith more than a decade of working together through the Pavement Pre servation & Recycling Alliance (PPRA), the Asphalt Emulsion Manufacturers Association (AEMA), the Asphalt Recycling & Reclaiming Association (ARRA), and the International Slurry Surfacing Association (ISSA) bring a wealth of knowledge to their members and others with involvement in pavement preservation through their meetings, seminars, publications, educational resources and network opportunities. In line with “Getting Value from Your Industry,” the theme of the annual meeting on February 23-26 in Bonita Springs, FL, we focus here on an education resource from each to enable you to get the most from the educational benefits our associations provide.

Asphalt emulsion manual AEMA, through a partnership with the Asphalt Institute Asphalt Institute(AI), (AI), offers offers thethe Basic Basic Asphalt Emulsion Asphalt Emulsion Manual, Manual, currently currently in its in fourth its fourth edition. edition. This manual is the industry’s key publication for explaining the characteristics of asphalt emulsions and their uses. The Basic Asphalt Emulsion Manual also contains information about when, where and how emulsions should be used. It will help you evaluate pavement systems for construction and maintenance and choose the emulsion that best fits your project’s specific conditions. The 4th Edition includes a glossary and index, the latest information about emulsion testing, grades and uses, new best practices guides, troubleshooting lists, coverage of all emulsion applications, improved organization and layout.

It is also fully illustrated with new photos and graphics.

Asphalt recycling publication ARRA offers AEMA, through the Basic a partnership Asphalt Recycling with the Asphalt Manual – 2nd Edition, Institute or BARM2, (AI), which of fers is the single the Basicmost Asphalt comprehensive EmulsionpublicaManual, ever tion currently produced in itsonfourth the subjects edition. of hot in-place recycling, cold planing, fulldepth reclamation, and cold recycling. Each section offers chapters on detailed project analysis, mix design, construction, specifications and inspection. Also included is a 22-page introduction providing detailed definitions of all asphalt recycling and reclaiming disciplines (including hot recycling), chapters covering rehabilitation strategies and project evaluation and a glossary of terms and acronyms. This manual is not written in such detail so that one could use it to completely evaluate, design, specify and/or construct an asphalt recycling project. It does, however, provide information on various asphalt recycling and reclaiming methods, benefits and performance of asphalt recycling and reclaiming, project selection guidelines, mix design philosophies, construction equipment requirements and methods, quality assurance, inspection and acceptance techniques, specification requirements and definitions and terminology.

Pavement preservation web training ISSA provides AEMA, throughfree a partnership web-based with trainthe Asphalt ing sponsored Instituteby (AI), theoffers Federal the Highway Basic Asphalt Emulsi\ (FHWA). Through a seAdministration ries of online classes, participants can learn cost-saving pavement preservation techniques that benefit your agency/

organization with this training based on the ISSA High Performance Slurry Systems Inspectors Manual, the ISSA Design Technical Bulletins and the Asphalt Emulsion Manufacturers Association’s Basic Asphalt Emulsion Manual. Currently awaiting the launch of their Phase Two classes, ISSA’s Phase One web-based training addresses two core disciplines. The first, “How to Construct High Quality Chip Seal Treatments,” is an introduction to best construction practices for chip seals. This course provides an overview of chip seal treatments and why they are needed. It discusses selecting the appropriate materials for chip seals and how to store, transport and apply sprayed asphalt treatments. This module also explains best practices for equipment. The two-part class “How to Construct High Quality Slurry Seal and Micro Surfacing Treatments” focuses on providing practical information to assist in the construction and inspection of high performance slurry system projects (slurry seal and micro surfacing) and construction best practices of both slurry seal and micro surfacing as published in the ISSA High Performance Slurry Systems Inspector’s Manual. These items are just some of the many resources available from AEMA, ARRA and ISSA to anyone looking to implement and promote the highest standards of ethics and quality of the technologies, processes and applications within the pavement preservation and recycling industries. To learn more about these resources and the associations who provide them, you can visit ppralliance.org/ resources.

50 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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All stackers create material segregation.

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PAVEMENT PRESERVATION Kennametal Road-Ready Milling Drums The Road-Ready milling drums feature Pro-Fit or Quick-Change block systems, and are balanced to reduce machine vibration. • Drums designed to specific customer parameters • User-selectable design elements include cutting pattern, diameter, width, advance rate and rpm • Drum configurations also available for a number of pavement conditions and road machine OEM specifications • Maintenance tool kit consists of two wedge pullers, a flex drill, bucket spare sleeve and sleeve-removal tool Search: 10087727

See Us At World of Asphalt Booth #1741 Atlas Copco Dynapac PL2000S Cold Planer

Advanced Automation for Asphalt Drum Mix Plants

Leveraging Libra’s 40+ years of experience designing and manufacturing asphalt plant automation, the PlantWise Drum Mix Control System offers producers unparalleled technology, ease-of-use, and configurability. • Adaptability for Retrofit or Total Plant Control of Nearly Any Plant

• Real-Time Trending of Key Process Parameters

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The Atlas Copco Dynapac PL2000S hydraulically powered, high-capacity cold planer features four-track steering, a front loading system and a mechanical belt-driven cutting drum. • Working width of 79 in. and a 13-in. cutting depth • Operated by two joysticks • Automated sequential processes for conveyor belts and water spraying system • 600-hp Cummins QSX 15 diesel engine • 977-gal. water tank Search: 10078174

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The PM200 half-lane milling machine offers an optional 88-in. cutting rotor in addition to the standard 79-in. rotor. • 66,359-lb operating weight or 69,445 lbs with optional rotor package • Quick-release conical tool holders • 12.6-in. maximum cutting depth • Optional dust-reduction package with 88-in. rotor option Search: 10077596

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52 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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SAKAI Road Planer and Stabilizer

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The ER552F high-speed pneumatic tire road planer and PM550 road stabilizer offer easy access to the cutting teeth and toothholders for servicing and tool repairs and replacement. • ER552F road planer features a motor grader-like bogey suspension system, 561-hp Tier III diesel engine and an 81-in.-wide cutter drum assembly that cuts to 9 in. deep in one pass • Four-wheel-drive PM550 road stabilizer includes a high-torque, two-speed rotor, a 57-gpm top working speed and a 496-hp Komatsu six-cylinder Tier III diesel engine • Optional auto-spray emulsion system Search: 10240407

The Poly Bolt-On TUFPADS HIGHTOP track pads are now available in 10-, 12-, 14- and 16-inch versions for different brands and models of asphalt milling machines. • Designed to last 25% to 50% longer than standard bolt-on track pads • Bolt onto a steel triple grouser shoe for easy installation and removal and reduced replacement costs • Available as a TUFPADS BLUES track pad with extreme blue polyurethane, which lasts 15% to 30% longer than the original black polyurethane Search: 10080260

