Asphat Contractor September 2016 by ForConstructionPros.com

30 Years of Innvoations Create More Productive, Efficient Milling Machines Page 38

Latest Technologies for Production, Paving & Preservation September 2016

Using Drones to Make Your Asphalt Plant More Profitable

30 CELEBRATING

Page 58

Years

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The tracked Cedarapids CR662RM RoadMix paver and MTV offers the traction needed for full-width paving.

Full-Width Paving Eliminates

How

Joints, Improves Quality & Saves Time Page 20

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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 SEPTEMBER 2016

COVER STORY

DEPARTMENTS PAVING INNOVATIONS

32 PAVEMENT PRESERVATION

38 PLANT MATTERS

PAVING INNOVATIONS

20 How Full-Width Paving Eliminates Longitudinal Joints, Improves Quality & Saves Time

Full-width asphalt paving can be accomplished on a range of projects from the two-lane city street to the multilane interstate.

PAVING INNOVATIONS

PAVEMENT PRESERVATION

28 Unconventional

38 The Evolution of the

Asphalt Paver

This gravity-fed paver is designed for ease and quality production.

30 Rubber Modified

Asphalt Usage Continues to Grow

More than half of the states either use or are testing rubbermodified asphalts today.

32 Understanding Engines in the Age of Tier 4 Pavers

Some contractors shy away from the new engines, but once you understand the technology, the maintenance is easy.

Milling Machine

Innovations through the years have created more productive, versatile and smarter machines.

44 How to Avoid Bumps in Asphalt Overlays

Following crack sealing “best practices” assures smooth, bumpfree finished pavement

48 In-Place Recycling

Seminars Designed to Promote Pavement Preservation

50 Preservation Products

Milling machines, reclaimers, infrared equipment & more.

34 Paving Products

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

58 PLANT MATTERS

58 How a Drone Can Make

Your Asphalt Plant More Profitable

Legal drone operation can help asphalt plants with stockpile management, maintenance, marketing and saving money.

64 The Benefits of

Outsourcing Your Maintenance

Service companies can help you focus on the job of producing asphalt while increasing your bottom line

70 Laurel Asphalt Reduces

Odors, Keeps Neighbors Happy

Custom -blend, eco-friendly odor control eliminates odorous emissions for asphalt production facilities.

74 Cliff’s Notes

Formulas to keep in the forefront

77 Plant Products

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

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

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A WIRTGEN GROUP COMPANY

Brand New Highway Class Paver SUPER 2000-3i.

TECHNICAL HIGHLIGHTS > High-performance paver for use in highway construction and large-scale commercial applications

> Multiple screed options including front or rear extensions or a high-compaction screed for placing stiff mixes and base materials

> Ergo Plus 3 for easy paver operation > Daily maintenance-free paver with large fuel tank for a day’s work or more

www.wirtgen-group.com/america

WIRTGEN AMERICA, INC. · 6030 Dana Way · Antioch, TN 37013 · Telephone: 615-501-0600 Search: 10075523

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TABLE OF CONTENTS IN EVERY ISSUE

8 Editorial

Infrastructure funding is bridging the gap in this divisive election year.

10 New Products

Sakai launches SW654 Series vibratory rollers.

September 2016 Vol. 30, No. 7

Published by AC Business Media Inc.

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

18 Technology Update

How to use telematics to improve risk management.

90 The Last Exit

Can your caffeine fix also fuel roadways?

SPECIAL REPORT: QUALITY CONTROL TECHNOLOGY A look at products to aid contractors in testing and proving the quality of their asphalt mix designs.

Published and copyrighted 2016 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).

Search: 12176781

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

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Search: 10074806

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September 2016 • Vol. 30, No. 7

EDITOR'S PERSPECTIVE

Infrastructure Funding Bridges Gap in Divisive Election Year

Published by AC Business Media Inc.

Lisa Cleaver, Editor

lcleaver@ ACBusinessMedia.com

t's been a strange year in politics, with an election hosting two people which polls show are the most flawed and untrustworthy candidates to run for president in the history of the country. Even with all the craziness, one thing is able to unite both sides: infrastructure. A national poll released by the Association of Equipment Manufacturers (AEM) in August found that half of registered voters say the nation’s infrastructure has gotten worse over the last five years, and a majority of voters said roads and bridges are in “extreme” need of repair. The findings, part of a new national poll commissioned by AEM to gauge voter perceptions and attitudes about the current and future state of U.S. infrastructure, found that registered voters, regardless of political affiliation, recognize the declining state of the nation’s infrastructure as an issue that should be addressed and believe that the federal government should do more to improve infrastructure across the board. Key findings include: • 46% believe the state of the nation’s infrastructure has gotten worse in the last five years • A significant majority (80%- 90%) say roads, bridges and energy grids are in some or extreme need of repairs • 49% feel the federal government is primarily responsible for funding repairs to the nation’s infrastructure • Seven out of every 10 say increasing federal

funding for infrastructure will have a positive impact on the economy • Voters across the political spectrum think that the federal government should do more to improve the nation’s overall infrastructure, with 68% of Republicans, 70% of Independents and 76% of Democrats sharing this sentiment It's clear that Americans understand the connection between improved infrastructure and its impact on the economy. Both Hillary Clinton and Donald Trump have also shown an understanding and have expressed strong support for increasing funding for infrastructure. For her part, Clinton plans to add $250 billion in new infrastructure investment and provide $25 billion for capitalization of a new national infrastructure bank. Trump says he will at least double Clinton's numbers and probably go further, with one report stating his investment would reach $1 trillion. He plans to use infrastructure bonds, taking advantage of current low interest rates and the willingness of “citizens” and others to invest in a fund for that purpose. With only a few weeks left in this unprecedented election cycle, it's critical to pay attention to each candidate's ideas and proposals. Throwing out numbers is easy, but will the follow-through be viable? For the full AEM report, visit aem.org. Thanks for reading!

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

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8 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 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 Sakai Launches SW654 Series Vibratory Rollers Tier 4 Final rollers feature a Kubota engine

esigned to meet the rigors of daily use in mediumsized to highwayclass paving jobs, the Sakai SW654-series rollers are designed for small to large tonnage jobs requiring oscillation. These include thin lifts, bridge decks and compaction over existing utilities or near aging structures. General paving applications for the single eccentric shaft SW654 and SW654B and twin-eccentric shaft SW654ND oscillating rollers include widening of roadways to compaction of shoulders and ramps to parking lots and driveways. The “B” model features a split drum suited best for operating in tight corners without pushing or shoving material.

Engine upgrade All of the 8-speed SW654-series models achieve Tier 4 Final emissions compliance with Kubota’s 3.33 L diesel engine rated at 73 bhp. Cost of operation is further reduced with Sakai’s new ECO Compaction Mode (ECM). ECM reduces fuel consumption up to 37%. Vibratory compaction by the 58-in.-wide, 42-in.diameter drums is achieved at 3,000 vpm in low frequency or 4,000 vpm in high frequency for fast, efficient achievement of specified density targets. High-frequency rear drum dynamic linear pressure ranges from the SW654 roller’s 395 PLI to the

Caterpillar CB54 XW Tandem Vibratory Roller The CB54 XW tandem vibratory roller offers compaction performance, application versatility and operator comfort to maximize productivity while providing exceptional product quality. • 79-in. standard compaction width • 8-mph max travel speed • 137-hp Cat C4.4 engine with ACERT • Machines are capable of performing effectively on a variety of mix types, while keeping pace with the paver, helps customers maximize resources and lower their capital investment Search: 12176975

SW654ND roller’s 715 PLI. All Sakai tandem drum rollers employ crossmounted drive and vibration motors to evenly apply force to the mat as well as prevent material shoving or pushing during compaction. The upgrade also retains innovations such as Sakai’s unique, custom-designed shock isolators that reduce the transmission

of vibration back to the operator and critical machine components; a super-heavy-duty articulating and oscillating center hitch design for superior chassis stability, ground contact and operator control; neutral-activated dynamic hydrostatic braking, one of three separate braking systems found only on Sakai products for maximum operational safety. Search: 12192099

Cimline Magma M-2 Crack Sealer Magma M Series offers an AutoStart feature that requires just a few simple steps to get the pavement maintenance started. • After the push of a button and three green lights illuminating, the operator is notified of cracksealing readiness • Operating in urban and suburban settings means the equipment must be community friendly, Magma has clean, efficient Tier 4 diesel power engine with sound reducing muffler and added sound control from an optional engine cover Search: 12226854

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

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roadtec.com 1.800.272.7100 423.265.0600

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NEW PRODUCTS Carlson CP75 Commercial Class Paver The CP75 commercial class paver features a 74-hp Cummins Tier 4i engine that delivers more power, improved fuel economy and high torque at lower rpms. • Operator-focused platform includes screed-mounted controls, intuitive lever and switch placement at operator stations a lowered front hood and other standard crew comfort features • High Flow Conveyor System eliminates segregation by combining the efficiency and anti-segregation performance of a rubberized belt with the durability and reliability of a chain and slat system • Electrically heated EZC813 screed includes full-length element hold downs, adjustable deck cones, an adjustable slide track system and more • Options available include the commercial class EZC815 electrically heated screed, LED flood lights and grade and slope automation Search: 12087872

KPI-JCI and Astec Mobile Screens 2056 Vanguard Jaw Crusher

BoltHold Anchors from Asphalt Anchors Group

KPI-JCI and Astec Mobile Screens has expanded its Vanguard product line with the new, more compact 2056 Vanguard Jaw. • 20-in. x 56-in. jaw crusher for sand and gravel applications, and also excels in recycled concrete and mining applications

Asphalt Anchors Group (AAG) has developed Bolthold anchors, which are designed to be a reliable way to attach structures directly to asphalt. • Even in thin asphalt (2-in.), the pull resistance is up to 2,500 lbs. • Units are installed flush with the asphalt surface • Internal thread accepts a bolt that is used to attach the structure to the anchor • Anchors are available with either 3/8-in. or 7/16-in. threads • Anchors bond to asphalt using an epoxy or cement (generically called "grout") • An oversize hole is drilled in the asphalt and filled with a fast curing grout, and the anchor is dropped in; displaced grout is pushed into the crevices in the asphalt and in the gravel layer below, binding the anchor on the one side, and to the asphalt on the other side • Mount anything from runway plane arresting systems and jet blast deflectors to signs, bike racks and car ports Search: 12212697

Atlas Copco Dynapac F800W Paver • Single cylinder auto-tension system • Wear seat provides easy access and increased uptime • Corrugated stationary wedge increases the crusher gap and maintains a steep nip angle • Electric motor mount, v-belt drive and guarding are all integrated on the machine, providing an easy-to-install compact package for mobile or stationary application Search: 12188076

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!

The Dynapac F800W wheeled paver offers a paving capacity of up to 1,000 tph and 8- to 19-ft. paving widths. • Carlson EZIV08-15 vibratory front extension screed • 34-kW, hydraulically driven, oversized generator heats the full width of the screed at all times • Smart controls automatically lock screed, halting leveling, feed and vibration when the paver comes to a stop • Dual, swing-out operator platforms • Two-speed hydraulic motor and heavyduty torque hub provide ample tractive force for paving and enable transport speeds up to 11 mph • 173-hp Cummins QSB 6.7 Tier 4 Final engine Search: 12214773

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

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THE FACES OF ASTEC PARTS

When Astec parts salesman GREG PAINTER is not calling on customers to support their parts needs, you can find him on the water fishing or in the woods hunting. But when you call, he’ll trade that fishing hat for a hard hat, because he is always your parts man.

An ASTEC parts salesman knows that being successful in his job means that you count on him to deliver when needed. So when you need a part, he will take the call because no matter what else he is, he is always your parts man.

Anyone can stock parts and ASTEC stocks the world’s largest inventory of parts for asphalt plants. But ASTEC doesn’t just stock parts. ASTEC delivers the industry’s best customer service. That is what sets us apart.

Any part, any brand. We can help.

Search: 10072061

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NEW PRODUCTS

Diamond Road Smoother The Diamond Road Smoother is an all-in-one machine designed to smooth roads of bumps before preservation treatments such as chip seals, slurry seals and thin overlays. • Combines a fast and accurate diamond tooth grinding system in a truck and trailer • Contains a water tank, profiling sensors, accurate grinding head with long averaging arms, brooms, vacuum system and arrow boards • Designed for asphalt or concrete • Multiple pivoting wheels on each arm smooths individual humps and dips, leveling naturally all kinds of surface defects • 8-ft. grinding head and fast forward speed • Automated system is designed to increase the amount of roadway that can be smoothed each day Search: 12231404

Commodity HD Building ClearSpan's Commodity HD Building features an open side to provide easy access for multiple vehicles. • Design allows for structure to be broken down into separate storage bays • Add custom covers and end panels • Side panels available to partially or completely enclose • Built to withstand corrosive environments • Frame built from triple-galvanized steel • Covered with 12.5-oz., 24 mill rip-stop polyethylene fabric which is UV resistant and available in four color options Search: 12221501

Check out our Digital Buyer’s Guide! Thousands of products available for your asphalt production and paving business can be found in our Digital Buyer’s Guide at forconstructionpros.com/directory.

Portable Solar Powered Tower Larson Electronics' portable solar powered tower is on a 7-ft. trailer and can be used to power lighting, cameras, sensors or other electrical equipment mounted atop the manual crank mast. • 30-ft., three-stage steel mast • 7- by 7-ft. single axle, two wheel trailer with four outriggers • Two 265-watt solar panels • 400aH capacity battery bank • Delivers 12 volts • 16- by 160 by 8-in. junction box mounted at top of mast • 8- by 8- by 8-in. junction box mounted at top of first stage of mast • External Nycoil tubing around mast to run Ethernet cable to junction boxes • Solar panel frame angled at 45° • Electrical components encapsulated in NEMA 3R job box bolted to trailer • Cooling system circulates air within job box Search: 12226870

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

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Search: 10072222

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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: 10072736

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TECHNOLOGY UPDATE

How to Use

TELEMATICS to Improve RISK MANAGEMENT

By Lisa Cleaver, Editor

here are many ways telematics can improve how you manage your equipment fleet. Risk management and monitoring driver behavior are two ways telematics can help you improve your bottom line. For example, telematics can lead to safer driver behavior and lower insurance rates. Insurance companies tend to look favorably on construction companies that incorporate telematics into their operations, says Andy Peterson, Risk Engineering Commercial Auto Segment director for Zurich North America. “Telematics is a great coaching tool to help change driver behavior,” he says. “It’s not just having the telematics installed that’s important, it’s how effectively you use the tool that matters.” The price for telematics technology is coming down, making it more cost effective for contractors to install systems and reap the benefits of all the data that is available. While most contractors are aware of the operational benefits of telematics – equipment location, hours of service, idling times, etc. – Peterson says there’s a lot more information that contractors can use to decrease risks and modify driver behavior during trucking operations. Some items that can be monitored by a telematics system include: Headway monitoring and warning which allows companies to know how closely their drivers are following vehicles in front of them. Many drivers overestimate how much headway they have to the car in front of them, resulting in insufficient time to react if the car ahead unexpectedly stops or slows down. Hard braking is a good indication of driver behavior. Hard braking is a measure of driver events where there has been rapid deceleration. It can also be an indicator of following too closely, aggressive, inattentive or unsafe driving. Speed measurement can relay how fast a driver is going. Management may set

parameters, and if they are broken, an alert is generated, such as an email. “These are just a few examples of how you can monitor driver behavior,” says Peterson. “As a telematics user, you may be overloaded by the information from these systems. Given limited resources, it’s best to focus on one or two items, such as hard braking. You can’t chase every speeding event that comes your way, but if you have a driver who is consistently hard braking, you can take steps to modify that behavior.”

