The latest trends in plant automation Page 52
EXCLUSIVE!
Technology Update:
How to pave an
Telematics, 3D Pavers, Wearable Technology & More Page 64
AWARD-WINNING
RUNWAY How Summers-Taylor used planning & jobsite logistics on the Tri-Cities airport project in Tennessee and won a NAPA award Page 18
November 2015 • www.ForConstructionPros.com/Asphalt
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NC
RL D HA SE C , LO ER NC NT E E E C UR N H IO OC T N BR E NV CE CO EN E T ER OT ONF L C AR
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UNMATC HE D PORTABL E S Our HELI-TANK™ unit combines a hot oil heater with heated asphalt tanks. It is available in six different sizes with capacities from 10,000 to 35,000 gallons.
ADDITIVE TANK
LEVEL INDICATOR AND FLOAT
INSULATION INSULATED BULKHEAD
HIGH- LEVEL PROXIMITY SWITCH
HOT OIL HEATER
UNLOADING PUMP
The hot oil heater is one of five Heatec heaters with outputs from 700,000 to 2,000,000 BTU/hour. The storage tanks have serpentine heating coils heated by hot oil.
FUEL TANK METERING PACKAGE
The tank has 6 inches of insulation and is fully insulated. It has high and low level limit switches to prevent overfilling and coking the coils. Numerous options are available, including the following: • • • • • • • •
Mixers for polymers Foundation options Piping options Chassis options Fuel tank options Additive tank options Metering package options Unloading pump options
H E AT E C , I N C .
RUN-AROUND VALVE
HELI-TANK FEATURES WITH OPTIONAL COMPONENTS
HEATING COILS
MIXER SHAFT & IMPELLERS
PLATE FOUNDATION
Other options include a sock filter for the hot oil line, fuel preheater mounted on the rear frame extension, liquid level indicating systems and alarms, and fold-down handrails. An optional telephone dialer automatically reports heating problems when unattended. Many of these features are illlustrated above. The HELI-TANK unit is unmatched for its versatility. Please call today for more information.
HEATEC
®
an Astec Industries Company
5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com Search: 10073245
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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 NOVEMBER 2015
COVER STORY
DEPARTMENTS PAVING INNOVATIONS
28 PAVEMENT PRESERVATION
38 PAVING INNOVATIONS
PLANT MATTERS
18 How to Fix an Airport Runway
Planning, jobsite logistics and crew support land SummersTaylor a NAPA award for the Tri-Cities Regional Airport runway project.
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PAVING INNOVATIONS
PAVEMENT PRESERVATION
28 Paving a Small Town
38 Rigorous Maintenance
in Asphalt
The mayor of a small town in central Iowa achieves his goal of paving all the streets with asphalt without raising taxes on the citizens.
34 Paving Products
Pavers, rollers, screeds, material transfer vehicles & more.
Keeps Milling Machine with High Hours Cutting a Path Koss Construction Co. is determined to keep its historic W 2200 going via standard service intervals.
PLANT MATTERS
52 The Latest Trends in Asphalt Plant Automation
Technology helps asphalt producers gain control, harness data, increase profits.
60 Cliff’s Notes
Why daily reports are important to manage your asphalt plant.
46 PPRA Fall Meeting Offers New Ideas, Perspectives
61 Plant Products
Over the course of two days, 32 presentations focused on the pavement preservation industry.
Plants, baghouses, mixers, dryers, silos, automation systems & more.
48 Preservation Products Milling machines, reclaimers, infrared equipment & more.
Dillman builds tough equipment. Equipment that performs reliably for years. Equipment you can count on to produce high quality asphalt mix. Full plants. Single components. Individual parts.
Dillman gets the job done
Search: 10072736
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TABLE OF CONTENTS IN EVERY ISSUE
TECHNOLOGY UPDATE:
81 Advertising Index
8 Editorial
Is U.S. infrastructure ready for post-Panamax?
10 New Products
A look at the latest equipment and technology available to the asphalt industry.
64 How to Optimize Telematics with a Maintenance Management Program
82 The Last Exit
Teaching old asphalt new tricks with Delta S Asphalt Rejuvenator.