Wirtgen 3800 CR The 3800 CR is able to cold-in-place recycle a full lane of pavement in one pass, stabilizing with foamed asphalt “green mix” or any other stabilizing medium. • With a conveyor mounted, it will also serve as a full-lane cold mill • In recycle mode, the full-lane working width is complemented by a recycling depth of up to 6 in. • In the cold milling mode, it will mill to 13.75 in. deep in the upcut mode Search; 10282012

Search: 10074524

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVEMENT PRESERVATION BOMAG BM 600-15 Milling Machine

Blastrac BMP-4000 Ride-on Milling/Sawing Machine

Roadtec RX-600e/ex

The BMP-4000 ride-on sawing and milling machine is designed for large applications such as road construction. • Changing the hydraulic motor allows swapping between milling and sawing • Equipped for sawing 2.36 in. deep and milling 2.5 in. deep • Double hydraulic micrometric adjusts to set the working depth • Milling drum made from a single piece of specially selected steel • 60 heavy-duty, quick-change milling picks Search: 10858378

Roadtec’s RX-600e/ex half-lane cold planer offers three or four tracks. • The new RX-600e is powered by a Cummins QSX 15 Tier 4 final engine with a maximum power of 675 hp (496 kW) @ 1,850 engine • Guardian remote telematics system • Simplified controls • 32-in.-wide conveyor • Variable Cutter System allows unit to cut at widths of 24, 36 and 48 in. without changing the cutter housing • Various drum options allow smooth machine operation in different applications

The BM 600-15 milling machine features a rotor geometry that efficiently reduces vibration, increases service life and allows for easy drum replacement. • 125-hp Deutz diesel engine • 23.6-in. standard rotor cutting width • Suited for municipal repair work, removal of asphalt strips, fine milling work, utility trench work, joint cutting or for milling up-close to manhole covers and curb lines • Vibration-isolated components ensure operator comfort • Optimal visibility from a seated position Search: 10616679

Search: 10913551

What the RTFO!!!

Finally, an RTFO that meets stringent AASHTO and ASTM specifications! • Quick 8 minute temperature time to recovery after loading samples, meets ASTM and AASHTO requirements • Easy to remove bottom tray allows for quick change of elements or spill clean-up • High-temperature silicone compression fit gaskets securely grip RTFO Bottles • Double-walled stainless steel oven maintains temperature to 246⁰C ± 1⁰C (475⁰F ± 1.8⁰F) • Platinum Resistance Temperature Detector (RTD) ± 0.1⁰C from 0⁰-246⁰C, (± 0.18⁰F from 0⁰-475⁰F) Manufactured in cooperation with

Made in the U.S.A.

800.444.1508 • 740.548.7298 • globalgilson.com Search: 10073126

54 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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Dickson Road Pro 6200 HD

Neal ESSP 750 Trailer-Mounted Sealcoating Machine

The Road Pro 6200 HD features the Impacts S1200 shotblasting head, which produces a 47-in. blast width. • 225-hp John Deere diesel engine • Optional tooling packages include flail grinders, milling cutters, diamond blades and brushes • High-capacity, integrated dust collection system • 12 forward and four reverse speeds via a heavy-duty hydrostatic transmission and planetary wheel drives Search: 11151626

Neal Manufacturing’s 750T trailermounted machine features an electric super sand pump (ESSP) system that produces as much as 100 gpm for up to 50 percent faster coverage than diaphragm pumps. • 750-gal. capacity • Transfers up to 100-gpm piston pump • 16 lbs. of sand per gal. capability • Equipped with a convenient water tank hand-wand holder, which eliminates the risk of damage from leaking sealer to cars, the machine or other surfaces • 18 hp Kohler Command PRO gas engine • Heavy-duty agitator drive with infinite forward/reverse • 6 ft. hand wand • 75 ft. of reinforced hose Search: 11312448

Renova Asphalt Recycler This asphalt recycler recycles existing pavement into HMA that can be used to make repairs year-round with the RENOVA Rejuvenator. • 1-ton batch capacity • Easy to transport • Only a two-person crew required to operate Search: 12117571

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVEMENT PRESERVATION Wirtgen W 200 Hi Milling Machine

SealMaster OptiPave Surface Sealer

The W 200 Hi cold milling machine offers a hydraulically driven milling drum assembly that can be displaced 15.75 in. to the right or the left, providing maximum flexibility for operating in tight quarters. • Milling drum assembly can be moved while in operation and provides a zero edge on both sides for work right up to and flush with curbs or concrete barriers • Edge protector can be raised by 16.5 in. on both sides so the machine can work flush with the edge, even when cutting deep • Powered by a 580-hp Tier 4i-compliant engine • Includes the Level Pro automatic level control, Parallel-to-Surface (PTS) system and the Intelligent Speed Control (ISC) system • Optional Vacuum Cutting System (VCS) reduces particulate emissions at the cutter head

SealMaster OptiPave is an eco-friendly asphalt-based emulsion pavement rejuvenator and surface sealer. • Seals, protects and replenishes pavement binder, extends the service life of pavement and is designed to make roads look like new • Provides a barrier against damaging effects of moisture intrusion into asphalt pavement • One-coat application process with minimal traffic disruption Search: 12069518

Search: 11324237

Weiler TT250 Tack Trailer The TT250 tack trailer features a 250-gal. oval shaped tank that allows for easier cleanout and recirculation of tack. • The 300,000 BTU burner is fueled by twin propane tanks • A 5.5 HP Honda engine powers the 15 GPM direct-drive pump for optimal performance • Tack is distributed through a 5-ft,6-in. wand attached to a 50-ft. hose reel or the optional 6-ft. - 9-ft. spray bar with seven (7) indepedently controlled nozzles Search: 12131962

Cimline Matrix 1500 Melter/Applicator The Cimline Matrix 1500 is a 150-gal. melter/ applicator designed is for cracksealing pavements. • Oil-jacketed tank and recirculation feature • User friendly digital controls allow the operator to start the 22-hp diesel engine and maintains sealant temperature within one degree • Electronic ignition burner is diesel fired with an angled burner chamber providing 250,000 BTU of heating • Direct-drive agitator in the tank maintains temperature and prevents scalding • Standard 20-foot SuperFlex III electrically heated sealing hose