Various incarnations There are myriad telematics systems available on the market today. Some are hard-dash installed into the vehicle, some are “plugand-play,” and others are simply app-based solutions on smart phones. Event camera systems can be considered one of the most advanced systems available. These systems can view traffic ahead and activity in the cab of the vehicle. It can also be programmed so that when triggered, it will record several seconds before and after the event. For example, following a hard-braking incident, company management reviews the video and determines the driver had plenty of following distance but failed to note stopped traffic ahead early enough. The subsequent coaching session can focus on the actual deficiency rather than just the fact that they had a hard brake. Each telematics system has its advantages and disadvantages and you have to pick one that fits your business. “It doesn’t take a complex system to monitor hard braking,” says Peterson. “In certain limited circumstances, an app-based solution might work best for you, and it’s cheaper than an event camera system. But a smart phone app has challenges with mixed signals and false positives, so you have to weigh what’s going to work best for your company.”

Distracted drivers According to statistics from the National Highway Transportation Safety Administration (NHTSA), even though the number of fatal crashes has been declining in recent years, the overall crash count in the country, including property crashes, is increasing. “There’s a lot of distractions for drivers today,” says Peterson. “In addition to more traffic, drivers are dealing with texts, emails, phone calls – even conversation can be distracting.” Peterson says management can campaign for less distractions for drivers by building it into the corporate culture. “There needs to be a cultural shift when it comes to sending and receiving calls and texts,” he says. “We all know that texting while driving is bad, but there seems to be a disconnect between what we know and what we do.” Peterson says this decree needs to come from the top down. “Ask drivers to place their phones on ‘do not disturb’ to eliminate texts and stop or restrict phone calls while driving,” he says. “Drivers can be instructed to only answer or make a phone call when safely parked.” Telematics data can help you improve risk management and monitor driver behavior, which can help you increase your bottom line, but more importantly, it can create a safer environment for everyone sharing the road. And while zero incidents is a great goal, Peterson says the focus should always be on improving the numbers day by day. “Don’t let the idea of getting to zero stop you from getting better,” he says. Zurich Insurance Group (Zurich) is a multiline insurer that serves its customers in global and local markets. It provides a wide range of general insurance and life insurance products and services. Zurich’s customers include individuals, small businesses, and mid-sized and large companies, including multinational corporations, in more than 170 countries. For more information, visit zurichna.com.

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

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50 YEARS OF INNOVATION. THAT’S A HECK OF A RÉSUMÉ.

VECTOR CONTROL

With over five decades of experience fueling it, the Equinox™ burner delivers unrivaled productivity while achieving the lowest NOx emissions of any burner on the market. Combine it with the Vector Control for unbelievable fuel savings and the advantage is clear. 5201 N. Orange Blossom Trail · Orlando, FL 32810 ∙ 407.290.6000 ∙ GeneralCombustion.com Search: 10073093

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PAVING INNOVATIONS

How

FULL-WIDTH PAVING

Eliminates Longitudinal Joints, Improves Quality & Saves Time Contractors paving the massive Autoroute 30 skirting Montréal, Quebec, used a full-width paving technique to improve road quality during a recent lane expansion project

20 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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On full-width paving projects, the paver will pull a much heavier load, so make sure the paver’s drive system will deliver the required power and traction.

ddressing the challenges associated with properly paving and compacting the unconfined joint has plagued the asphalt industry for decades. There have been many techniques developed for achieving density at the joint to meet specification, offering varying degrees of success. If not constructed and compacted properly, the longitudinal joint is a weak point in the new road, and the first failure point. What if, instead of spending the extra time, effort and money to address the challenges of properly paving and compacting the joint, it is eliminated entirely? “If the right conditions exist, I’m a big proponent of full-width asphalt paving to eliminate the longitudinal in between the travel lanes,” says Bill Rieken, road building specialist for BOMAG. “You are eliminating a potential weak spot in the road, and you can significantly improve the mat’s quality, while reducing paving time.”

Full-width asphalt paving can be accomplished on a range of projects. At the city or county level, the contractor could pave both lanes of a two-lane city street or county road in a single pass. On the mainline, asphalt pavers will often pull widths of at least 28 ft. “This allows for paving of two 12-ft.-wide travel lanes plus a small shoulder in a single pass,” explains Reiken. “It eliminates the joints between travel lanes as well as between the travel lane and the small shoulder.” Regardless of whether it’s a two-lane road or multilane interstate, removing the cold joint enables the paving contractor to more readily achieve compaction density and smoothness across the entire mat width without density drop-off at the joint. By eliminating additional passes with the paver, it also increases paving efficiency and reduces the time required to pave the full length of the project, all-the-while improving the longevity of the road.

Contractors paving the massive Autoroute 30 skirting Montréal, Quebec, used a full-width paving technique to improve road quality during a recent lane expansion project. Nouvelle Autoroute 30 s.e.n.c., the company in charge of completing the expansion, not only had responsibility for designing, constructing, operating and financing the CAD $1.5 billion effort, it was also responsible for maintaining the road for 35 years. It was in the owner’s best interest to construct the new roadway in the most efficient and cost-effective manner and in a way that minimized future maintenance costs. Therefore, contractors paving the highway’s asphalt portion used a Cedarapids mainline paver equipped with a screed set to a 30.2-ft width, enough to pave in a single pass the two 13.8-ft-wide travel lanes and one 2.6-ft-wide small shoulder. A Cedarapids commercial Hydraulically extendible screeds work well on narrower full-width projects, since they offer extendible paving widths up to 20 ft.; 26 ft. with bolt-on extensions.

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

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PAVING INNOVATIONS paver followed closely behind the mainline paver to pave in echelon the full shoulder, leaving a hot joint for the rolling crew to compact.

While full-width paving offers several significant benefits, it’s not quite as easy as the contactor deciding that the company is going to pave all roads full width. Certain conditions must exist – like the ability to shut down a two-lane roadway to traffic so it can be paved in one pass – and there is some preplanning required. “All the components of the project from plant production to trucking to the paving equipment to the rollers must work in concert together to deliver a successful full-width

The 10-ft hydraulically extendible screed attached to a mainline paver offer variable paving widths from 10 to 20 feet, potentially making them a good choice for full-width paving of narrower city streets, county roads and highways. Hydraulically extendible screeds also have fixed-width bolt-on extensions help to expand maximum paving widths to up to 26 feet. Contractors should consult with the manufacturer to make sure crownable extensions are available to accommodate the crown point at the shoulder when paving at these extended widths. Many times contractors will purchase a fixed-width screed specifically for paving fullwidth projects, especially for widths extending beyond 26 ft.

attachment design for quick installation,” adds Polk. Make sure the manufacturer offers slopeable extensions to accommodate the crown point at the shoulder. Rieken cautions that paving at extended widths exerts more force on the screed than if the paver were paving at 12-ft widths, so he recommends some adjustments to the screed to handle these extra forces. “The manufacturer and/or distributor will work with the contractor to ensure the appropriate bracing and ballast is added, so

paving project,” mentions Tom Kiselica, road building specialist for BOMAG. “The paving train must move along consistently, so if the plant doesn’t have the capacity to keep up or not enough trucks are planned for delivery, the quality can suffer.” One key equipment component to a successful full-width paving project is selecting the right screed. The number of crown points in the road can determine the type of screed required – hydraulically extendible or inline fixed-width – as there will be different crown points between the travel lanes for two-lane roads and between the driving lane the shoulder for wider paving.

“They will often set up an inline screed at the yard to meet the road’s profile and ship it to the jobsite, so it can be pulled off the trailer and attached to the paver,” says Henry Polk, paving product marketing manager for BOMAG. The efficiency gains and cost savings associated with paving in a single pass more than offset the cost of having a dedicated screed for full-width paving. The benefit to a fixed-width screed stems from the variety of attachments offered, so a contractor can build the screed’s width to meet specific project needs. “Our Fastach 10 extension segments are available in 6-, 12-, 24-, 36- and 60-in widths and offer a pin-lock

it has the necessary structural integrity and proper ground contact pressure to withstand the added force of paving full-width,” he says. Kiselica adds, “We don’t want to run on the heel or nose of the screed. We want it to run at a slight nose-up altitude of approximately 1 to 1.5°.”

Before you start

Full-width asphalt paving can be accomplished on a range of projects from the two-lane city street to the multilane interstate. It can improve quality, speed up the paving process and lower costs.

Smooth & steady With the correct screed selected and configured appropriately, contractors must also carefully plan for the project. The goal with full-width paving is to keep the paving train consistently moving in order to eliminate screed settling and truck-end segregation of the asphalt.

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

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On full-width jobs, the plant must be able to supply enough mix to keep the paving train moving consistently or quality can suffer.

“You will use more material in the same period of time, so you must first consider your asphalt production needs,” says Rieken. The paving crew will potentially lay in excess of 500 tons of asphalt per hour, especially at widths reaching 30 ft., so the asphalt plant must have the dedicated production and storage capacity required. “A contractor may have to pull material from two different plants if one plant cannot supply enough material,” adds Kiselica. Trucking is the vital link between the plant and paver, and the contractor must have the right number and type of trucks to ensure continuous quality paving. Fortunately with

the road closed to vehicles, traffic congestion and truck transit time often isn’t impacted as much as when the trucks have to dodge in and out of traffic to deliver asphalt with partial lane closure projects. End-dump trucks are the least preferred transport method, since they are little more than a rectangular box, allowing the mix to segregate as particles roll to the truck’s sides and ends. “Live-bottom trucks are more preferred for their ‘V’ shapes to reduce particle segregation,” says Rieken. “Plus they offer faster unloading into the paver’s or material transfer vehicle’s (MTV) hopper, which helps to increase truck exchange efficiency and improve continuous paving efforts.” Paving contractors may have to anticipate doubling the rolling crew to match the increased mat width. With the largest mainline rollers, contractors may choose to put two compaction trains – breakdown, intermediate and finish rollers – behind the paver. “A rolling crew will be dedicated to achieving spec densities for one travel lane and the other will roll the remaining travel lane and small shoulder,” explains Bert Erdmann, product manager, heavy compaction for BOMAG. “This will allow the rollers to keep up with the paver and perform their compaction tasks at the right temperature range.”

Paving thoughts The paver will also be charged with pulling a much heavier load when paving at extended full widths. Therefore, contractors must select a paver that offers a combination of power and traction to efficiently pull off full-width paving. Both track and tire drive systems can be used, but Rieken advises contractors to carefully consider drive tire size. Paving contractors for the Autoroute 30

Beyond keeping a continuous paving process to increase quality, adding a paver or MTV with remixing capabilities will help eliminate material and thermal segregation.

project opted for the tracked Cedarapids CR662RM RoadMix paver and MTV, equipped with a Fastach 10 inline screed. The track drive system offered the traction required for full-width paving, and it spread the weight of the fully loaded paver over a larger area to prevent rutting of the subbase on base course paving. With its in-hopper Remix auger system replacing the slat delivery system of a traditional paver, RoadMix provided a thorough rebelending of the asphalt prior to it being channeled to the screed. With a conventional slat paver, asphalt movement is from the front of the hopper back, so any form of thermal or particle segregation of the mix in the truck will be transferred to the mat. Conversely, the RoadMix’s two counterrotating auger sets have a variable-pitch design that pulls material from all areas of the hopper and aggressively reblends 100% of the asphalt prior to delivering it to the screed’s spreading augers. The end result is a more homogeneous blend of asphalt delivered to the screed, which is void of both material and thermal segregation. “We are talking about increasing quality and efficiency through full-width paving,” says Kiselica. “While it is possible to pave full width using a traditional paver, why not give your crew the best chance for success by giving the material a final remixing to eliminate any segregation that may have occurred at the plant or in transit to the jobsite?”

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

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PAVING INNOVATIONS

Inline fixed-width screeds are often preferred for mainline full-width paving, especially for widths greater than 20 feet, since a variety of extensions allow the screed to be configured to the specific job.

Work with the manufacturer to make sure the screed can be configured with a slopeable extension that accommodates the crown point at the shoulder.

It is possible to complete a full-width job, especially those of narrower widths, by using just the paver to accept material from the truck. However as the paving width increases, most contractors will add an MTV to the paving train. This gives extra surge capacity to maintain continuous paving, even when there is a transport issue with material to the jobsite or a truck exchange problem. Additionally, some provide asphalt remixing to address segregation. “The benefit offered by our RoadMix,” explains Polk, “is that it can be used both as an MTV and paver, so it gives contractors additional flexibility at the jobsite. Plus its

track drive lowers ground contact pressure to less than 15 PSI, so it can be used on the critical base lift without the fear of rutting associated with MTVs using a tire drive system. Additionally, the CR662RM delivers the same asphalt remixing benefits when equipped as an MTV as it does as a paver.”

Significant payoffs With some careful consideration and preplanning, full-width paving will yield high dividends for the contractor and traveling pubic alike. First and foremost, the road is closed to traffic, giving the contractor complete control of the construction site. This

eliminates cars and truck traffic traveling at a high rate of speed adjacent to the paving area, which significantly improves safety for the work crews. Paving full-width also eliminates the weak-spot longitudinal joint running down the center of the road, boosting the road’s longevity and quality and saving the contractor the time and effort associated with rolling an unconfined edge and cold joint. This enables the contractor to achieve smooth profilograph readings across the entire mat width and better meet compaction densities without the drop-off at the joint. Finally, full-width paving allows the road to be finished more efficiently, in less time, with fewer passes and lower cost. Reducing the time it takes to pave the road allows the road to be quickly reopened to the traveling public, which makes everyone happy.

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

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LISTEN TO OUR CUSTOMERS NOT OUR COMPETITORS For 40 years and counting, ADM has been committed to producing quality, high-production asphalt plants. On top of that, we take great pride in delivering an unmatched level of service before, during and after the sale.