Spaulding Asphalt Dump Trailer The 6-ton asphalt drump trailer from Spaulding Mfg. offers a hydraulic fitting and hose with 5,000-psi burst rating. • Hydraulic top doors • Hydraulic rear door • Fuel: 12V DC Diesel or propane • Fuel Storage: 2-100 lb LP tank or 20 gallon other fuel source • 200,000 BTU Search: 12136526

Crafco Super Shot Melter/Applicator The Super Shot Melter/Applicator has an optional compressor, auto loader, engine cover and router carrier. rejuvenator and surface sealer. • No valves • Few moving parts • No hose pressure build-up • Available in three sizes Search: 10087091

Search: 10077718

56 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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Search: 10075155

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PLANT MATTERS

Portable Plant Selection

101

The top three things to consider when selecting a portable asphalt recycling plant By Lisa Cleaver, Editor

ith the demand for recycled materials increasing, a portable asphalt recycling plant can be an important part of your equipment fleet. Selecting the right unit will mean optimum production and efficiency for your operation. According to industry manufacturers, there are three main areas to consider when it comes to selecting the right portable asphalt recycling plant: portability, production and maintenance.

An easy-to-setup machine is a must when selecting the right portable asphalt recycling plant.

Portability It’s critical for contractors to consider portability and the time involved in setting up the asphalt recycling plant. “Ease of set-up is extremely important because downtime is incredibly costly for the producer,” says Patrick Reaver, product development manager for KPI-JCI and Astec Mobile Screens. “You want to be able to move into a jobsite, set-up quickly and begin crushing and screening almost immediately.” Some plants are very labor intensive and take days to set up, but with fully hydraulic models, it may only take contractors about an hour. This is because hydraulic systems help reduce the need for contractors to use cranes for moving equipment in place. Contractors also need to consider Department of Transportation (DOT) regulations when considering portable asphalt recycling plants. “Due to the weight of portable units, contractors transport the hopper feeder separately to meet weight regulations, which requires additional lifting and transporting equipment,” says Sean Donaghy, national sales manager, IROCK Crushers. IROCK’s optional Hydraset Hopper for the RDS-20 reduces this hassle for contractors, says Donaghy. “A single operator can remove or install the hopper in minutes, which makes it easy to set up. This benefits operations that don’t have lifting equipment and additional workers on site.” Size also relates to the portability of a unit. “In urban areas, there is likely to be very little available real estate to devote to the crushing equipment,” says Jay Giltz, Eagle Crusher sales. “Smaller units, like our E-Plant that can both crush and screen, are usually key to operating in these areas. But even operations in rural areas may be constrained similarly and require compact units versus larger, multi-unit setups sometimes seen on jobsites.”

58 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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Production What kind of production can you expect to receive from the plant? “For all jobs, you must have the equipment on hand to meet, if not exceed, the requirements of the job,” Giltz says. To understand how much production is needed, a small calculation is done. Production rates are generally measured in tons per hour (tph). From there, calculate the number of days per week the plant will be in operation to determine the total output. For example, if a company needs 500,000 tons per year, its plant should produce just short of 42,000 tons each month, Donaghy says. If the plant is set up to run three days per week — approximately 13 days per month — for eight hours per day, the operation will need to process 400 tph. Understanding how much production is critical to determining which size machine is needed. “Buying too large or too small of equipment is harmful to production rates,” Donaghy says. “When plants are too small, they become incapable of meeting production goals. If plants are too large, extra costs grow from maintaining a plant that isn’t maximizing its production potential.”

Understanding how much production you’ll need is critical to determining which size machine is needed.

When considering size, it’s important to review business plans, calculate shortterm growth initiatives and buy a plant sized to allow for that growth while still maximizing efficiencies, says Donaghy.

Maintenance Ease of maintenance is one of the most critical factors to consider when selecting your portable asphalt recycling plant. “Processing recycled asphalt pavement (RAP) creates a very, very dirty environment,” Reaver says. “Producers should seek an asphalt recycling plant that can handle this severe environment. Production numbers are useless if material builds up and shuts the machine

down.” KPI-JCI and Astec Mobile Screens has specifically designed its machines to make maintenance as easy as possible for the producer to avoid a situation where the sticky RAP builds up and shuts the machine down, says Reaver. “For example, all of the cross members inside our screen boxes are rounded so material doesn’t build up,” he says. “We also use a remote-mounted radiator on our ProSizer 3100 so you can get to both sides easily and clean the radiator.” The important thing to keep in mind is that producers should really seek equipment that is specifically designed with

When considering size, it’s important to review business plans, calculate short-term growth initiatives and buy a plant sized to allow for that growth while still maximizing efficiencies.

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PLANT MATTERS the asphalt environment in mind. “Many producers attempt to use traditional aggregate equipment for recycling asphalt, and these machines weren’t designed with RAP in mind,” Reaver says. “When seeking out new equipment, producers should avoid tight, compact machines that can’t be serviced very easily, as well as standard radiator packages that do not offer pre-filtering.”

Screen time

Taking your production on the road When selecting the right portable plant to take your asphalt production on the road, there are some key points to consider. Jeff Dunne, sales with Asphalt Drum Mixers (ADM) Inc. says when it comes to portable plants, take note of these top features: • Counter-Flow Design. “This design is simply more efficient than other technologies, offering complete aggregate drying, better mix quality, and higher overall production of recycled asphalt,” Dunne says. “It’s also a cleaner technology, meaning much lower emission concerns and longer baghouse life.” • Length and Diameter of the Drum. “Typically, the longer the drum the more efficiency, and the larger diameter the drum the better mixing, less carryover and higher overall production rate,” he says. “But it’s better to choose size based on what best fits an operation’s needs and capabilities.” • Sizing and Location of Recycle Entry. “Someone running 100% RAP as opposed to a mixture of RAP and virgin aggregate will want to introduce materials in different drum locations for the best results,” Dunne says. “So having multiple entry options will enhance an operation’s flexibility.” Dunne says today, counter-flow plants are becoming the norm, whereas parallel flow plants are being seen less and less. “With all the advantages of counter-flow comparatively and the increasing interest in less emissions and the use of recycled asphalt.” Controls are constantly being updated as the newer plant owners come into the market. “The latest in controls feature more modern interfaces and computer generated diagrams,” he says. “They also offer internet access, which allows for simple data transfer and easier troubleshooting.” For a productive, efficient portable plant, the burner, flighting and the correct sized drum and baghouse combination are crucial. “An improper or de-tuned burner will result in poor fuel efficiency as well as increased emissions,” Dunne says. “Of similar importance, the condition of combustion flighting can also cause significant issues with fuel efficiency and emissions. Regular maintenance and repair are crucial.” A baghouse supplies air to an asphalt plant while removing exhaust gases, steam and dust produced during the aggregate drying process. The amount of air available dictates production capacity and efficiency. “An improperly sized baghouse can cripple its abilities,” Dunne adds. “That’s why the correct pairing of these two components is key.”

With portable asphalt recycling plants, the screening component is one of the most important features. Manufacturers are evolving this feature to take it to the next level of efficiency and production. “When it comes to recycling asphalt, producers need a very efficient screen so the crusher can do its job,” Reaver at KPI-JCI and Astec Mobile Screens says. “We believe the way to be the most efficient and productive is to combine a horizontal shaft impactor with a high frequency screen, and I believe you are seeing more manufacturers turn to the horizontal shaft impactor for their asphalt recycling plants. “The more efficient you are, the fewer fines you generate and the less coating you take off the rock, which is key,” he explains. “The goal is to keep the rock still coated in oil and simply break it apart. You don’t want to grind all of the coating off the rock by over-crushing it.” Adding screening decks also allows efficiency to increase. IROCK’s RDS-15 and RDS-20 plants feature a doubledeck screen and a conveyor that returns oversized materials from both screens. “Reducing the amount of manual

60 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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work involved in the recycling process significantly improves productivity,” Donaghy says. “While it might sound like a simple task, returning material from both decks via a return conveyor can reduce expenses and boosts production by as much as 20%.” Eagle-Crusher has recently developed its E-Plant that offers a third screen deck, allowing the top and middle decks to be returned for crushing and by putting more emphasis on screening material before crushing. “The inclusion of triple-deck screens and grizzly pre-screens mean more material can be processed faster and at less cost,” says John Powell, Eagle Crusher sales. “On the E-Plant, material that is already close to spec can be screened away before crushing and the tripledeck screen means more material can be

screened. This reduces screen blinding. Only after near-spec material has been screened does it go for crushing. “All of this means that less material is actually crushed,” he continues. “This reduces costs on wear parts and reduces downtime required to replace worn-out parts.” Giltz says the future will likely bring tighter specs for material, meaning changes will need to be made in screening to continue to meet the necessary tons per hour. “Tighter specs will likely result in the development of a cross between traditional vibrating screens used today and high frequency screens,” he says. “Something that allows for higher speeds and increased screen angles to increase efficiency, especially on portable plants.”

Eagle Crusher’s E-Plant offers a third screen deck to boost production.

Make maintenance easier by purchasing plants designed for the demanding asphalt environment.

Donaghy also sees a trend in customers demanding smaller-sized material for RAP. “We’re seeing this demand because the finer material is flexible in terms of placement and results in a smoother surface,” he says. “With this, plant technology needs to incorporate additional screen decks so contractors can produce multiple sizes of material. “As customer demand increases for smaller-sized material, manufacturers also need to make adjustments to screen boxes that allow for this without compromising production rates,” he continues. “This means designing larger screen boxes to allow more material to pass through.” Take all of these considerations into account when selecting a portable asphalt recycling plant for your operation. But keep this important feature in mind: reliability. “While there is emphasis on new technology, especially computer-controlled crushing systems, reliability is still the most important thing,” Giltz says. “It doesn’t matter if the crushing system should be able to do 500 tph, if the computer system fails, it will do zero tph.”

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PLANT MATTERS › CLIFF’S NOTES

How to Properly Maintain the Baghouse C Some easy-to-follow steps to get the most from your baghouse operation By Cliff Mansfield

s ever yone knows, the purpose of a baghouse is to remove the fines entrained in the airstream from our drum before we emit that air to the atmosphere. The various state regulatory agencies have written specifications regulating how much dust we can release each year. As plant operators, it is our responsibility to ensure that we are not exceeding those limitations. Your eyes are one of your most valuable tools in gauging the efficiency of that cleaning process. If you look at your exhaust stack and you can see dust in the airstream then you know that there is a problem. Polarizing sunglasses are very helpful to see any dust in your stack. In essence, they highlight the dust. If you see any dust, you need to immediately schedule a “visualite” test to see where the leaks are. Any dust leaks should be addressed immediately. Proper daily operations of a pulse jet baghouse are as follows: • 80 - 90 psi of mainline air pressure • Pulse interval time should be set to maintain 3- to 5-in. of Delta ‘P’ (pressure drop) • Pulse “on” duration should be set for minimum “trail” (after flow of air on solenoid close) Proper daily operations of a rotary baghouse are as follows: • Rotor speed should be set to maintain 3- to 5-in. of Delta ‘P’ (pressure drop) The closer you run to 5-in. of Delta ‘P’ the better it is for the bags. With both systems, the draught through the drum should be maintained between 0.1-in. and 0.2-in. The primary goal is to keep enough draught to minimize puffing at the drum. This is simply an indication that

we are maintaining a positive suction in our drum at all times. As we all know, too much suction carries proportionally larger quantities of smaller sized aggregate from the drum to the baghouse causing unnecessary wear and messing with our gradations. The most confusion in baghouse operations has always been centered around the proper shut down procedure at the end of the day. The proper procedure for shut down is as follows: • End the process in your blending computer. • When the AC DIVERTS kill the pulsars/ rotors. • Reverse the AC pump and open the AC valve to clean out drum line. Turn on pulsars/rotors. • Run AC pump in reverse for about two minutes, then kill it along with the pulsars/rotors. • Leave ALL augers running until the plant is cleaned out. • Kill everything in reverse sequence of start-up. This is how the baghouse should be operated. Let’s examine the things that go wrong when the baghouse is shut down incorrectly.

Leaving pulsars/rotors on too long The most common problem associated with this is that there is a long lag until you start to get fines for the mix on start-up. You get a lot of “marbles” on start-up. In other words, waste. Additionally, your bags should have a layer of “cake” on them to keep the high velocity dust particles from impacting directly on the cloth which can significantly shorten bag life.

liff’ N ot s es

Shutting pulsars/rotors off too soon • The most common problem with this is that you get a surge of dust in your mix when you first start up in the morning. This means more waste and possibly contaminated mix in the silo. • A heavy surge of dust could potentially stall the augers, ending production for hours. All asphalt plants have their own little quirks. I adjust the amount of time I leave the pulsars/rotors on to fit the operational circumstances of the plant I am running. Perhaps you will need to leave your baghouse cleaning out for a bit longer. Maybe another minute or two. My advice is “don’t be bashful.” Find what works best at your plant. I guarantee you it will not be very far from what I am describing. I have operated several hundred plants, and this is the system I have developed over the last 39 years with many brands of asphalt plants on six continents from Australia to the Arctic Circle, from Oregon to Russia. Cliff Mansfield is owner of Cliff Mansfield Inc. and operates C.M. Consulting, an asphalt plant repairing, upgrading and operational training company. He is an asphalt plant engineer with 38 years of experience working with various brands and styles of asphalt plants. For more information on this topic, contact Cliff by calling 541352-7942 or visiting hotplantconsulting.com.