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PAVING INNOVATIONS

Unconventional Asphalt Paver is Effective on the Job Gravity-fed paver is designed for ease and quality production

oadtec employed some unconventional, but impressive, inspiration when designing the SP-100e Stealth Paver. The U.S. Military’s stealth aircraft are known for a radical shape and unusual paint that allow them to do things no other airplanes can do. The company used a similar strategy to create a paver they claim is unlike any others on the market. The Roadtec Stealth Paver is designed to reduce operating costs with its limited wear parts and high feet-per-minute paving. The angular design and black paint are designed to pay homage to the planes it emulates. The 32,360-lb. machine is designed to be a low-maintenance, completely gravity-fed paver specifically for operating in conjunction with a Roadtec Shuttle Buggy material transfer vehicle. The SP-100e accepts the hot mix asphalt (HMA) at the top of the machine, where gravity feeds the material through flow gates directly to the auger from the cone-shaped mass flow hopper. Gravity flow eliminates the need for slat conveyors, hopper wings, push rollers and tandem front boggies – and the cost of replacing the wear parts to these components. There is no need for the engine power and fuel consumption to run all of those

The SP-100e accepts the hot-mix asphalt (HMA) at the top of the machine, where gravity feeds the material through flow gates directly to the auger from the coneshaped mass flow hopper.

moving parts. The simple design is intended to reduce maintenance costs and initial purchase price ... in other words, cheaper to buy and cheaper to run. By combining the SP-100e Stealth Paver gravity fed system with the Roadtec Shuttle Buggy, it is intended to address several common issues found in conventional asphalt paving. The SP-100e hopper is designed to create further prevention of material segregation as the material moves through the machine. Finally, the head of material in front of the augers is automatically controlled by an electronic control system. All taken together, the HMA is expected to be delivered in one smooth motion to provide a uniformly placed mat with consistent density and smoothness. The solid-rubber wheeled Stealth is equipped with a Tier 4i, Cummins QSB 6.7 173-hp two-speed hydraulic engine, which operates at 2,200 rpm. This is a smaller engine that uses less fuel. Roadtec engineers were able to

derate the engine and provide fuel savings. The machine features a 10-ft. electricallyheated, vibratory screed with a 32-in.-long screed plate. Screed options include the standard, fixed-width Roadtec S-10, the front-extendable Carlson EZ III-10, the 48-in. housing with un-segmented rear moldboard Carlson EZ IV-10, the rear extendable Roadtec Eagle 10, and the 10-foot rear extendable Carlson EZ–R2. The Stealth can be operated from either side of the paver. Operator platforms can swing out to provide a line of sight for the machine operator. The machine’s controls and display screen move with the seat to allow for safe and convenient machine operation. Greater operator comfort is expected to be achieved through Roadtec’s FXS® airflow system that creates an air barrier between the back wall of the hopper and the operator. This feature is designed as an air curtain to push the asphalt fumes and heat up and away from the operator platform. All engine maintenance and inspection areas are designed to be easily reached through access doors on the sides and top of the paver. The hood lifts hydraulically and has a manual-lift back-up feature. The engine compartment is engineered to be roomy enough to make component access possible. In the end, just like the military stealth aircraft, the Roadtec SP-100e Stealth Paver is designed to precisely execute its own mission ... paving a smooth-finish mat.

The machine features a 10-ft. electrically-heated, vibratory screed with a 32-in.-long screed plate.

28 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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DIGITAL MONITORING OF YOUR TANK LEVELS AND VALVE CONTROL SYSTEM THE ORIGINAL

Meeker Equipment is proud to introduce our new LIQUID VISION Digital Tank Monitoring and Valve Control System to ensure safety and reliability when filling your tanks. FEATURE

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PAVING INNOVATIONS

Rubber Modified Asphalt

Usage Continues to Grow More than half of the states either use or are testing these hybrid asphalts today

odified asphalt is a critical piece of our national transportation infrastructure. Why? Because it improves the durability of our most heavily travelled roadways, keeping them smooth and safe for as long as possible. Modified asphalt typically includes additives in the binder, or the glue that holds the aggregate rocks together. These modifiers enable the binder to maintain flexibility over a broader temperature range, which means that the asphalt is better able to handle extreme temperatures without cracking or rutting. Modifying asphalt binders can be accomplished in many ways, and is no simple task. It takes knowledge, capital for specialized equipment, collaboration and coordination. Access to several large-volume and commercially viable modifying materials is also critical, because civil projects are huge endeavors and require a reliable supply chain. Binder modification began with synthetic Hybrid systems add MRP polymers, which and polymers or additives, are based on oil such as Rheopave XP10, to production and obtain maximum property, workability, sustainability and synthesis. As a result, prices cost reduction benefits. and supply match the ongoing volatility of the oil market. In recent years, a great deal of scientific study has gone into understanding the use of tire rubber powder for modification. More than half of the states either use or are testing rubber modified asphalts today.

Not subject to oil prices Already, advanced specialty chemicals such as Micronized Rubber Powder (MRP) are delivering top-end performance properties to asphalt binders and are in wide deployment. The beauty of modifying asphalts with MRP is that they are independent of oil supply and pricing volatility. Even with today’s historically low cost of oil, Rubber Modified Asphalt (RMA), which includes MRP and is produced to meet the most stringent DOT specifications, still offers notable cost savings over traditional polymer modified asphalt. MRP use also decreases the country’s dependence on oil imports, and supports local jobs and markets because most polymers used in road modification are produced outside of the United States. MRP is also the most environmentally friendly modification choice available, since it is derived from a surplus of end-of-life tire rubber. Each year over 250 million end-oflife tires are generated in the United States, leaving approximately 6 billion pounds of accessible raw material – more than enough to modify every road in the U.S.

Constant improvements Scientists are constantly developing new ideas and chemistries to improve RMA technology. One example is a movement toward hybrid systems, which add MRP and polymers or additives such as Rheopave XP10 to obtain maximum property, workability, sustainability and cost reduction benefits. These hybrid binders already meet emerging agency requirements, such as improved elastomeric properties. For example,

Florida’s DOT was In recent years, the first to develop a scientific study specification based on has focused on a hybrid system and understanding proved the success of the use of tire a modified binder by rubber powder for combining Rheopave modification. XP10 + MRP. Since then, several other states have upgraded their modified asphalt specifications to allow hybrid systems to be a direct alternative to polymer modified binders. Each year, more and more vehicles travel on our roads. Hundreds of millions of Americans rely on road safety and the ability to reach their destination quickly and comfortably. To ensure the ongoing reliability of the greatest transportation network ever created, it’s critical that we invest in technologies and materials that help us build better roads that cost less, last longer, require less maintenance and have minimal environmental impact. Environmentally sound, high-performing specialty chemicals, such as MRP, can do just that. Ryan Alleman is vice president of Lehigh Technologies, a specialty chemicals company that produces highperformance MRPs.

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

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P.O. Box 510767, New Berlin, WI 53151-0767 | email: wem@wemautomation.com ACON0916_30-31_PavingHybrid_JL.indd 31

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PAVING INNOVATIONS

Understanding Engines in the Age of TIER 4 PAVING

MACHINES By Brian Hall

he future of diesel engines is here, and it comes with a whole new language. We are being bombarded with new acronyms; DPF, DEF, SCR, NOX and its all regulated by the EPA, going into effect ASAP. Do we regen or not? And, if so, is it parked or passive? Not to worry, it’s all good. The EPA has made sure that equipment manufacturers are well informed and have all the tools necessary to ensure a clean environment for generations to come. But where does that leave the contractor who has to learn a whole new way of operating equipment? It can be confusing, but really simple once the operator understands what’s happening under the hood. In smaller machines (less than 100 hp), most of the machines on the market are Tier 4i, that is an in between stage between Tier 3 and Tier 4 Final. What you will find is that many of the machines utilize a Diesel Particulate Filter (DPF) that traps particulate matter so it doesn’t reach the atmosphere. This results in a nice, clean exhaust, but leaves us with one problem – where do the particulates go when they build up in the

filter? That’s where the regeneration process comes in. During regeneration, an extra amount of diesel fuel is injected into the system causing a hot exhaust burn. This hot exhaust burns the particulates into an ash, which is much less dense than the particulate. Most engine manufacturers estimate 3,000 hours before the DPF will fill with ash. At this time, you will swap the old filter for new. The key to reducing downtime is simple – keep your idle time to a minimum. Idling produces a cooler exhaust which results in a buildup of particulate matter. If you keep your engine as close to full RPM as possible, the engine will burn off most of the Regen Indicator – The operator must be aware of all the signals that the control panel might indicate. Ignoring a regen warning could cause a shutdown in operations.

The Tier 4

particulates and you installation won’t find yourself provides a in a situation where challenge to you are forced to do a the commercial parked regeneration or paver operator worse yet, require that due to the added an engine technician components. visit your unit. Easy, right? It really is. The key is watching your Tier 4 engine control panel. It will tell you what to do. That’s not where it ends though. Remember when you ran your old diesel engine out of fuel? Break the injector, bleed the air out of the system and start ‘er up. Not so fast with your new engine. These common rail fuel systems are computer controlled and deliver around 20,000 psi pressures. Crack an injector line and you could lose a finger or your eyesight. Thinking of pulling into your local fix-it joint for an oil change on your Tier 4 engine? Think again. Because of the recirculation of exhaust gases back into combustion, Tier 4 engines must use a CJ-4 oil that can handle

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

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Tier 4 Panel – The detailed control panel not only includes gauges, which were analog previously, but DPF Filter levels. The gauge in the top left is an exhaust temperature gauge, which should be monitored closely to prevent regeneration issues.

higher soot levels while still maintaining extended drain intervals. Thinking of bypassing the Tier 4 system? (Kind of like the catalytic converter systems of the ‘70’s) Careful. The computer control system will monitor the system and shut the machine down to a crawl if the system is bypassed. Nothing worse than being backed up with 10 truckloads of asphalt and a paver that will only idle. How about your fuel? I’m sure you have noticed the low sulfur diesel fuel at the pumps. The new Tier 4 engines must burn this new fuel as the higher content will not pass through the fuel system of this engine. We have entered into a new understanding of engine operation and maintenance. Our technicians (whether at the dealer or the end user) must be in tune with not only the maintenance intervals of the machine, but with the entire system. The operator must also relearn the way he operates the engine. No idling while waiting on trucks, regularly monitoring the DPF levels and making sure his operations will not be affected by an unplanned delay in production. The best news is the testing that goes into the installation. In this process, engineers from the engine manufacturer and the machine manufacturer go through a painstaking procedure to ensure that the engine performs flawlessly. It’s a brave new world, but it’s all for a better tomorrow. It’s been said that the new EPA restrictions mean that 25 Tier 4 machines put out the same amount of emissions as one machine without restrictions. Also, in some metropolitan areas, the exhaust coming out of the machine is actually cleaner than the air going in. Have we seen the end of the EPA restrictions though? Not by a long shot. Brian Hall is territory manager of the Mid South Region at VT LeeBoy. Search: 10073668

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

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PAVING INNOVATIONS Dynapac F1000T and F1000W Asphalt Pavers The F1000T (tracked) and F1000W (wheeled) 10-ft.-wide pavers feature an outboard auger drive and high-capacity slat conveyor system designed to eliminate centerline segregation. • Conveyor system delivers 600 tph of asphalt to a Carlson EZ III or EZ IV screed • Lay mats up to 12 in. deep on new placements and thin overlays on rehabilitation projects • Equipped with a 230-hp Cummins QSB-220 Tier 3 diesel engine and integrated Sauer drive system • Dual swing-out operator stations Search: 10426778

Caterpillar F Series Pavers Weiler E2850 Remixing Transfer Vehicle Weiler's E2850 Remixing Transfer Vehicle (RTV) is designed to help improve smoothness and handle large volumes on high-production paving jobs. • 300-hp Cat C9 engine with Acert Technology • Working speeds up to 194 fpm • 25-ton hopper capacity • Optional rear steer provides a tight inside turning radius of 14 ft. • Material flow divider with a momentary switch provides equal force to the front and rear wheels for enhanced traction when working on uneven terrain • Hydrostatic drive’s joystick control and variable speed dial make it easy for operators to match the pace of the paving train Search: 10983840

Illumagear Halo Light Personal Active Safety System

Roadtec BF 400 Road Widener The BF 400 can be used for road widening, shoulder work, maintenance and repairs of roads. • Soil, gravel, asphalt and lean concrete can also be placed • Conveyor belt is made with a special structure that is heat resistant up to 356°F • Surface of the road functions as a reference guide for the material placement • Screed slope, material height and width can by adjusted hydraulically

The Halo Light is a personal active safety system that attaches to any standard hard hat and produces a ring of light around the wearer, enabling them to see and be seen at all times. • Tension spring mounting system connects securely to any hard hat • Four light modes (Halo, HI-Alert, Task and Dim) with up to 276 lumens of power in 360° • Dual safety and task light visible over a quarter mile while fully illuminating the task area • Comes with rechargeable battery that provides 12+ hours of full power • Easy single-button functionality Search: 11248138

Generator power on board the AP1055F tracked and AP1000F wheeled asphalt pavers has been doubled to 70 kw to heat the standard 8-ft. screed from 40° F to 265° F operating temperature in 15 minutes and the SE60V XW screed extended to 33 ft. up to operating temperature in 25 minutes. • SE60V, SE60V XW and SE60 VT XW screed options offer both vibratory and tamper bars • Backlit touch-panel controls run Cat grade and slope systems from either side of the machine, up on the tractor or down on the screed • Proportional extender control offers two speeds and can be operated from the screed, tractor or pendant controls • 1,766-tph throughput capacity • 225-hp C7.1 Tier 4 Final engine with Eco Mode and Automatic Engine Speed Control Search: 12017712

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!

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34 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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EagerBeaverTrailers.com

and you're a "click" away from getting all the information you need from our nearest dealer.

35 GSL/PT

• CAPACITY: 70,000 lbs.

50 GSL/PT

• CAPACITY: 100,000 lbs.

55 GSL/PT

• CAPACITY: 110,000 lbs.

Lowest Loading Angle Available! Our tapered front beam gives you a 3 degree load angle.