62 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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PLANT MATTERS Libra Enterprise Information Server The Enterpise Information Server from Libra Systems is designed for plant-to-office integration. • Creates a seamless gateway between the office and production facilities • Allows authorized personnel realtime access to company-wide data anytime, anywhere • Online decision support Search: 10079365

ADM Recycle Systems Asphalt Drum Mixers Inc. offers four models of portable and stationary recycle systems that allow plants to use milled material in hot mix asphalt (HMA). • 15-ton capacity • Continuously welded at the seams • Bins contain angle irons and midsection stiffeners for reinforcement • Steeply sloped sidewalls help prevent material from plugging or bridging • For RAP transfer, includes a heavy-duty weigh conveyor that is 2-feet wide and between 45- and 65-feet long • Based on plant conditions, up to 50 percent of HMA can contain recycled pavement • Portable units feature heavy-duty I-beam frame on a gooseneck trailer Search: 10082306

Stansteel Hot Mix Asphalt Plants Stansteel’s complete heavy-duty high-production hot mix asphalt plants include both counterflow drum mixer and batch plants. • Batch plants up to 16,000-pound batch size • Complete counterflow drum mixers up to 850 tph • Heavy-duty design and construction Search: 10084926

Gencor Ultrafoam GX2 System Gencor introduces its latest development in warm mix technology with the Ultrafoam GX2 . • Can achieve consistent foaming at varying production rates without the use of a powered mixing device • AC and water can be introduced at widely different flow rates and pressures • Compressed Air Purge releases remaining water in the piping and hose between the unit mounted on the drum when temperatures approach freezing • Water Flow Alarm senses water and transmits alert to the operator if loss of water flow to the unit occurs • Pump heater features a convective heat bulb used inside the pump enclosure to prevent pump and internal components from freezing • Weatherproof enclosure provides freeze and dust protection to the pump and electronic parts Search: 10223065

Search: 10074781

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PLANT MATTERS

Eagle Hybrid Traxx Impactor Plant The Hybrid Traxx track-mounted impactor plant features diesel electric power for both the impactor and the plant, with hydraulic operation powering the tracks. • Equipped with Eagle Crusher’s new UltraMax II Impactor • Largest under-crusher clearance in the industry at 18 in. - making it ideal for concrete and asphalt processing • Independent hydraulic adjustment for primary and secondary curtains reduces wear cost and provides precise product control • 42-in. x 40-ft. conveyor fixed at a 10-ft. discharge height allows for direct loading of trucks • Features a sculptured 3-bar, solid-steel rotor backed by the industry’s first 5-year rotor guarantee Search: 10090720

Astec ProSizer The ProSizer 2612V from Astec Mobile Screens is designed for processing RAP millings for the asphalt producer. • Closed circuit mobile plant • Double-deck VariVibe high-frequency screen with horizontal shaft impactor (HSI) crusher

Meeker Batch Plant RAP Kit

Kleemann Mobicat MC 110 R EVO Mobile Jaw Crusher

• Hydraulic screen angle adjustment and rotary screen tenioning system can meet different RAP application demands • Central grease points • Set-up time of less than 15 minutes Search: 10086296

The 99,200-lb. Mobicat MC 110 R EVO mobile jaw crusher combines the advantages of a professional stone crushing plant with those of a recycling crusher. • Powered by a 324-hp diesel engine and hydraulic crusher drive, it has an inlet opening of 44” x 28”, allowing for a maximum feeding size of 42” x 26” and a feeding height of 26” x 394” • Maximum feed capacity of 300 tph • Hopper walls integrated in the chassis and a fully hydraulic crushing gap adjustment ensure quick setup times

The Meeker Batch System features precise control of RAP. • Unique weighing system allows for higher RAP percentages in mix • Positive control of stem release • Steep sloped bin walls on rap bins for trouble free operation • PLC touch screen controls Search: 10086128

Maxam Solo Drum Mixer The Maxam SOLO Drum’s patented technology advances counter-flow technology to a new level of efficiency. • Separates the control of the exhaust

Search: 11272750

E.T. Clancy Asphalt Plants E.T. Clancy Co. has specialized in selling asphalt plants and equipment for 40 years. • Complete inventory of drum plants, batch plants and components • Assist in plant dismantling and set up, as well as trucking Search: 10086122

stack temperature from the control of the mix temperature with the MAXAMizer heat Recovery System • Directly heats the RAP without superheating the virgin aggregate and without producing blue smoke with the RAPTOR Recycle System • Support trunnions continuously selfalign with the TrooTrac alignment system • Eco-friendly advantage of AQUABlack Solutions warm mix system Search: 10280224

64 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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PLANT MATTERS Dillman Voyager Plant Dillman introduces the 200-tph Voyager plant designed for producers who require a plant made to move several times during the paving season. • Can be dismantled, moved to a new site and set up and ready for production in about five work days • Whisper Jet 50 burner, 34,000 cfm pulse jet baghouse and the PMII control system • Four-bin cold feed is standard with the option of adding more bins • Recycle system optional

Tarmac International RAP & Shingle Bins Tarmac International’s RAP and Shingle Bins use American-made drives and bearings. • Stationary or portable • 18- to 50-ton capacity • Feed rates up to 250 tph • Optional load cells Search: 10740782

Search: 10616687

Systems ADP-GUI Drum Mix Process System The ADP-GUI Drum Mix Process System (ADP100 with optional Windows-based Graphics User Interface) is designed to proportion aggregates and additives according to prescribed mix design formulas and measures and controls liquid asphalt mass flow rate so blends are accurately interlocked to the measured aggregate flow. • Asphalt tank inventory and selection monitor • Feeders capable of being controlled and metered include: aggregates, dust, antistrip, latex, crumb rubber, water, slurries and mineral filter • Stores multiple mix formulas Search: 12129248

Astec V-Pack Stack Temperature Control Astec’s V-Pack Stack Temperature Control System extends the range of mixes that can be produced without requiring the flights be adjusted. • “V-flights” unique drum flights with a deep V-shape • Automatically controls exhaust gas temperature across a range of mix types and operating conditions by making drum speed changes • Keeps baghouse temperature relatively stable as mix temperature changes and even as mix types change • V-flights produce a uniform veil of virgin aggregate across the entire drum, regardless of how full the drum is, the plant’s production rate, or the RAP percentage used; this enables drum speed changes to be effective as a means of controlling stack temperature • Monitors exhaust gas temperatures at the baghouse inlet as the primary reference for control