Other Standard Features of this series:

“Name Brand Tires”, currently Sumitomo • Apitong Deck • All wheel anti-lock brakes • Air ride suspension • Lock in lock out outriggers • Roto-rings • Imron paint • 100% sealed wire harness • Hydraulic Hauling Pin • Hi-clearance self lifting gooseneck

For a quote on any model, please call 800-257-8163

ANNIVERSARY

1946-2016 >> EagerBeaverTrailers.com

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PAVING INNOVATIONS Vögele MT 3000-2i Material Transfer Vehicle

Volvo DD105 Tier 4 Final Double-Drum Compactor The 10-ton DD105 sets the tone for compaction innovation, built upon an all-new, visibility-enhancing pedestal frame backed by a lifetime warranty, and available with the latest options to boost job quality, including eightamplitude settings and Volvo Intelligent Compaction with Density Direct. • Front and rear 66-in wide drums • Powered by a 114-horsepower Tier 4 Final 3.8-liter Volvo engine • Fuel savings can be maximized with features such as auto-idle and ECO mode, which can further reduce fuel consumption by up to 30% • Standard dual-amplitude settings allow the operator to easily adjust drum forces according to material depth, and an optional eight-amplitude setting provides precise control • Available with two optional IC systems — Volvo IC and Volvo IC with Density Direct. Both systems offer pass mapping, temperature mapping and data storage features, offering improved quality assurance and control • Pressurized water system with triple filtration, providing uniform coverage with variable flow to prevent material pick-up • Operating weight: 22,051 lb Search: 12185806

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 reartilting 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 Search: 12113037

TransTech PQI 380 OTR Non-Nuclear Roller-Mounted Asphalt Density Device TransTech Systems PQI 380 On-theRun (OTR) non-nuclear roller-mounted asphalt density device is a noncontact, on-the-run, real-time system for monitoring the density of HMA during road construction. • Mounts directly to asphalt rollers • Provides real-time asphalt density measurements during rolling, unlike current intelligent compaction systems • U.S. highway design specifications for asphalt are based on density, density is reported directly • Easy integration with CAN output that allows use with GPS data logging systems to capture geo-located, twodimensional compaction Search: 12188200

Carlson Safety Edge End Gate Carlson's Safety Edge End Gate features a bevel using heat and extruding material for higher density. • Applied bevel will not deform under compaction process • Bevel rotates from 90 degrees for matching joints to 30 degrees for applying the safety bevel • Spring loaded so won't interfere with ride quality characteristics or deviations in milled surfaces • Third end gate jack to roll in and out of bevel faster and safer • Hinged lower unit is replaceable

Sakai SW354 and TW354 Vibratory Rollers The tandem-drum SW354 and combination-type TW354 vibratory rollers feature 24-hp Kubota Clean Diesel Solution engines that do not require diesel particulate filters or regen. • ECO compaction mode reduces fuel consumption by up to 35% while maintaining consistent compaction performance • Dynamic linear pressure of the 47-in.-wide, 27-in.-diameter drums is rated at 205 lbs./in. • Other compaction performance factors include centrifugal force of 6,530 lbs., amplitude of 0.012 in. and vibratory frequency of 4,000 vpm. • Theoretical gradeability is 38%, or 21° of incline • Oil bath lubrication provides lowmaintenance yet effective drum vibrator protection Search: 12190054

Search: 10253521

36 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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Atlas Copco CA1400 Soil Roller The Tier 4 Final compact CA1400 soil roller offers two speeds and amplitudes for added versatility on a variety of applications, including pipe trenches, roads, streets, steep slopes and parking lots. • 66-in.-wide drum and two amplitudes — .032 in. and .067 in. — allow contractors one unit for compacting a wide range of materials • Using the adjustable settings, operators can change the amplitude to suit different lift thicknesses • In addition to two amplitudes, operators can set the speed on the CA1400 to high or low to achieve different compaction results on a variety of applications and materials • Cross-mounted 75-hp Kubota diesel engine sits perpendicular to the CA1400’s frame Search: 12176711

Asphalt Distributors

ChipSpreaders

Topcon SmoothRide Road Scanning System The vehicle-mounted resurfacing solution for paving and milling projects uses a combination of core Topcon technologies designed to deliver the smoothest surface possible, while efficiently managing the quantity of material for each project. • The workflow consists of a vehicle-mounted road scan, existing and finish surface design, and machine control using GNSS with sonic tracker sensor guidance — each phase devised to contribute an overall time and cost savings, as well as maximize crew safety for projects • Once the road information is gathered, operators can use Mobile Master Office point data processing software to recreate the existing surface • MAGNET® Office with Resurfacing is then used to digitally create a highresolution model of the required finished mat • The resurfacing module allows operators to create a design using specific regulatory requirements such as minimum thickness, desired cross-slope, and overall smoothness • That information is taken to a paver or milling machine, allowing variable depth performance, the result is a much smoother road and faster completion times

Live Bottom Trailers

Heavy Duty Trailers

Search: 12185811

MOBA PAVE-IR Scan System MOBA PAVE-IR scan system provides a non-destructive method for detecting thermal segregation in asphalt pavement in real time. • Intelligent temperature scanner measures asphalt temperature over the entire paving width of up to 8 meters • Temperature profile displayed in real time on a full-color TFT touch screen display • All files stored for additional analysis in the office and for quality proof • Documents complete job with GPS coordinates and a temperature scale Search: 10083559

Asphalt Transports

E. D. Etnyre & Co.

www.etnyre.com 800-995-2116 email: sales@etnyre.com Search: 10072816

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

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PAVEMENT PRESERVATION

The Evolution of the

MILLING M

Innovations through the years have created more productive, versatile and smarter machines By Lisa Cleaver, Editor

illing machines, also known as cold planers, complete the same task today as they did 30 years ago, but they have seen several innovations over the years and are continuing to evolve. It was actually two events in the 1970s that brought about the creation of the modern milling machine. According to the Basic Asphalt Recycling Manual from the Asphalt Recycling and Reclaiming Association (ARRA), the petroleum crisis of the early 1970s and the development and introduction in the mid-1970s of large scale cold planing equipment, complete

38 Asphalt Contractor â&#x20AC;˘ www.ForConstructionPros.com/Asphalt â&#x20AC;˘ September 2016

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The milling machine pictured to the left is a Milltec, which was the transition brand from Barber Greene to Roadtec mills, circa 1988-90.

G MACHINE A ‘necessary evil’ “Not too long ago, the milling process was considered a necessary evil in which a paving contractor was forced to mill from time to time to correct a curb line or scarify a bridge deck,” says Jeff Wiley, senior vice president at Wirtgen America. In the 1980s, milling machines were hydro-mechanical with manual or lever valve controls. Grade control was hydraulic and used contacting sensors. “There was no great emphasis on smoothness of the cut surface,” says David Peterson, application engineer with Caterpillar Inc. “The machine was simply used to remove material.” Although those systems were very reliable, today’s milling – with its need to establish a super-smooth substrate for supersmooth HMA pavements – requires a more sophisticated system. “Today you can read out dual grade, grade-and-slope, stringline sensing, averaging, laser-reference, and GPS coordinates,” says Wiley. “One ground man could easily control the grade from either side of the machine, compared to always having two ground men in the past.”

Production, reliability increases with easily replaceable tungsten carbide milling tools, were the catalyst for a renewed interest in asphalt recycling. In the early 1970s, recycling asphalt was relatively disjointed and inefficient, but the oil embargo at that time created a demand for a more efficient way to recycle asphalt. Incorporating recycled asphalt in the mix meant less liquid binder was required, lowering the mix production costs and the required amount of virgin aggregate. The milling machine solved many economic problems associated with limited oil supplies and high material costs of the time, much the same as it can do with today’s prices.

According to Joe Musil, a former engineer with CMI/Terex Roadbuilding, Bill Swisher, owner of the same company, realized the potential in recycling asphalt and, in 1974, created the Roto-Mill, which was the first dedicated milling machine in the United States. It was derived from a rear load dirt trimmer that had a conical tooth drum installed in lieu of a spade tooth drum, to cut both concrete and asphalt. Since then, milling machine manufacturers have been proactive in the development of the technology for these units which have advanced exponentially in the last 30 years.

The base components and features of the original machines — cutters, conveyors, engines and machine weight — are still the required components of today’s machines. However, these components have evolved over time. With the emphasis on increasing production, cold planer design evolved from “rear loading” to “front loading” machines in order to facilitate truck loading and truck maneuvering, says Kyle Hammon, product manager - Mills, Stabilizers, Brooms with Roadtec Inc. “Early milling machines were designed to operate as ‘rear load,’ meaning the secondary conveyor would extend over the milled surface to load the dump truck,” he says. “The

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

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PAVEMENT PRESERVATION

A classic Cat PR 450 milling machine.

machine would be moving in reverse compared to how they’re conventionally operated today.” While this was the most efficient way to remove material from the cutter housing at the time, it created issues with trucking and traffic flow problems. Machines with front discharge conveyors were introduced in the 1980s, which made it easier for the truck to move with the milling machine and in and out of traffic. Higher production and greater reliability are coveted by today’s contractors. A milling machine that would cut 2 inches in the 1980s at 30 fpm has been replaced by one that can cut up to, and over, 100 fpm today. “Thirty years ago, you would mill for an hour or two, then have to work on the machine for an hour,” says Wiley. “Today’s machines are much more reliable, and downtime is minimal.”

Machines with front discharge conveyors were introduced in the 1980s which made it easier for trucks to move along with the milling machine and also in and out of the traffic flow. Horsepower has increased significantly over the years from original 375-hp machines to those pushing 1,000 hp — which are capable of milling the entire width of a lane. Now, onboard computers boost productivity and performance, while optimizing fuel consumption and preventing overload of vital components. “The old days of cutter hydraulic and chain drives are gone, replaced by more reliable and efficient belt drives, with more power directed to the cutter,” says Wiley. New equipment designs mean less down time in the

cutter maintenance area as well. “Reliable bolt-on and pressed-in holder systems – which are critical to continued productivity when retooling a drum, or tool replacement after hitting buried iron – are far superior to the weld-on holders of the past,” he says. “It all amounts to greater ease of operation, with less stress on the operator and ground men.”

Versatility Today’s contractors expect more versatility out of their milling machines and manufacturers are delivering. “Variable widths are available with segmented cutter housings to allow contractors to bolt on extensions to their cutter housing to change widths,” says Hammon with Roadtec. “Some mills are bi-directional, meaning they can operate in either direction. This allows the machine to downcut with the cutter drum, which provides better sizing, and also to provide a rear load conveyor, both are very useful for cold-in-place recycling applications.” Three- and four-track

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machines are now offered to fit contractor need and preference. Track design has changed over the years to deliver more traction when working in deep or tough cuts. Steel tracks with polyurethane pads have helped to increase tractive effort of these machines. There are also more choices available today in terms of cutting width and power for milling machines. For instance, smaller mills have been developed to efficiently handle smaller scale tasks such as milling around manhole covers. Customers now have the option to diversify their fleets which can benefit them by broadening their specialized capabilities. This affects how they manage their fleet as well as how they estimate jobs. “Added machine flexibility and utilization means more dollars and higher profits,” says Wiley. “The most significant technology advance has been the new ability to use one machine for multiple applications. “For example, today you can buy a machine on which a contractor can quickly change cutter patterns, from perhaps a 5/8-in. spacing to a 1/4-in. spacing to fit particular jobsite requirements,” he says. “You can also fit smaller cutter widths into the same unit to cut a smaller-width cut instead of having to acquire or rent a whole new machine to do that width.”

PCD bits, a.k.a. “diamond bits”, are designed to last 40 to 80 times longer than carbide bits and have reduced risks associated with bit replacement. “Diamond bits do not change length as they are used which is different than carbide,” says Peterson. “Carbide bits get dull and grow shorter as they wear, causing uneven milled surfaces and potentially causing grade inaccuracies. Dull bits can also lead to more fuel burn– up to 15% more. Diamond bits will stay sharp longer and will always stay the same length, providing smoother, more accurate cuts with less strain, less fuel consumption and less wear on the machine.” Cutting patterns – such as micromilling with a fine-tooth drum – are also Track design has changed over the years to deliver more traction when working in deep or tough cuts.

customizable to particular jobs with many options offered to the contractor.

Dust control The silica dust issue has shaped milling machine design in recent years. In late March of this year, the Occupational Safety and Health Administration (OSHA) issued its final rule which reduces the permissible exposure limit (PEL) for respirable crystalline silica to 50 micrograms per cubic meter of air and requires employers to use engineering controls (such as water or ventilation) to limit worker exposure. As of January 1, 2017, all cold planers over 60,000 pounds must be equipped with a method for pulling dust away from the mixing chamber to protect the ground crew from exposure to silica. Milling machine manufacturers have been proactive with the issue and have already begun modifying their machines to meet the

Cutting innovations Tooth consumption was very high years ago. “Today, you use less teeth because they have at least three to four times the life as compared to the past,” says Wiley. One recent innovation in this realm is the introduction of PCD (polycrystalline compact diamond) bits. “Ordinary carbide tipped tools need replacement quite frequently,” says Peterson. “Stopping the mill to replace these can be costly considering you might be stopping a fleet of trucks, an asphalt plant and a paving crew; plus, you might have time restrictions on certain jobs like tunnels or airport runways.”

Today’s telematics systems give more operating data to contractors than at any point in the cold planer’s history on the market.

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

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PAVEMENT PRESERVATION new limits. Most of the standard approaches from manufacturers include a blower at the lower conveyor to capture the dust from the cutter housing and channel it up the conveyor. Tapping into the machine’s on-board water system for cooling cutter teeth, a sprinkler system on top of the belt is used to keep the dust down. At Bauma this spring, BOMAG unveiled a prototype for a different approach to dealing Smart technology along with more sophisticated machine design have helped increase speed and accuracy on milliing projects.

with silica issue by eliminating the dust. “The system works by electrostatically charging the silica dust so it binds together to form larger flakes that cannot be inhaled by workers, thus nullifying the potential detrimental effects of silica dust,” says Tim Hoover, product manager, mills and MPH equipment for BOMAG Americas. “We are currently putting the system through field evaluations.”

Smarter machines Today’s milling machines are also smarter than they were three decades ago. Throughout the years, the industry has seen an expansion in technology for grade control. “Today’s sonar control system with multiple-eye skids help to control the depth of cut better than manual sensors that run off of string lines,” says Hoover at BOMAG. “This requires a more sophisticated machine design with more electronics, but it has helped to increase speed and accuracy.” Taking advantage of advanced electronics on engines and modifying hydraulic systems, today’s

machines have load controls on engines. “If the machine encounters a tough-cut section of the pavement that puts more load on the engine, the milling machine automatically adjusts speed to the difficulty of cut,” he says. “This improves productivity while reducing wear and tear on the machine.” Telematics systems for milling machines give more operating data to key contractor and dealer personnel than at any point in the

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Manufacturers have equipped their machines with dust control technology that taps into the machines on-board water system and limits worker exposure.

cold planer’s 40-year history on the market. “Telematics can track fuel usage and machine utilization,” says Hoover. “Additionally, fault codes can be forwarded to key service personnel, so minor issues can be addressed before they become major expense items. These systems can also track machine location as well as automatically give service reminders.” Looking down the road for milling machine design, technological innovations will be at the forefront for these machines. “The milling process and the end result will be similar, but new technology will allow troubleshooting in the field to be remotely controlled,” says Wiley at Wirtgen America. “Maintenance will be monitored from a main office, and actually already is in some areas. “Cutter designs could change dramatically from what we know today, to a much cleaner design,” he continues. “The operation of these machines will be less stressful, with more operational functions performed by the machine. There will be even more accurate control of grade, and the quantity of millings placed in the truck. Someday more advanced technology could enable one-person operation, instead of three.” Another trend to keep an eye on: 3D control systems. “Pavement rehabilitation using 3D control systems allow reshaping of the surface during milling,” says Wiley. “They work independently of references on the ground, instead using a digital terrain model as specified parameter for the milling depth. A milling machine equipped with the 3D control system delivers the desired milling accuracy in the millimeter range.”