Doosan DL200-5 and DL200TC-5 Loaders The DL200-5 with Z-bar linkage and DL200TC-5 tool carrier with parallel lift linkage utilize a hydrostatic drive system to improve fuel efficiency, enhance machine positional control and reduce brake wear. • 142-net-hp diesel engines achieve Tier 4 Final compliance without the need for a diesel particulate filter • Power, Standard and Economy power modes and Max, Traction control and S-Mode traction modes • Both units have a 2.6-cu.-yd. bucket capacity, and they deliver 22,481 (DL200-5) and 21,357 lbf. (DL200TC-5) of breakout force and 9-ft. 6-in. (DL200-5) and 8-ft. 9-in. (DL200TC-5) dump heights. • Speed management feature Search: 12144398

IROCK Tracked & Wheeled Conveyors IROCK Crushers offers wheeled conveyors that are road portable and can be hauled to different locations or relocated on site with the help of a truck; tracked units make maneuvering around a jobsite easy as they can move under their own power and can be folded and loaded onto trailers for relocation from site to site. • Tracked T-8048 conveyor features a 48-in.-wide belt and stretches 80 ft. long, and it can stockpile material up to 33 ft. 2 in. • Wheeled M-5030, M-6030 and M-8036 units feature a fifth wheel pin with a radial plate for 180-degree rotation • M-5030 stockpiles to 22 feet • M-6030 can stockpile to 24.5 feet • M-8036 can stockpile to 30 feet Search: 1214490

Search: 12058427

66 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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SPECIAL REPORT FINANCE FORUM

The Family Office: An Alternative Capital Solution By Jay S. Lipsey

here are many circumstances that lead an owner to decide it is time to sell or bring a capital partner into the business. A retiring owner may not have a willing successor or the younger generation may want to grow the business but lack sufficient capital to take it to the next level. While a business owner may desire to sell their business outright, very often earn-outs, seller notes and minority stakes mean that their professional and economic future are tied to the ongoing performance of their business, now under new ownership. Family offices are organizations dedicated to managing the wealth of an ultrahigh net worth family, usually with a net worth of at least $200 million. The origins of their wealth most commonly stem from the sale or operation of a successful private business, providing them with an inherent understanding of the unique circumstances of family businesses. Selling or partnering with a family office might be a better option if any of the following statements apply: • If what happens to your business, employees, and community matters to you post-sale. • If you are going to have an ongoing interest and involvement in the business, and care about partnering with someone who can add value. • If you require a creative, flexible structure outside of the “plain vanilla” asset sale.

Maintaining your legacy While obtaining a fair price is a major part of selling a business, owners must realize that buyers may have differing intentions. Strategic buyers and institutional firms often treat small and mid-sized acquisitions as candidates for downsizing or a quick flip. Many prospective sellers place a premium on

purchasers and partners who are likely to respect the knowledge and experience of various key stakeholders, including employees, suppliers and the community at large. Family offices will offer that respect because they come from family businesses themselves. Another advantage that family offices offer is that of a longterm perspective, fostering a multigenerational outlook for the company’s future. Rather than chasing quick, speculative profits, family offices are committed to patiently creating sustainable value by running the business the right way for long-term performance. For example, their conservative nature often translates into using minimal amounts of debt to ensure the resilience of the business during recessionary times.

Experienced outlook Having the right owner can dramatically impact the value of a given company. While some family offices consider a variety of sectors, most tend to prefer investments in industries where they have experience— generally where they initially made their money. Partnering with a family office can provide a business with the benefit of a knowledgeable owner who can add value by sharing best practices and any other skills that contributed to their prior successes. Unlike traditional investment funds, which generally have dozens if not hundreds of investors, most family offices focus their attention towards the success of a limited number of companies.

Flexible capital Without the restrictions placed upon traditional institutional and public buyers, family offices have the ability to structure a transaction in a personalized way most relevant to a business owner. For example, an agreement may allow for a staged

buyout over time or the opposite — for the original owners to buy back into the company. Many family businesses seeking growth capital are sensitive to “forced exit clauses,” which enables an investor to force a sale of the entire business after a stipulated amount of time. Traditional funds have a fixed lifespan and therefore require this clause to ensure they can return capital back to their investors.

Challenges of family offices Working with a family office presents some unique issues which should be taken into consideration. Since numerous family members must often approve potential investments, deals tend to take longer to complete. From our experience, family offices invest not just based on the numbers but also upon the relationship; and often request multiple one-on-one meetings to get comfortable with their future partners. Additionally, some family offices can be hard to find due to their preference for privacy. Others operate publicly, with an active role trying to meet business owners to see if there exists a fit between the parties. The family office has been a rising source of capital that can offer business owners a collaborative partner with parallel objectives. When owners place importance on the values behind their business rather than solely the highest price that can be attained in today’s market, the family office can provide a superior long-term solution that better accommodates employees, communities and other stakeholders. Jay S. Lipsey (jlipsey@mccombiegroup.com) is a partner with McCombie Group, a private investment firm that actively seeks to deploy long-term equity into established, family-owned operating businesses.

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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CLASSIFIED ADVERTISING

ASPHALT PLANTS ·

Phone: 970-260-2435 • www.aggdesigns.com

· · · · · ·

Late model Terex E225P Counterflow Drum Mix Plant 5 Bin Cold Feed, Self-Erect Silo, Baghouse, 20,000 G. A/C Tank CMI Impulse II Controls, Complete MCC and Control House

· · · ·

Astec 400 tph portable Double Barrel plant CMI 500 tph portable drum plant CMI 400 tph portable counterflow plant Astec 250 TPH Portable Double Barrel Plant Astec 250 tph portable Six Pack ADM 225 tph portable counterflow plant Terex 225 tph portable counterflow plant ADM 110 tph portable drum plant 10,000# SS asphalt batch plant 4000# Barber Greene asphalt batch plant Astec 150 ton silo & slat conveyor

· · · · ·

Astec 500 tph Double Barrel drum only Gencor 65,000 CFM portable baghouse 500 barrel portable self-erecting mineral filer silo Four bin cold feed system Astec 75,000 CFM Baghouse

Please Call For Complete Inventory

Plant for sale? Call Clancy! Serving the Asphalt Industry for over 45 years 500 Bbl Self-Erect Portable Mineral Filler System Weigh Pod w/ Reverse Weigh; Pneumatic Gate; Load Cells Rotary Vein Feeder, Blower, Pulse Jet Baghouse

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

DRYER/DRUM SPECIALISTS “Serving the rock and asphalt industries since 1985” WE ARE SECOND TO NONE IN SERVICE AND SATISFACTION ALIGNMENT

Just as your vehicles need proper alignment, so does your dryer. Nearly all external dryer problems are caused by trunnion and frame misalignment. Long-term mis-alignment causes damage resulting in downtime and costly repairs. Even units that seemingly float properly can in reality be drastically out of alignment.