One recent milling innovation is PCD, or diamond, bits. These cutting teeth will stay sharp longer and will always stay the same length, providing smoother, more accurate cuts with less strain, less fuel consumption and less wear on the machine. Search: 10074819

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

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PAVEMENT PRESERVATION

How to Avoid

in Asphalt Overlays

Following crack sealing “best practices” assures smooth, bump-free finished pavement By Jessica Stoikes, Associate Editor

ide quality and a lasting pavement are two things everyone can agree on when it comes to the surfaces we drive on. Pavement preservation in the form of crack sealing and overlays are essential to extending the life of a pavement. However, while rare, bumps in overlays can form. These bumps threaten both ride quality and pavement life. Crack sealing is a common method of pavement preservation because it prolongs pavement life by preventing water intrusion into the base layers as cracks develop in the pavement surface. During the life of most asphalt pavements, overlays are then placed on top of sound pavements that have properly sealed cracks. These overlays rehabilitate and further extend pavement life. During breakdown rolling of the overlay, transverse bumps and cracks have been known to form above and in front of the location where crack sealant was placed in the underlying pavement. There are multiple reasons that may cause this phenomenon, including mix design, climatic conditions, paving and compaction equipment, timing of the overlay with respect to sealant placement, sealant type and pavement grade. The proper application of crack sealant, along with the proper compaction of the overlay, can prevent formation of these bumps or significantly reduce the likelihood that bumps could form.

The bump stops here Sealing cracks in a pavement that will eventually receive an overlay requires special attention as any crack sealing method should be allowed at a minimum six months to cure before an overlay is placed.

If the proposed overlay is to be more than 2-in. thick and is to be constructed in more than one lift, follow these crack preparation procedures: • Route and seal cracks flush with the existing and surrounding pavement • Overband of the crack repair should be no more than 3-in. wide • Overband should be as thin as possible and should not exceed 1/8-in. thick

• Note: distresses are more likely to occur if an overlay is placed within a year of a pavement that has had crack sealing completed with overbanding methods. If the overlay to be placed is less than 2-in. thick, special care must be taken during crack sealing: • Cracks must be routed • Sealant must be placed flush to the pavement surface or slightly below the surface • Sealant may be squeegeed and flush filled if the band is less than 3-in. wide. A slight under fill is preferred • Do not use a sealant shoe for sealant application As sealant ages, it has a tendency to form an oxidized, non-tacky surface which resists overlay adherence. Exposure to traffic tends to wear away sealant in pavement surfaces and smooth it down level with the pavement surface. This is why it’s recommended that overlays take place at least a year after crack sealing.

Proper sealant placement In the process of overlay compaction, the rollers tend to shove the mix forward. If this happens on an underlying pavement surface which has uniform restraining characteristics, a smooth finished surface can be achieved. However, if the underlying pavement surface varies significantly due to irregularities or conflicting materials — like those that may be present after crack sealing — uneven shoving could result in unwanted bumps. When the hot mix asphalt overlay is placed, the underlying pavement will absorb the heat and expand due to the temperature change. As the heat from the hot mix warms the original pavement surface, cracks become narrower, which in turn causes the crack sealant to be pushed upwards. Most crack sealants have adhesive and elastic properties that when pushed upwards may stick to the overlay and limit overlay displacement during the compaction process. This could create a slight bump. Bumps caused by crack sealant are rare, but when they do occur it’s likely because too much sealant has been applied. In this case, the overlay grows and results in a bump which expands as it warms. This is easily remedied by scraping excess sealant off the pavement or by applying a scratch coat of HMA prior to the overlay application. The quality of the sealant also matters. If the crack has a hard, stiff sealant in place, it may not adhere to the overlay; and soft, lowmelt temperature sealants may soften enough when heated by the overlay to not restrain the mix if it displaces during compaction. Medium stiffness sealants with elastic properties may have a tendency to soften, adhere and restrain the overlay.

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

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Cat f-series Pavers ®

tHe neW standard

70 kW integrated generator saves time and fuel. • 15 minute screed plate heating • 15,000 hour service life • System monitoring keeps operator informed Learn more at www.cat.com/f-seriesPavers facebook.com/CATPaving youtube.com/CATPaving

QEXC1879-01 © 2016 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Search: 10075307

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Your New Asphalt Plant Pays for Itself in Less Than

2 Years

DOUBLE BARREL XHR The high RAP capability of the Astec Double Barrel ÂŽ XHR is taking the industry by storm. Operating this drum results in real savings that add up. 1

Reliably produce mix with up to 70% RAP content to save raw material cost. Operate in the most efficient way possible and save fuel with the V-Pack TM stack temperature control system 2. 1 2

Based on 3% moisture Only available on the ASTEC family of asphalt plants

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DOUBLE BARREL XHR Exclusive Feature Package

• • • •

Astec Warm Mix System Stainless Steel Drying Chamber Stainless Steel Combustion Flights V-Pack TM Stack Temperature Control System

Search: 10072061

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PAVEMENT PRESERVATION

In-Place Recycling Seminars Designed to

Promote Pavement Preservation By Lisa Cleaver, Editor

he staff of Asphalt Contractor recently attended the Asphalt Recycling & Reclaiming Association’s (ARRA) In-Place Recycling and Reclaiming Seminar in August in Lake Geneva, WI. The In-Place Recycling & Reclaiming Seminar, with a live demonstration, is designed as a forum for pavement professionals representing state, local and federal agencies, contractors, suppliers, consultants, academia, and MPOs, all working together to take advantage of the synergy to be gained from sharing information and identifying common issues for further investigation. The seminar provided a platform for national pavement professionals to present the state-of-the-art technologies that went on to be the building blocks of the Basic Asphalt Recycling Manual (BARM).

A look at each process During the conference, representatives from each ARRA discipline, including hot in-place recycling, thin pavement techniques, cold inplace recycling, full-depth reclamation and

soil stabilization, gave an overview of each process, what type of equipment is used and at what point in the pavement lifecycle each process is best suited. There was also a look at industry trends, including intelligent compaction, GPS control and aerial survey, that can help both agencies and contractors get the best results out of their pavements. Representatives included Rock Solid Stabilization & Reclamation, Gallagher Asphalt, Roadtec, Midstate Companies, Cat Paving, Topcon and more.

Live demos The live demonstration attended by the staff of Asphalt Contractor included several different types of full-depth reclamation (FDR) and soil stabilization techniques. On a 3,000-foot section of Klemman Road near Hebron, IL, just south of the Illinois-Wisconsin border, the Rock Solid Stabilization & Reclamation crew demonstrated 4- and 8-inch FDR with oil emulsion, 12-in stabilization with cement, and a 12-in. stabilization with Jolena, a fly ash/cement combination.

Left: A Caterpillar RM500B rotary mixer performs 12” soil stabilization with cement. Right: A Wirtgen 240i performs an 8” FDR with oil emulsion.

Attendees got to see how the process was performed step-by-step, get an up close look at the equipment and materials in action, ask questions and network with their peers. Jonathan Pease, president of Rock Solid Stabilization & Reclamation Inc., headquartered in Genoa City, WI, helped coordinate both the In-Place Recycling Seminar and live demo in Lake Geneva, as well as one held the week prior in Fargo, ND, which included live demonstrations of several types of processes. “This conference is really designed as a collaborative effort between the ARRA association members and equipment suppliers to help promote these techniques to state and local agencies,” says Pease. “It’s crucial for them to understand all the tools available for making their pavements last. It also saves taxpayer money if the right process is used at the right time in the pavement’s lifecycle.”

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

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WEILER E2850

ENGINEERED INNOVATION

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

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

Visit www.weilerproducts.com or the paving specialist at your Cat® dealer for more information. Search: 10075409

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PAVEMENT PRESERVATION Roadtec RX-500 Cold Planer The 500-hp RX-500 cold planer is available with four-track or optional three-track assemblies. • Allows cutting up to 13 in. deep with widths of 6 ft. 3 in., 6 ft. 7 in. or 7 ft. 2 in. • Light and maneuverable for urban applications • Two-stage front load-out conveyor with 60° swing to either side

Etnyre Variable Width ChipSpreaders Etnyre's Chipspreaders’ exclusive variable width hopper features individual power gates across its entire width. • Power 'batwings' in rear receiving hopper • Fixed spread hoppers from 10 to 15 ft. • Sliding operator's station • Power shifting seat allows operation from left or right side of machine • 200- to 240-hp engine options • 24-in.-wide conveyor belts • Planetary drive axles with wet disk brakes • Computerized transmission control Search: 10078189

Caterpillar PM620 and PM622 Cold Planers The 73,260-lb. PM620 and 74,580lb. PM622 half-lane milling machine perform controlled full-depth removal of asphalt and concrete pavements in a single pass. • 79- (PM620) and 88-in.-wide (PM622) high-production rotors provide a 13-in. maximum cutting depth • Three keypad-controlled cutting speeds match the rotor rpm torque with conditions • Standard Automatic Load Control • Operator's station includes dual operating controls including joystick steering/propel lever, upper conveyor controls and rear track steering controls • 630-gross-hp C18 ACERT turbocharged, six-cylinder diesel engine meets Tier 4 Final standards and is iso-mounted to reduce vibration Search: 12186872

Search: 10084652

Rosco Maximizer 3 Rosco's Maximizer 3 offers a 8- to 16-foot extendible spraybar. • 400-gpm Viking asphalt pump • Automatic in-cab controls • Enviro-Flush cleanout system • Tank sizes from 1,000 to 4,000 gals. • Internal spraybar valves Search: 10087858

SAKAI Road Planer and Stabilizer 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 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 hightorque, 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

Rayner RoadSaver II The RoadSaver II is designed for slurry seal and micro surfacing. • Various options allows you to design the exact machine for your needs Search: 10086645

SealMaster CrackPro 260 Heated Hose Machine Oil-Jacketed melter for hot pour cracksealing materials. • 260-gal. melter/applicator • Oil jacketed • Insulated with 1.5-in. ceramic, covered by 16 gauge steel • Diesel fired burners • Direct-drive full sweep agitation • Air compressor option • Heated applicator hose Search: 12227606

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

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Search: 10073532

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PAVEMENT PRESERVATION Wirtgen W 210i and W 200i The Wirtgen W 210i and W 200i milling machines are compliant with U.S. Tier 4i emissions requirements. • W 200i is powered by a single engine generating 535 hp; its operating weight is 59,922 lbs. • W 210i has nearly all of the same features as the W 210i, except for added power in cutting applications, features a unique fuel-saving drive concept utilizing two diesel engines, generating a total 680 hp with both engines engaged; its operating weight is 63,670 lbs. • Sstandard milling width of 79 in., but can be fitted with optional 59 in. or 87 in. cutting units • Three selectable engine speeds enable a broad range of applications, such as large-scale surface course rehabilitation, complete pavement removal at full depth, and fine milling, and have a milling depth of 0-13 in. • Parallel-to-Surface (PTS) technology automatically keeps the cutter housing • Intelligent Speed Control system incorporates an electronic flow divider that makes the four tracks work in harmony when turning a radius Search; 11324487

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BOMAG BM1200/35 Cold Mill The BM1200/35 cold milling machine offers a 47.2-in. cutting width and 13-in. maximum cutting depth and features a rear rotor design that optimizes milling performance. • Cutter design with the BMS 15 interchangeable holder system incorporates a single bolt for holder retention and requires a low tightening torque of 75 ft.-lbs. • 349-hp MTU Tier 4 Final diesel engine offers power to efficiently mill asphalt at speeds reaching 105 fpm • 85-, 95- and 107-rpm milling drum speeds • 25.6-in.-wide inside and 23.6-in.wide outside conveyors with capacities reaching 6,357 ft. per hour • 224.4-in. maximum conveyor discharge height • Pressurized water injection system offers a variable flow rate of 0 to 1.6 gpm to the cutter housing

Bergkamp offers the MAXX line of truck-mounted Frictional Mastic Surface Treatment Applicators, which allow users to apply premixed frictional mastic surface treatments and premixed slurry seal over highways, roads, parking lots and airport runways. • Available in two models, the MA20 and MA30 • Applies a material mix that is made to precise specification, resulting in fewer operator calculations and on-the-job adjustments, which minimizes operator training time • Full-length ribbon mixer works to maintain the proper material consistency during transit, pumping and spraying operations, regardless of the truck engine speed • Pavement treatment is applied with hydraulically operated, variablewidth, low-pressure spray bar that has side-shift capabilities Search: 12164401

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Kennametal Road King Series The new Road King series from Kennametal is a single tool system designed for both reclamation and milling road projects. • Body design accentuates easy penetration with less stress on the washer, retainer, and holding system • Series of optimized tip designs (flat bottom as well as valve seat) for varying job conditions, along with a single body design that accommodates all of them, greatly simplifying inventory • Increased body hardness on all tools to maximize wear resistance • Fluted body design supports better tool rotation behavior, improving tip wear • Head design also leads cut material away from the tool, reducing the buildup of fines between retainer and shank Search: 12197345

Bagela BA4000 Portable Asphalt Recycler The Bagela BA4000 Portable Asphalt Recycler recycles either broken chunk or milled asphalt at a rate of up to four tons per hour. • Diesel powered, trailer mounted, continuous operating asphalt recycler, designed to recycle asphalt using convection type heating • By design, flame from the burner does not come in direct contact with material inside mixing drum • Material is loaded into front of recycler via a hydraulically operated hopper and discharged through rear of mixing drum at rear of recycler • Capable of recycling either broken chunk or milled (RAP) asphalt Search: 12122447

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

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PAVEMENT PRESERVATION Caterpillar Diamond Cutting Bits

KM 8000T Dump Asphalt Hot Box/Reclaimer The Keizer-Morris 8000T dump asphalt hot box/reclaimer is designed to reclaim stockpiled asphalt. • Transport and warm cold mix asphalt • Propane or diesel heating systems • 2 or 4 ton units available • Funnelled hopper walls • Triple wall construction • Dual 3-in. insulated loading lids • Easy open cantilevered handles • Dual insulated shovel ports

Cat Diamond Bits can save operating costs and fuel efficiency by 15%. • Proprietary technology uses high pressure(1 million pounds per square inch) and high temperature (3000° F) to interlock the diamond grains into the stinger tip, which is set on the carbide body • By remaining sharp for hundreds of hours, Cat Diamond Bits dramatically reduce your costs and grow your bottom line • Last up to 80x longer than carbide tips, keeping crews more productive, month after month • Assure faster project completions • Virtually eliminate labor costs for pick changes; eliminate unplanned, unproductive interruptions • Deliver proven fuel savings per ton of production • Enable faster milling speeds and increased productivity Search: 12186884

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MicroTekk Microsurfacing Treatment The MicroTekk system combines a unique process and materials to increase a pavement’s durability and delay or mitigate cracking, while extending the life of the microsurfacing layer. • Increased workability • Extended construction window • Less aggregate and water sensitivity • Short-term raveling resistance Search: 12130835

Renova Asphalt Recycler The RENOVA Asphalt Recycler is the sustainable solution for making asphalt pavement repairs. Using the patented RENOVA process is efficient, saves money and preserves the environment and natural resources. • Recycles existing pavement into HMA that can be used to make repairs year-round with the RENOVA Rejuvenator • Easy to transport • Saves up to 30% on repairs • Only a 2-man crew is required to operate • 1 ton batch capacity Search: 12117571

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

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Strategies in a Changing Market KNOWLEDGE•GROWTH•SUCCESS 2017 NAPA AN N UAL M E ET I N G

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TAKE THE NEXT STEP IN LEADERSHIP

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PLANT MATTERS

DRONE How a

Can Make Your Asphalt Plant More Profitable

Legal drone operation can help asphalt plants with stockpile management, maintenance, marketing and saving money By Jessica Stoikes, Associate Editor

nmanned aerial systems (UAS) or drones seem to be dominating many conversations in the construction industry. The asphalt industry has taken these drones from a marketing tool and turned them in to a real way to increase profits in their plant operations. John Dougherty, owner of Louisville Paving and Construction based in Louisville, KY, says the use of drones has revolutionized the way they do business and they continue to find new uses for them every day. “Being a pilot, I like anything to do with flying so when I noticed drones at World of Asphalt three years ago, I immediately recognized the speed that they could bring to many labor intensive tasks,” Dougherty says.

Stockpile management done faster & cheaper One of the first things that Dougherty thought the drones could help him with was stockpile management. Think about how you currently manage your stockpiles. If you’re like most plant owners, you have a worker physically go to each stock pile with a GPS rover, climb up and down the piles marking points and tracking the data. That captured data is downloaded and checked before loading into a take-off program that converts the volumes into tons. Not only is this exhausting for your worker, it can take them up to four days per plant to complete. Dougherty estimates the old process would cost his company $1,080 in labor to complete per plant. That’s at a rate of $45/hour for 24 total hours. Compare that to using a drone and Dougherty is saving himself almost $1,000 per quarter, per plant location. Here’s how: First, you need to map out a flight plan.

Using drones to monitor and manage stockpiles, Lousiville Paving saves up to $1,000 per quarter per plant location.

Louisville Paving uses DJI Ground Station to complete the flight plan. Using Google Earth to set a boundary, the app that controls the drone generates a flight plan that can control the drone from takeoff to touchdown. Manual controls can override the flight path if need be. Dougherty estimates this process takes him about 20 minutes and once a good flight plan is established, it can be reused for future flights so this step is eliminated. “Once onsite, there is a pre-flight checklist that I go through ever time, just making sure that all the components are in good working order and the conditions are right to fly,” Dougherty says. “The pre-flight checklist, GPS acquisition and calibration takes about 15 minutes. Flight time varies depending on

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

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location and area needed to cover, we can fly all our Middleton Plant in one flight that lasts about 10 minutes.” During flight, the drone’s camera is busy taking a series of overlapping images with GPS coordinates. GPS coordinates on the images are being converted into 2D and 3D maps that are used to create a point cloud that forms a visual 3D model. Once on the ground, the data the drone has collected is processed into a program called PIX4D Mapper. From those images and data, Dougherty can produce output analytic data such as volumes and contours of the materials on the property. That data can be stored in his existing takeoff program and the flight plan reused. Dougherty says stock pile management using drones has a labor cost of $90 to complete per plant. That’s for two hours at $45/hour. That's almost a $1,000 saved with this use alone. “Before we used drones, we didn’t really have a process for plant and quarry stockpile management and there were times we might be down waiting on materials,” Dougherty says. “Now, we monitor both our stockpiles and our quarries to anticipate supply problems to allow us to make job mix formula (JMF)

adjustments as needed before we need to interrupt our crews. “And since we can more easily monitor our stockpiles, we do it more frequently now was well,” Dougherty continues. “This allows us to forecast potential deficiencies in products, enabling us to plan accordingly.”

Dougherty says to work with a potential vendor to be sure you’re not only getting the drone to best complete the work you want, but also the software. “An internet search can find almost anything you need, but you need to talk to the vendor and be satisfied it will do what you want it to do,” he says.

Plant maintenance made safer While you may think that no one knows your asphalt plant like a maintenance team in the trenches every day, you should consider that drones can help your team do the same inspections, not only safer, but also more efficiently, saving both time and money. Drones can easily fly up to areas on the plant that are difficult to reach, keeping your crew safe on the ground. Dougherty says drones make it easier to monitor and document elevated ductwork, drag conveyors and bin tops for any issues. The

Using a drone with 3D mapping capabilities, Louisville Paving is able to see stockpile quantities more frequently than by manual measurements, making them more able to readily adjust quantities and avoid shortages.

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

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PLANT MATTERS The NEW Small UAS Rule went into effect on August 29, 2016. Make sure you’re operating your drone legally by visting www.faa. gov.

images taken can be inspected by plant personnel and potential problems can be more easily caught before they cause any real issues. “If we can catch plant problems before they result in a breakdown, that leads to huge cost saving implications,” Dougherty says. Plan to use your drone as part of the daily walk around, especially on portable plants to make sure everything is up and running before the guys on the jobsite can even think about being delayed by a plant breakdown.

Start-to-finish project monitoring Drones are also great for helping your company plan out projects. With the same 3D mapping that Louisville Paving uses for stockpile management, Dougherty also uses his drones to map topography of jobsites before crews even get onsite. He says this can help with the bid process if they suspect a quantity bust on a job. “We overlay the typo we take with the drone on to the plan design and generate our own quantities,” Dougherty says. This can help them accurately bid jobs and turn them down if the profit won’t be there based on their quantities. “We also fly all site jobs after they are cleared to check elevations so we can verify quantities before we even get out there,” Dougherty adds. “Many existing elevations on plans coming from the engineer are generated before the site is cleared which impacts the accuracy of the results. Obviously, knowing the actual elevations is beneficial.” In addition to mapping the typography of a jobsite in order to manage quantities, drones can inspect jobsites for silt control, security and progress. This helps with project information dissemination as drones can let any member of the project team know the project status after a quick 15-minute flight. Drones can generate

Get Legal While anyone can purchase a drone, contractors are most likely operating their drones for commercial use and need to insure they are covered before they can operate their drone legally. The NEW Small UAS Rule (Part 107) went into effect last month. For more information see: https://www.faa.gov/uas/media/ Part_107_Summary.pdf The Federal Aviation Administration (FAA) currently authorizes the use of UAS/Drones for commercial or business purposes on a case-by-case basis. You may not fly your UAS/Drone for commercial purpose without a Section 333 Exemption. Dougherty recommends becoming a member of the Unmanned Aerial Vehicle Systems Association (UAVSA) for help this this. UAVSA’s multiple Part 333 Exemption Services program is designed to assist all UAVSA members in understanding, participating in, applying for and receiving a 333 Exemption for the authorized flight of drones in the National Air Space (NAS). Since the process involved in applying and filing for a 333 Exemption can be complicated and laborious, UAVSA provides to its members a 333 application service assistance program to help them get the hard work done efficiently and affordably. In addition to the Section 333 exemption, there are three other specific items the FAA lists as “main requirements” you will need to operate unmanned aircraft in a business capacity: • A Certificate of Waiver or Authorization (COA) that is specific to the airspace of your operation • An aircraft registered with the FAA • A pilot with an FAA airman certificate (Sport certification minimum) The FAA’s final interim rule (FIR) also requires drone registration at a cost of only $5. You will also need to ensure your drone is properly insured which most insurance companies have readily gotten onboard with based on the increasing popularity of drones. UAVSA can also assist contractors with this, visit http:// www.uavsa.org/ for more information.

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

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PLANT MATTERS

as-built models that can be sent to project managers to identify any delays or budget overages. This also adds to increased safety as drones are able to quickly identify hazards even on large jobsites. Originally, Dougherty was just thinking he’d use his drone for stock pile management but now, “we’re still finding uses for it,” he says. Drones can cost anywhere from $1,000 to $30,000 depending on what capabilities you desire. The more you want the drone to do, the more the unit and the software will cost. Some contractors simply want drones for taking aerial shots of completed work for marketing. Before drones, about the only way to get these shots was to hire a pilot who could take shots from their aircraft. At a minimum cost of $600 per flight, purchasing a low-cost drone would be worth the investment. “Aerial photography and videography of jobsites make for great marketing tools whether online, in print or when pitching jobs in person,” Dougherty adds. “And it’s great PR with clients as everyone is fascinated with drones.”

Lousiville Paving also uses their drones for asphalt plant maintenance. Flying them up to hard to reach areas for inspection while keeping the crew safely on the ground.

Drones can assist in project management from start to finish. Using 3D mapping, Louisville Paving researches typography of a site to assist in the bid process and also to obtain more accurate quantites before a project begins.

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

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PLANT MATTERS

The Benefits of Outsourcing

Your Maintenance Companies like Adams Asphalt Plant Services can help you focus on the job of producing asphalt while increasing your bottom line By Lisa Cleaver, Editor

hen your asphalt plant is running efficiently, it’s using less fuel, reducing emissions and putting more money in your pocket. When it’s not running efficiently, however, it can lead to downtime, less production and a decrease in profits – all which will directly impact your bottom line. With today’s shortage of qualified technicians and the pressure to keep producing, even a minor repair can wreak havoc on your plant’s schedule. Enter a company like Adams Asphalt Plant Services, a one-stop source for maintenance, repairs, fabrication, plant moves, retrofits, and consulting for asphalt plants owners and managers. Owner Jon Adams is a 25+ year veteran of asphalt plant operations. He worked for the same company overseeing the maintenance and production of various types of asphalt plants at the company’s three divisions until he started Adams Asphalt Plant Services in 2003. He also has a team of professionals who have years of hands-on experience.

Qualified techs Adams began the business in central Wisconsin but moved the headquarters to its current location in Johnson Creek, less than an hour west of Milwaukee, in 2005. He has four crews – about 10 employees – that are located in Wisconsin but work nationally. Adams says the shortage of qualified laborers makes a business like his even more important to an asphalt plant’s balance sheet. “We hire welders and fabricators and train them to perform these tasks,” he says. “There’s a shortage of labor across our industry; there’s definitely a deficit. We don’t have enough tech

schools. We just don’t have the people to serve our industry.” Because of this, asphalt plants can run into a giant roadblock if they don’t have the people to do even the basic maintenance, says Adams. Therefore, they have to outsource their maintenance in order to

Adams Asphalt Plant Services is a one-stop source for plant maintenance, repairs, fabrication, plant moves, retrofits and even consultation.

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

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PLANT MATTERS stay competitive. “We offer off-production-hour maintenance – we can work through the night,” he says. “That way, the asphalt plant can be back online the next morning and not miss a beat.” Adams argues that the ROI for outsourcing maintenance is greater than keeping a stable of maintenance techs on staff. “We do this every day – this is all we do,” he says. “We’re not also trying to run the mix, troubleshoot the paving crew and all the other items an asphalt plant manager is trying to do. We come in, do what is asked as quickly as possible and leave. It’s quality service, performed

Sweeting says Adams’ crews are well equipped with the tools needed to get the job done. Adams has a full-fledged fabrication shop in Johnson Creek, but also brings much of it with them in the fully-equipped mobile fabrication shop that travels to every jobsite. “I’ve done the ROI on hiring Adams or having the staff and tools ourselves,” says Sweeting. “It’s a wash really, but he keeps his staff and equipment up to date and it’s one less thing I have to worry about. They’re faster and more efficient than we could be. “My plant operators are trained to operate a plant,” he continues. “I like them to do just that – concentrate on the plant operation.”

More than just maintenance and repairs

The Adams crew travels all over the country completing repairs for asphalt plants that may not be able to find the skilled workers needed for maintenance.

efficiently and safely.” Mark Sweeting, plant control manager with Wolf Paving, a Wisconsin asphalt producer and paver serving the Madison and Milwaukee area, uses Adams Asphalt Plant Services for both major and minor repairs as well as normal maintenance on its two asphalt plants. “We use them for everything from A to Z,” says Sweeting. “When we have a major breakdown, they’re out here quickly and repair the problem efficiently.”

Adams Asphalt Plant Services does more than just maintenance and repairs. They also do new asphalt plant design, engineering and construction as well as complete plant relocation. They can also work with you during the decisionmaking process of purchasing a new asphalt plant. Rick Croy with Dunn Road Builders, headquartered in Laurel, MS, hired Adams via a recommendation for a plant setup in 2014. The company has three asphalt plants and plans to set up another in the coming year and will use Adams to complete the process. “Adams’ crews worked seven days a week,” says Croy. “They hit the ground running and really listened to my people. They communicated every step of the way with the plant superintendent. “They do this every day,” continues Croy referencing the experience Adams crews have. “We can concentrate on running the asphalt plant while they do the set up. It works well for us.”

Safety emphasis “We’re a one-source company with a heavy emphasis on safety,” says Adams. “Our team is our most valuable asset, and we go to

Services offered by Adams Asphalt Plant Services • New Asphalt Plant - Design, Engineering and Construction • Complete Asphalt Plant Relocation • Heavy Construction and Fabrication • Emissions Testing and Burner Analysis & Adjustments • Repairs / Rebuilds / Retro-fits • Welding / Pipe Welding Service • Sourcing of Both New and Used Equipment • Preventative Maintenance • Consulting and Training • Trunnion Alignments • Custom Built Dust Augers • High Wear Plate Sales (chrome carbide) • New Asphalt Pump Skids • New Asphalt Tanks • New Cold Feed Bins • New Scale conveyors • Complete Baghouse Services (new bags and cages) • Complete Maintenance Inspection Reports • Waste Oil Heaters • Waste Oil Pump Packages • Pneumatic Dust Systems • Mineral Blowers • Mineral Filler Silos • Mineral Piping • Mineral Dust Elbows • Tank Insulation/Reskin • Plumbing Insulation great lengths to ensure their safety. Through training and education, we arm our staff with the proper knowledge to keep a safe work environment.” That means regular training, including bringing in resources to keep employees up to speed and certified.