SIGNS OF MIS-ALIGNMENT

✔ Metal flakes from tires or trunnions ✔ Trunnion mis-location and trunnion bearing failure ✔ Poor wear/contact on tires and trunnions ✔ High drive motor amperage ✔ Excessive vibration ✔ Thrust roller and bearing damage ✔ Tire pad and keeper wear ✔ Lack of proper floatation Evans & Daniels uses precision laser and sighting techniques to restore your unit to proper alignment settings.

RESURFACING

Evans & Daniels uses highly specialized grinding equipment that can fit into the tightest of spaces. We resurface tires, trunnions, thrust rollers and tire thrust faces. We don’t require cranes, lifting assistance, or steel framework. In most cases, we can grind during regular production conditions.

COMMON WEAR PATTERNS ✔ Tapers ✔ Washboard ✔ Concave / Convex ✔ Shoulders ✔ Lumps / Divots / Cracks ✔ Rollover

TIRE & TRUNNION RESURFACING — TRUNNION ALIGNMENT — PREVENTIVE MAINTENANCE

www.evansanddaniels.com — 570-779-1982 68 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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CLASSIFIED ADVERTISING

LIME ADDITIVE Pugmill Systems manufactures top-quality portable and stationary pugmills for lime additives, soil cement, and stabilized base. 100-1500 TPH. Durable, low maintenance design.

Boeing 70-ton Silo & Slat Conveyor

PUGMILL SYSTEMS, INC. Manufacturers of Davis Pugmills (931) 388-0626 COLUMBIA, TN www.pugmillsystems.com

Batching Loadout Truck Scales Okidata 320 Printers www.BatchingControls.com 603-566-4330

✔ Boeing 70-ton Silo & Slat Conveyor ✔ Slat Conveyor is 70-ft x 36" ✔ 8-ton Batcher

Paving Fabric Installation Machines

Price: $39,500 USD, As-Is-Where-Is North Central USA, Stock# SS02-151 Clark Loney 888-220-1277 • Fax 707-929-0569 Email: clark@asphaltequipment.us www.asphaltequipment.us

In Stock: New 500 and 750 Pugmills Conveyors, Belt Feeders

Servicing OLD & NEW Batching Systems since 1984

Telescoping 1’-19.5’ Grizzly 600T & 1’-16’ Cub 300T 6 Patents Install Fabrics & Grids Virtually Wrinkle Free Mounts for Endloaders, Buckets & Oil Trucks Cuts Labor Costs & Speeds installation Time Roll Pullers™ for Truck Unloading - 3" & 4" cores

GAC® for 38 years "The World’s Best" www.gacco.com m@gacco.com • 619-222-5111

THIS COULD BE YOUR AD!

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

To place an ad in Asphalt Contractor Call Denise Singsime 1-800-538-5544 ext: 1245 dsingsime@ acbusinessmedia.com

Astec Relocatable 300TPH Double Barrel Plant ®

NEW LISTING IN GOOD CONDITION. AVAILABLE NOW. LOCATED IN LUMBERTON, NC. contact Astec sales

423.867.4210 ext.1245

VIEW ONLINE # 820

astecused.com ASTEC, INC.

an Astec Industries Company 4101 JEROME AVENUE • CHATTANOOGA, TN 37407 USA • 423.867.4210 • FAX 423.867.4636 • www.astecinc.com

February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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CLASSIFIED ADVERTISING

RAP-14731 Astec Skid Mounted Double Barrel

• 7ft Diameter Drum • Hauck SJ520 setup for Oil but Nat. Gas acceptable

• 150hp drive • Dismantled ready • 4 NEW spare trunnions to load • Replacements wear parts included as well

RAP-14645 H&B 10,000 LB. BATCH PLANT

• H&B 10K Batch Plant • Cedarapids 10028 Dryer w SJ360 natural gas

• Single RAP Bin w Grizzly • 55k CFM Baghouse 6x16 bags 378 bags

RAP-14723 ASTEC CROSSOVER SLAT

• Inclined 36” x 30’ • Electric Blanket Heat • Walkway on One Side • 3-Way Chute

RAP-14759 CMI/CAT PORTABLE DIRECT FIRED AC TANK

RAP-14601 GENCOR HY-WAY HOT OIL HEATER

• TC-3630-IC • 07-054

RAP-14699 RELIABLE ASPHALT PRODUCTS 10FT X 14FT HEAVY DUTY - RAP BIN

• 30,000 GALLON PORTABLE AC TANK • NEW 1988 • DF30D • sn DF30P - 194

• DIRECT FIRE BURNER • TANDEM AXLE 10:00 x 15 tires.

RAP-14741 CEI HOT OIL HEATER

RAP-14692 MINERAL FILLER SILO

• HYFGO-200/4269 • 2.0 mbtu capacity • Combo Burner

• Setup for Natural Gas • Includes Gas Regulator

RAP-13915 ASTEC 60K CFM BAGHOUSE

• Airlock • Weigh Pod

• Constructed of ¼in plate with 3/8in flat bar stiffeners with the top frame constructed of channel. Leg assemblies to be constructed with ¼ bent plate and utilize channel bracing

• 1.8mbtu capacity • Model CEI-1800A • sn C05-085

• Powerflame modulating burner, setup for fuel oil

• RBH-58:DB 98-007 • Horizontal Cyclone • Skid Mounted Arrangement

• 10,843 sq ft - 5.5 to 1 = 60,000 cfm

70 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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CLASSIFIED ADVERTISING

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

Come see us at the World of Asphalt Nashville, TN March 22-24, 2016 Booth 3216





   

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



 



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

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

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

 

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

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0% FINANCING FOR 84 MONTHS OR GET A BIG CASH DISCOUNT February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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CLASSIFIED ADVERTISING

2014 Wirtgen W250i

2014 Wirtgen WR250

c/n 0018908

s/n 622.0018

c/n 0035224

• MILL • • 1,402 HRS

8’ CUTTER

• WATER/EMULSION SYSTEM • 945 HRS

2014 Wirtgen W150i c/n 0018896

s/n 613.006

• 4’ CUTTER • 1,087 HRS • BASIC FCS • SLOPE

s/n 08WR.0012

2013 Wirtgen W50DC c/n 0018894 s/n 905.0751

2012 Wirtgen WR2500S s/n 04WR 0477

• 4 WHEEL • 210 HRS • 5600MM CONVEYOR

• NEW TEETH & HOLDERS • 3,469 HRS • 8’ CUTTER • ALL OTHER STANDARD EQUIPMENT

CALL TODAY! 2011 Hamm HD140VO

2012 Hamm HD140VVHF

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• ROPS • LIGHTS ON ROPS • PAVEMENT TEMP SENSOR - FRONT • 3,070 HRS

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• 84” • ROPS • 1,855 HRS

(952)884-2301 - www.hayden-murphy.com 72 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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ADVERTISERS’ INDEX Aggregate Designs Corp.