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

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PLANT MATTERS “We’re a growing business and integrity is important,” says Jon Adams, owner Adams Asphalt Plant Services.

“We regularly bring in field experts to train our team on rigging, working in confined spaces, CPR and much more,” says Adams. “On a semi-annual basis, industryleading safety instructors train our team on the safety issues facing our industry.” Adams has been enhancing his safety

program over the last year and has invested a lot – both time and money – in having the proper procedures to meet or exceed contractor’s requests and requirements. He recently hired an operations manager whose job it is to ensure safety procedures are followed. Adams knows that a clean safety record is important, but he says his safety program is about more than that. “Yes, it lessens our risk of getting fined and helps us to get more work, but it’s really about keeping

our employees safe,” he says. “What we do is dangerous, and I want my crews to be prepared as best as possible. “We want to be a leader in safety, and this is how we get there,” he says. Adams works hard with clients so they can see that Adams Asphalt Plant Services isn’t about maintenance or relocations or consultations but about providing solutions to their problems. “Integrity in our operations is so important,” he says. “We do what we say. We bid correctly. We meet completion dates. We fulfill our promises. Clients see how we react and overcome obstacles; communication is key. We work hand in hand with the contractor. We’re a growing business and integrity is important. It’s what we’ve built this business on, and it’s what will continue to grow us.”

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68 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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PLANT MATTERS

Laurel Asphalt Paves the Way for Reducing Odors and Keeping Neighbors Happy

Custom -blend, eco-friendly odor control eliminates odorous emissions for asphalt production facilities By Dr. Laura Haupert and Ron Mulford

hile the asphalt and aggregates arenas are undergoing a time of great innovation, odor management will always be a challenge. One of the unavoidable byproducts of the asphalt production process is a mixture of volatile hydrocarbons, mercaptans, hydrogen sulfide and heat, which may cause a unique mixture of foul odors. In addition, with many of today’s industrial facilities, including asphalt production, there has been a demographic shift where new residential development creates closer neighbors. This suburban sprawl has significantly impacted asphalt plants and how they deal with neighbors. There has been a dramatic rise in odor complaints, which often end up in

the press. This can be a major challenge that keeps plant managers up at night.

Customized solution Fortunately, the solution is as simple as a process additive that can be mixed directly into liquid asphalt used in hot mix plants to control the odorous emissions. In most cases, it only takes a small amount of the correct additive to a plant’s liquid storage and handling process to reduce the odors. Before the odors become airborne, they are eliminated. Additionally, new odor issues have arisen due to the changes in liquid asphalt composition. To address this new challenge in the industry, OMI Industries offers a specialized solution that tackles these unique odor challenges through an offering of customized

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

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PLANT MATTERS solutions designed by OMI’s PhD chemists. Ecosorb solutions use natural ingredients to eliminate industrial odors without use of harsh chemicals or masking fragrances. By adding Ecosorb to liquid asphalt during transfer and handling processes, it is possible to eliminate all types of odors from asphalt. The result is less odorous asphalt production and storage, regardless of its composition. This type of additive does not alter the physical properties of the asphalt. For example, the flashpoint and softening point and ductility all remain the same, even when using a 1,000ppm concentration of the additive.

By developing sound odor-mitigation strategies, it is possible to build goodwill in the community, as highlighted by Laurel Asphalt’s efforts. When this happens, asphalt production plants can operate at top capacity with little impact on the surrounding communities. As a result, everyone wins.

Dr. Laura Haupert is the director of research and development for OMI Industries, and Ron Mulford is the

equipment division manager for OMI Industries. OMI Industries specializes in developing natural solutions for the treatment of industrial odors and offers technology and equipment, which eliminates odors without the use of harsh or hazardous chemicals, expensive emission control systems or masking fragrances.

Laurel Asphalt’s strategy Located in Laurel, MD, this producer provides asphalt for a wide-range of state, county and private projects. In 2013, the company opened up a new asphalt production plant in Elkridge, MD, which is now located in the middle of a residential district. As a result, Laurel Asphalt received a widerange of odor complaints from neighboring residents. The facility tried to mitigate the issue by installing a vaporization refrigeration system, which was placed on the top of the tanks, for potentially holding the smell down. Unfortunately, this new system could not contain the foul smells. With odor complaints increasing everyday, the team at Laurel Asphalt conducted additional research and discovered the Ecosorb custom blend solutions — and tried a sample. Based on the success of the sample, in 2015, Laurel Asphalt decided to move forward with working directly with OMI Industries to develop its own custom additive called Ecosorb AP-100A. After four months of use, the plant held an open house for residents to extend a hand to the community and acknowledge that the odor situation had been mitigated. The lively event was complete with food, music and more importantly … no odors. “Within less than a month, the odors were completely gone and we have not received any more complaints from residents,” says Chris Waters, plant and operations manager at Laurel Asphalt. “The solution was a lifesaver for us.” In addition, Laurel Asphalt found the ecofriendly aspect of Ecosorb to be very compelling. From planting trees on the perimeter of the facility to receiving awards for its clean facilities and environmental efforts, the use of Ecosorb aligns well with Laurel Asphalt’s green efforts. Search: 10073374

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

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PLANT MATTERS › CLIFF’S NOTES

Formulas to Keep in the

FOREFRONT

C li f Not f’s es

Some friendly reminders for new operators By Cliff Mansfield

ost experienced plant operators know these formulas and will find this boring. However, this issue of “Cliff’s Notes” is directed to the less experienced operators, the new guys. They will find these things both interesting & informative. To convert horsepower to KW: • Multiply horsepower (h) by .7457 • Assume the following: h= 350hp • EXAMPLE: 350x .7457= 261 KW

Conveyors To find the speed of the conveyor: • Calculate the sheave ratio, i.e.: 10” drive,

18” driven • 10 divided by 18 = .555 Multiply motor speed by the answer = input RPM • Input RPM divided by gear box ratio x diameter of head pulley x .2618= belt speed in FPM • Example: Assume an 1800 RPM motor, a 25-1 gear box and an 28” head pulley: 1800 x .555= 999 divide 25 = 39.96 x 28= 1118.88 x .2618= 292.92 FPM To calculate the length of a slat conveyor at a 45-degree angle: • Measure height (h), multiply by 1.41416 • Assume the following: h= 65' • EXAMPLE: 65x 1.41416= 91.9204 feet long slat at 45 degrees

To calculate the speed in FPM of a slat conveyor, the following information is needed: • Motor RPM- (rpm) • Motor sheave size- (ms) • Driven sheave size- (ds) • Gear box ratio- (gbr) • Head sprocket size- (hs) • Assume the following: Rpm= 1755, ms= 8", ds= 14", gbr= 25.13 to 1 and hs= 9" • Calculate the sheave ratio, i.e.: 8" drive, 14" driven • Multiply motor speed by the answer = input RPM • Input RPM divided by gear box ratio x diameter of head pulley x .2618= slat speed in feet per minute

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

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Search: 10073849

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PLANT MATTERS › CLIFF’S NOTES • EXAMPLE: 8 divided by 14 = .571 x 1755 = 1002.86 input rpm div. 25.13 gbr = 39.91 head shaft rpm 39.91 x 9 = 359.19 x .2618 = 94.04 FPM

Asphalt Oil To find asphalt % by total mix: • Add oil to aggregate then divide oil by total of the two • Assume the following: 250 tons aggregate used, 15 tons oil used • Example: 250agg + 15oil = 265 15 div 265 = .0566% oil by total To calculate where you should be running with a known aggregate TPH: • TPH of dry aggregate x % of oil, div. 100% of oil = oil tph • Assume the following: 70tph aggregate (dry), 5.4% oil • Example: 100% - 5.4% = 94.6 70 tph x 5.4% = 378 div 94.6 = 3.99 tph of oil To find the number of gallons delivered on a particular bill of lading: • Net weight in pounds (x), divide 8.328 (pounds per gallon of water, which has a specific gravity of 1.0) = y • Divide y by the specific gravity (z) listed on the delivery ticket for the oil you are using • Assume the following: x= 66,920, z= 1.0273 • Example: 66,920 divide 8.328= 8,035.54 (y) 8,035.54 divide 1.0273 (z)= 7,822 gallons at 60 degrees Fahrenheit To find asphalt gallons per ton: • Look up AC pounds per gallon at the oil's temperature (x) • Divide that number into 2000 • Assume the following: x = 7.81 • Example: 2000 div. 7.81 = 256.08 gallons AC per ton at the chosen temperature To convert gallons of oil to tons: • Look up AC pounds per gallon at the oil's temperature (x) • Multiply that number by number of gallons • Divide that number by 2000 • Assume the following: x = 7.81 • Example: 7.81 ppg x 25,000 gals = 195,250# div 2000 = 97.625 tons of oil at (x) temperature To find out how many tons of oil are in an AC tank: • Check oil temperature (t) • Measure liquid, convert inches to gallons (g)

• Find temperature on compensation chart and get conversation factor (f) • Read oil pounds-per-gallon* at 60 degrees (p) • Assume: t= 325 degrees • g= 12,834 gallons, f= .9105, p= 8.456 • Example: 8.456 x .9105= 7.699ppg at 325 degrees 7.699ppg x 12,834gals = 98,811.37 pounds 98,811.37 # divide 2,000 = 49.41 tons

General Facts A plant loses about 3% of its production rate per 1,000 feet of elevation due to the thinning of the air. Plants are designed to remove 5% moisture. Obviously, the higher the moisture, the lower the production rate. NAPA publishes a series of charts to figure losses for elevation and moisture. Visit asphaltpavement.org for more information. To figure how much mix you can make with a given quantity of oil: • Tons oil divided by percent of oil in mix = yield • Example: 28 tons div. .055%= 509.09 tons of hot mix produced To find pounds-per-gallon of any oil: • Find specific gravity listed on 'bill-of-lading' (g) • Multiply pounds-per-gallon of water (8.33)* by the specific gravity (g) of the oil • Assume: g= 1.0273 {actual reading for Oregon PBA-2} w= 8.33 • Example: 8.33 x 1.0273= 8.56pounds-pergallon for the oil at 60 degrees *Actual PPG of Water To find U.S. gallons capacity of a cylindrical tank: • Measure the diameter (d) and the length (l) • Square the diameter, multiply by length, then multiply by .0034 • Assume: d= 95", l= 337" • Example: 95x 95x 337x .0034= 10,341 gallons

Baghouse It requires approximately 165 CFM of air to produce 1 ton of hot mix. To find the correct baghouse size for a particular drum: • Radius x radius x 3.142 (pi) x *1000= CFM required • Example: Assume a 9 foot drum. 4.5 x 4.5 =

20.25 x 3.142 = 63.6255 x 1000 = 63,625.5 CFM • This drum would require a 65,000 CFM baghouse * 1,000 feet per minute equals the air velocity through the dryer/mixer. This figure is usually down around 750 to 850 fpm, but using 1,000 fpm gives us a little bit of over sizing which is a good thing since we don’t want the air-flow through the baghouse to limit production rates. To find the square feet of cloth in a particular baghouse, you need to know the diameter of bag (D), lengths of bags (L) and number of bags (N): • The formula is: D x 3.142 = A • A div 12 = B • B x L = SF (sq. ft. per bag) • SF x N = total sq. ft. of cloth in baghouse To find air-to-cloth ratio (should be under 5.- to-1 in batch, and 5.5-to-1 in drum plants): • Determine square footage of an individual bag (X) • Multiply that by the number of bags (Y) • Divide that answer by baghouse CFM (Z). X times Y = total square feet of cloth (sq/ft). Z divide sq/ft = air to cloth ratio Most manufacturers figure drum air velocity at between 900 and 1,000 FPM. Viking pump sizing • HL225 .01898 gallons per revolution • K225 .1055 gallons per revolution • L225 .23 gallons per revolution • 2"Q34 .23 gallons per revolution • 3"Q34 .61 gallons per revolution Used in conjunction with an accurate tachometer, these pump specifications can be helpful to calculate pump outputs when considering erratic mix sample results relating to asphalt content.

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 39 years of experience working with various brands and styles of asphalt plants. For more information, contact Cliff by calling 541352-7942 or visiting hotplantconsulting. com.

76 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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PLANT MATTERS McCloskey I44R Impact Crusher McCloskey International introduces the I44R, which combines crushing, screening and recirculating to provide seamless production. • For aggregate and concrete recycling applications • 42-in.-diameter x 43-in. wide impactor side wall angles to allow better material flow • Redesigned under pan delivers more throw and enhanced material movement • All new feed boot on main conveyor to accommodate more material flow from the under pan • Radial return conveyor allows recirculated oversize to either go back to the hopper, be stockpiled or fed to another machine • Open chassis design allows for easy access to maintenance points • Optional water pump and dust suppression system Search: 12197375

Meeker Batch Plant RAP Kit

Evoflex CA from Ingevity 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 product maintains flexibility and low temperature crack resistance • Facilitate blending of 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 Search: 12195028

ADM EX Series Asphalt Plants Asphalt Drum Mixers Inc. introduces its EX Series asphalt plants with single-drum counterflow technology. • Produce 100 to 425 tph • Capable of processing high percentages of RAP • Using counterflow technology, unit has separate drying and mixing zones to achieve the maximum level of heat transfer and fuel efficiency • Designed to virtually eliminate unsafe hydrocarbon emissions • System reintroduces residual gases back to the drum's combustion zone • Available in portable or stationary; meet federal and state specs • Plant controls are sophisticated in their abilities, yet simple in operation Search: 10658422

The Meeker 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

Ecosorb Asphalt Additives Ecosorb additives are a natural and effective solution for significantly reducing hydrocarbon emissions as well as eliminating organic or inorganic odors associated with asphalt and fuel oils. • Do not contain amines • Will not react negatively with your binder Search: 10088966

Astec Double Barrel XHR Astec's Double Barrel XHR (eXternal mixer, High RAP) aggregate dryer can produce up to 400 TPH with up to 65% RAP/RAS. • Employs two mixing technologies: an outer chamber on the drum and an external mixer • V-Pack Stack Temperature Control System maintains as low an exhaust temperature as possible when running a high RAP/low virgin mix • Stainless-steel drum and combustion flighting withstand the higher temperatures associated with running high RAP Search: 12191409

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

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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 • Uses field-tested components proven to perform in a variety of conditions • Built around the Dillman unified drum • Includes a 50-ton SEB to ensure a quick set-up without the need for cranes • Whisper Jet 50 burner, 34,000 cfm pulse jet baghouse and the PMII controls • In place of the 50-ton SEB, customers can choose a 100-ton crane erect silo Search: 10616687

KPI-JCI and Astec Mobile Screens K300/6203CC Gencor Ultrafoam GX2 System Gencor’s Ultrafoam GX2 warm mix technology can achieve consistent foaming at varying production rates without the use of a powered mixing device. • AC and water can be introduced at 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

The new portable K300/6203CC is a highlymobile crushing and screening plant designed for sand and gravel, quarry or recycle applications. • Combines a heavy-duty, roller bearing Kodiak Plus K300+ Cone Crusher with a triple-shaft, low-profile horizontal screen • Modular design offers flexibility for easily converting the plant to meet producer configuration requirements, resulting in a quick turnaround from order to delivery • Axle configurations to fit all of your transportation requirements • Allows producers to utilize a single chassis to produce up to three finished products or supplement existing demand in a small footprint, reducing the number of auxiliary conveyors required to get the job done Search: 12187665

Eagle Skid-Mounted RAP Recycling System

Search: 10223065

ClearSpan Low-Profile Building

Tarmac American-Made Equipment Tarmac International offers Americanmade equipment to the United States and global markets. • Complete new plants, new components, replacement parts • Consulting cover complete plant energy audit, air pollution control review, production boost • Used equipment: for sale or for listing Search: 10087449

The Low Profile Building from ClearSpan Fabric Structures is designed to be built on blocks, foundations, containers, helical piers or posts of any height, ensuring that the building’s clearance meets any application. • Short sidewalls to create a structure that is as tall or short as needed • Features a peak design and utilizes ultra-strong truss arch design • Triple-galvanized structural steel • Covered with 12.5-oz., 24-mil rip-stop polyethylene fabric that is UV resistant and comes in four color options • Covers allow natural light to filter through, eliminating the need for artificial lighting during the day

Eagle's skid-mounted RAP Recycling System features a one-touch computer screen that switches product from top to base and back. • Introduces RAP into drum mixers for any size specifications • Produces up to 50% RAP for the necessary mix in 400600 TPH recycling drum mix plants Search: 10360694

Search: 12194516

78 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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SPECIAL REPORT QUALITY CONTROL TECHNOLOGY

QUALITY CONTROL

in the lab setting

he quality of your asphalt mix is crucial to a successful paving job. The faster you know if your mix is meeting all its specs, the faster you can get it the job or correct problems. That’s why quality control equipment in the lab is of vital importance to today’s asphalt producers. In the following pages, we’ve gathered the latest offerings from leading suppliers of asphalt lab testing equipment. For more information on any of these products, or to see more quality control products, visit our Buyer’s Guide at ForConstructionPros.com/directory. In addition to features and benefits, you can find spec guides, videos and more on thousands of products for the asphalt contractor.

James Cox & Sons Texas Overlay Tester This state-of-the-art test equipment determines the crack initiation and crack propagation experienced within asphalt mixtures. • Designed to simulate the expansion and contraction movements that occur in the vicinity of joints or cracks and which result in reflection cracking in overlays • Characterize both the crack initiation and crack propagation properties of asphalt mixtures Search: 11225100

Humboldt Hamburg Wheel-Tracking Tester The HA-1000 Hamburg wheel-tracking tester is used to test submerged, compacted hot mix or warm mix asphalt specimens as per AASHTO T 324 standard. • Device consists of a reciprocating wheel that is rolled over the specimens while measuring the rate of permanent deformation • A constant load of 705 N +/-4.5 N is applied to the specimens with a sinusoidal wheel speed of 1 ft/sec in a constant temperature controlled water bath up to 70 °C (+/-1.0 °C) An LVDT jig is used for continuous measurement of permanent deformation along the path of the rolling wheel • Accommodates cylindrical or slab specimens. • Software for automatic determination of Stripping Inflection Point (SIP), number of passes to SIP, number of passes to failure Nf and other calculated parameters • Stainless steel construction with temperature-controlled water bath up to 70°C • Superpave Gyratory Compactor available for specimen compaction Search: 12238934

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

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SPECIAL REPORT QUALITY CONTROL TECHNOLOGY Gilson MO-36 Rolling Thin Film Oven

Anton Paar SmartPave Asphalt Rheometer The SmartPave is a dynamic shear rheometer (DSR) based on the latest MCR rheometer technology with the well-established EC motor system. • For dry sample heating and stepby-step instructions for measuring procedures according to AASHTO T315, AASHTO T350 (TP70), AASHTO TP101, ASTM D7175, ASTM D7405 and DIN EN 14770 • For measurement of ground tire rubber (GTR) modified asphalt binder as well as for viscosity measurements according to AASHTO T316, ASTM D4402 and DIN EN 13302, a unique Peltier temperature device for concentric cylinder geometries is available • Fully automated temperature calibration • Toolmaster patented system for automatic recognition of measuring systems and accessories • QuickConnect coupling: Easy, onehand measuring system connection • Large working space for convenient sample filling, trimming, and cleaning • Ethernet connection for remote control of the instrument through the company network • Any type or combination of rheological tests, both in rotational and oscillatory mode, are possible Search: 10076984

The Gilson Rolling Thin Film Oven (RTFO) is designed to measure the effect of heat and air on asphalt binder properties. • Controlled flow of heated air is directed into the openings of horizontal glass bottles as they rotate on a carousel rack, simulating short term aging of binder during production, handling and paving operations • Programmable operation allows accuracy, repeatability and simple operation with minimal training • Built-in NIST Traceable Platinum RTD Sensor is mercury-free and precisely controls temperatures to +/-0.1°C • Double-wall stainless steel construction maintains temperatures up to 246°C (475°F) at 1°C (1.8°F) uniformity. Thermal shut-down switch activates at 250°C • Exceeds ASTM D2872, AASHTO T 240 and California 346 with fast 5 to 8 minute temperature recovery time after loading samples • High-temperature silicone compression fit gaskets securely grip RTFO bottles for easy insertion and reduced risk of spring-clamp breakage Search: 12188106

Brookfield DV2T Viscometer & Thermosel System

The Asphalt Analyser is fully compliant with the latest ASTM, AASHTO and BS Draft standards specifying equipment and procedures in determining the asphalt binder content of hot mix asphaltic and bituminous mixtures by the use of solvents. • After extraction there are no problems with destroyed minerals and all components of the mix are available for further investigation • It produces quick results • No calibration curves are required • Results have a much higher accuracy and with better repeatability of results

Brookfield's DV2T Viscometer and Thermosel System with SC4-27 spindle is designed for testing asphalt binder viscosity. • Measures fluid viscosity at given shear rates • Choice of traditional standalone operation and automatic operation through programs downloaded from the PC or with complete control by PC using Brookfield RheocalcT Software • Full color graphical touch screen display • PG Flash Software can be used to program the DV2T to control all aspects of the test and data collection without the need for the operator to monitor the instrument

Search: 10206259

Search: 12238923

Cooper Asphalt Analyser

80 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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Search: 10074983

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SPECIAL REPORT QUALITY CONTROL TECHNOLOGY Grieve 1025 Cabinet Oven

Pine SuperPave AFG2Gyratory Compactor Pine Test Equipment's AFG2 Superpave Gyratory Compactor is designed to compact asphalt specimens. • Handles soils, emulsions, and concrete • User-friendly • Compacts material at a constant consolidation pressure, a constant angle of gyration, and a fixed speed of gyration using an electomechanical system • Users set the consolidation pressure, the angle of gyration parameters, and the mode of operation via the control panel • Integrated computer control system, a control panel with display, two USB ports, an Ethernet jack, a completely enclosed compaction chamber, an integrated angle of gyration measurement system Search: 10084435

Grieve offers its No. 1025 400ºF floor-level cabinet oven designed for heating asphalt road cores at the customer’s facility. • Workspace dimensions measure 46” W x 28” D x 60” H • 14 KW are installed in Incoloy-sheathed tubular elements to heat the oven chamber • 1,500-cfm, 1 1/2-hp recirculating blower provides horizontal airflow to the workload • 6-in.-thick insulated walls • Top-mounted heat chamber • Aluminized steel interior and exterior • Other features include digital indicating temperature controller, SCR power controller, manual reset excess temperature controller with separate contactors and a recirculating blower airflow safety switch Search: 12239489

The Retriever from Instrotek Instrotek releases an allnew USB upgrade for the NCAT Ignition Furnace, the Retriever. • Upgrade kit that adds a USB data port to the NCAT Furnace allowing users to instantly access a digital file of NCAT asphalt content test results • Ability to collect and store data to a USB flash drive • Allows data to be cataloged, saved and emailed to agencies and customers from your computer • Works with your existing NCAT thermal printer or as a direct replacement • EZRetrieve software application displays burn results and includes: Sample ID number, mix type, technician’s name and digital signature • All data is encrypted for added security insuring the integrity of your test results Search: 10930376

82 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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Let's � talk·Custom-Built Control Centers I

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I 1 �Y§!�r�t§

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84 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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CLASSIFIED ADVERTISING

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

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CLASSIFIED ADVERTISING

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› Recommend measures to improve production methods, equipment performance, final product quality and crew performance. › Perform a variety of tasks in heavy/highway construction projects.

APPLICANTS MUST HAVE THE FOLLOWING QUALIFICATIONS: › Valid CA driver’s license with low point driving record. › Minimum 5 years asphalt paving supervisory experience with 3+ state highway experience. › Heavy equipment operating experience.

› Strong commitment to safety. › Able to work varying shifts and travel to project locations. › OSHA 30 and/or OSHA 10 certification preferred. › Strong leadership skills with the ability to manage

and train staff while leading crews. › Comprehensive understanding of CALTRANS regulations and project specifications relating to construction and paving activities.

APPLY BY completing an application at www.papichconstruction.com or contacting the main office for an application at 800 Farroll, Grover Beach, CA 93433, 805-473-3016. We are an Equal Opportunity Employer that offers a competitive wage and benefit package. Email a resume to jobs@ papichconstruction.com

Equipment for the asphalt industry. Full plants and individual components. New inventory added often.

86 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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CLASSIFIED ADVERTISING

Router

Used Crafco SS melters and EZ pour melters starting at $15,000.00.

Call toll free at 1-888-922-3630 email: nhmsltd@gmail.com

NHMS • P.O. Box 5315 • Akron, Ohio 44334 Additional used equipment available. All sales include onsite training.

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Used Crafco Model 200 routers starting at $6,000.00.

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

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CLASSIFIED ADVERTISING

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Improves Mix Production Efficiency

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88 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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CLASSIFIED ADVERTISING

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ADVERTISERS’ INDEX

Adams Asphalt Plant SVCS

Aggregate Designs Corp.

NAPA

Almix

National Highway Maintenance System Ltd. LLC

Asphalt Drum Mixers

26-27

NPE

Astec Inc.

13, 46-47, 65, 86

Papich Construction

BITCO Insurance Companies

Pugmill Systems Inc.

BOMAG Americas Inc.

Reliable Asphalt Products Inc.

Carlson Paving Products Inc.

Road Science

Caterpillar

Roadtec An Astec Industries Co.

11, 92

Clear Span Fabric Structures

Screen Machine Industries

C. M. Consulting

SealMaster

Desert Green Technologies

Systems Equipment Corp.

7, 83

Dillman

16-17

Tarmac International Inc.

Eager Beaver Trailers

TransTech Systems Inc.

E. D. Etnyre & Co.

Trimble Dimensions

E. T. Clancy Co.

Weiler

Evans & Daniels

WEM Automation LLC

FastMeasure by KTP Enterprises

Wirtgen America Inc.

5, 25

Gencor Industries Inc.

3, 69

Systems Equipment Corp.

15, 27

General Combustion

Tarmac International Inc.

Heatec Inc.

Tensar

Ingevity

Thermo-Max Corp.

Innophos

TransTech

K-M International

Trimble Dimensions

LeeBoy

Valley Industreis

Libra Systems

Weiler

Meeker

29, 75

Wirtgen America Inc.

5, 53

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

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THE LAST EXIT

Can Your

Caffeine Fix

also Fuel Roadways?

The popularity of coffee is creating millions of tons of coffee grounds which engineers hope to use as a strong base for roadways By Jessica Stoikes, Associate Editor

our morning routine probably includes a cup of hot coffee to wake you up and get you going for the day. Once you’re on your way and happily caffeinated, have you ever thought about the waste that’s created by your cup of joe? When people talk about the waste from cafés, they tend to focus on the massive pile of disposable cups that end up in landfills. But the average coffee shop also throws out around 22 pounds of coffee grounds a day; in most big cities, that can add up to around 200,000 tons of coffee ground waste per year.

Professor Arul Arulrajah, who leads the geotechnical group in the Center for Sustainable Infrastructure, is also an avid coffee drinker. “I see the baristas throwing away the used coffee grounds and I think, ‘why not look at this as an engineering material?’” he says. For the past few years, Arulrajah and PhD candidate Teck-Ang Kua have collected used coffee grounds from cafés surrounding Swinburne’s Hawthorn campus in Victoria, Australia. The objective of this study was to evaluate the possibility of combining a highly organic waste, coffee grounds, with industrial wastes such as steel slag and fly ash into a sustainable subgrade construction material by geopolymerization. They dry the grounds in an oven to around 120°F for five days, then sieve the grounds to filter out lumps. The grounds are then mixed. They use seven parts coffee grounds with three parts of slag. Finally a liquid alkaline solution is added to bind everything together. The mixture is compressed into cylindrical blocks that prove strong enough to use as the subgrade material that sits under a road surface in road embankments specified by various road authorities. “On average the cafés we collect from dispose of about 330 pounds of coffee grounds per week," Arulrajah says. “We

estimate that the coffee grounds from Melbourne’s cafés could be used to build three miles of road per year. This would reduce landfill waste and the demand for virgin quarry materials." Arulrajah and his team believe that this green geopolymer and the research findings have the potential to transform the construction industry with the sustainable usage of waste byproducts in future road subgrades. The researchers at Swinburne

coffee waste into fuel for cars and energy to heat local homes. After the company collects the waste, they bring it to a large local processing plant, where machines dry the grounds, extract the oil and turn the rest into biomass pellets that can be used in heaters. The oil will be used as biofuel for cars and trucks. Unlike biofuels like corn ethanol that are made from crops, the waste coffee biofuel is considered an "advanced," or carbon-neutral

University of Technology have also been investigating the use of crushed brick or glass and concrete for use in road construction.

biofuel. These materials are also cheaper than other alternatives, in part because of the fact that they're using something that would otherwise be thrown away — coffee shops currently have to pay to have the grounds trucked to landfills, incinerators, or anaerobic digestion plants. Bio-bean says they already have customers eager to buy the product. Cheers to fueling your body while contributing to a more sustainable world!

Fuel your morning and your car Since coffee waste is so abundant, other companies are investigating additional ways to recycle these grounds for use beyond waste in a landfill. Bio-bean, a company founded in London by an architecture student, plans to start turning

90 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2016

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