Hydronix

Almix

Innophos

Asphalt Drum Mixers

28-29

KPI-JCI

Astec

13, 38-39, 69

LeeBoy

Bomag

Belly Band

Libra Systems Corporation

Carlson Paving Products Inc.

Meeker

Clear Span Fabric Structures

OMI Industries

C. M. Consulting

PROcru

Dillman

16-17

Pugmill Systems Inc.

Eager Beaver Trailers

Reliable Asphalt Products

E. D. Etnyre & Co.

Roadtec an Astec Industries Co.

11, 76

E. T. Clancy Co.

Road Widener

Evans & Daniels Inc.

Sakai

E Z Road Inc.

Sealmaster

Fast Measure By KTP Enterprises

Superior Tire & Rubber Corp.

23, 63

Gencor Industries Inc.

Systems Equipment Corporation

35, 49

General Combustion

Tarmac International Inc.

Gilson Company Inc.

Transtech Systems Inc.

Hayden-Murphy

Volvo Construction Equipment

Heatec Inc.

Wirtgen America

Homestead Valve Division

Seal the deal on Site PRovIdE PRojECT quoTES bEFoRE You lEAvE ThE jobSITE. The FREE bidGuru App, developed by Pavement Maintenance & Reconstruction, creates immediate, custom quotes for: Sealcoating Asphalt overlays Cracksealing Other pavement maintenance

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February 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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THE LAST EXIT

Asphalt Gets

SALTY

By Jessica Stoikes, Associate Editor

alt has long been the hero each winter when Mother Nature begins to wreak havoc on our roads. However, salt can be easily removed by rain or automobiles and requires frequent application on roads to be affective and is quite costly. That frequent application can add up to 20 million tons dumped on our roads each year. Add to that the fact that anti-icing agents are corrosive to asphalt and have a negative impact on the environment and it’s clear why scientists are seeking other alternatives to combat icy roads. A team of researchers at Turkey’s Koc University recently created an asphalt mixture that is embedded with salt so roads can de-ice themselves. Roads paved with this salt-embedded asphalt should even be able to prevent ice from forming in the first place.

In a previous study, Koc researchers developed a functional polymer composite consisting of potassium formate (HCOOK) salt pockets dissolved in a hydrophilic gel medium and dispersed in a hydrophobic SBS polymer matrix. Here, they developed an innovative method to obtain polymer composite-modified bitumen and investigated further the anti-icing properties of the functional bitumen. Moreover, this salt potassium formate has been widely approved as a more environmentally friendly de-icing solution compared to the other chemicals that have been used for de-icing in the past. Researcher say they were able to characterize the anti-icing properties of modified bitumen surfaces and demonstrated significant increases in freezing delay of composite-modified bitumen compared to base bitumen in a temperature- and humidity-controlled chamber.

Why it works

Will it last?

The researchers are calling the product a “Gelation-Stabilized Functional Composite-Modified Bitumen for Anti-icing Purposes.” The incorporation of these salts into asphalt bitumen, asphalt binder, and the controlled release of specific molecules from this hydrophobic medium can provide an effective solution for reducing ice formation on pavements. Bitumen has previously been modified by various polymers, however, an anti-icing function was not considered in those previous designs.

In lab studies, the researchers found that the salt infused asphalt delayed ice formation for 10 to 15 minutes. Certainly not long enough to put the salt trucks out of business, but it gives drivers a window of time to familiarize themselves with the conditions and hopefully help in the prevention of accidents. In addition, they characterized the release of HCOOK salt from polymer composite-modified bitumen and observed salt release within the range of 1.07–10.8% in 67 days in the lab depending on the composite content.

Scientists have developed a new saltfilled asphalt that prevents ice from forming on roads A team of researchers at Turkey’s Koc University recently created an asphalt mixture that is embedded with salt so roads can de-ice themselves. Roads paved with this salt-embedded asphalt should even be able to prevent ice from forming in the first place.

The researchers note that the effects could last even longer when used on real roads. In that instance, the salt-polymer composite would be evenly embedded throughout the asphalt. Thus, as cars and trucks drive over and wear away the pavement, the salt could continually be released — potentially for years. The resulting material was just as sturdy as unmodified bitumen, and it significantly delayed ice formation in lab studies for long-term durability. The researchers now plan to pave test sections and drive on them to prove the feasibility of the research. A possible downside of the ice-proof roads will be the wear and tear to cars and tires. Any salt compound can do corrosive damage to the structural integrity of tires and the underbelly of cars themselves. Regardless of the negatives, this research is not to be taken with a grain of salt. These roads could save millions of dollars on corrosive materials and the application efforts, not to mention the huge environmental impact if these efforts become widespread and take the place off common rock salt.

74 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • February 2016

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Work zones are dangerous, and night work elevates those dangers. With its easily adjustable platform for brilliant, directional lighting, the Carlson LED Blade Light enhances worker visibility while creating safer, illuminated work zones and mobile platforms. Along with its low profile design that eliminates glare, high efficiency and long lasting LEDâ&#x20AC;&#x2122;s, 12/24v DC or 110/240v AC configurations and its unique ability in not attracting insects, the LED Blade Light is paving the way for safer night work conditions.

No Glare. No Insects. No Heat. Safer Night Work. Search: 10072346

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OPERATOR COMFORT & CONVENIENCE

MAKE THE JOB EASIER

EACH ROADTEC PAVER IS ERGONOMICALLY DESIGNED FOR BETTER VISIBILITY, REDUCED NOISE, AND COMFORT. The New Clearview FXS® fume extraction system provides greater visibility to the front of the paver hopper, to the opposite side, and down to the augers. Paver controls are mounted to the pivoting seat station, which hydraulically swings out past the side of the machine for excellent visibility. All functions are easily accessible, including feed system and flow gate controls.

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Noise levels cut in half and improved visibility allow the operator to stay in constant communication with the rest of their crew.

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