68 Advanced Paving
Technologies to Develop “3D Paver”
70 How Wearable Technology is Saving Lives
72 Technology Products Telematics, grade controls, intellegient compaction systems, software & more.
WHAT’S ONLINE www.ForConstructionPros.com/Asphalt
NEW AASHTO INSTITUTE INCREASES AWARENESS ABOUT TRANSPORTATION INVESTMENT
INDIANA INVESTIGATING $71M CRUMBLING ASPHALT ISSUE Indiana Department of Transportation is investigating 188 roads — $71 million in
AASHTO officially launched the
asphalt — that might have
BATIC Institute: An AASHTO
been paved with asphalt mixed
Center for Excellence, which will
with too little binder, causing
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the roads to crumble and
of transportation finance, in-
cracks years earlier than they
cluding bonding, federal credit
should.
assistance, and public-private
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partnerships. Search: 12127059
MAKE HOTEL RESERVATIONS NOW FOR NATIONAL PAVEMENT EXPO
Check out the best places to stay for NPE 2016, Jan. 27th30th as Show Manager Amy Schwandt gives you an inside look at the best hotels in Charlotte, NC. Search: 12127706
NOVEMBER 2015 Vol. 29, No. 9
Published by AC Business Media Inc.
201 N. Main Street Fort Atkinson, WI 53538 (800) 538-5544 • www.ACBusinessMedia.com www.ForConstructionPros.com/Asphalt
Published and copyrighted 2015 by AC Business Media Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage or retrieval system, without written permission from the publisher. Asphalt Contractor (ISSN 1055-9205, USPS 0020-688): is published ten times per year: January, February, March/April, May, June/July, August, September, October, November, December, with an additional Buyer’s Guide issue published in August by AC Business Media Inc., 201 N. Main Street, Fort Atkinson, Wisconsin 53538. Periodicals postage paid at Fort Atkinson, Wisconsin and additional entry offices. POSTMASTER: Please send change of address to ASPHALT CONTRACTOR, PO Box 3605, Northbrook, Illinois 60065-3605. Printed in the U.S.A. Canada Post PM40612608. Return Undeliverable Canadian Addresses to: Asphalt Contractor, PO Box 25542, London, ON N6C 6B2. SUBSCRIPTION POLICY: Individual subscriptions are available without charge only in the USA. The Publisher reserves the right to reject nonqualifying subscribers. One-year subscription to nonqualifying individuals: U.S. $45.00, Canada & Mexico $65.00, and $95.00 all other countries (payable in U.S. funds, drawn on U.S. bank). Single copies available (prepaid only) $10.00 each (U.S., Canada & Mexico), $15.00 each (International).
6 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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CAT F-SERIES PAvERS ®
THE NEW STANDARD
Integrated Cat® Grade Control. • • • •
Operate from any of the four operator consoles Stays on the machine User friendly touchscreen On-the-go sensor selection
Learn more at www.cat.com/F-SeriesPavers
facebook.com/CATPaving youtube.com/CATPaving R
QEXC1880-01 © 2015 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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November 2015 • Vol. 29, No. 9
EDITOR'S PERSPECTIVE
Is U.S. Infrastructure Ready for Post-Panamax?
Published by AC Business Media Inc.
Lisa Cleaver, Editor
lcleaver@ ACBusinessMedia.com
The re-opening of the expanded Panama Canal could increase business at many East Coast ports to record-setting volumes — but are our highways ready?
W
ith the long-anticipated expansion of the Panama Canal nearly complete, logistics operations along the East Coast are close to seeing a gamechanging event become reality. The re-opening of the expanded Panama Canal in early 2016 could increase business at many Northeastern ports on the East Coast to record-setting volumes. Recent research by The Boston Consulting Group and C.H. Robinson predicts that up to 10% of container traffic could shift to the East Coast following the expansion of the Canal by 2020. While there’s little doubt that the shift of container traffic from China and East Asia will be reaching the shores along the East Coast, there is uncertainty as to whether the transportation infrastructure in the Northeast will be able to handle the increase in cargo demands. Many ports have had the foresight to initiate infrastructure projects including deepening the main channel of the Delaware River and raising the Bayonne Bridge in New Jersey. According to a recent article in Food Logistics by Eric Sacharski, industry insiders aren’t worried so much about the ports handling the increased cargo as much as the crumbling highway system that is already incapable of transporting current levels of traffic.
“The northeast highway system is severely limited,” says John Haggerty, vice president of business development at Burris Logistics, a supply chain solutions provider. “Washington D.C., Philadelphia, New York and Boston are traffic nightmares, and the worst traffic in the entire U.S. may very well be in Fairfield Country, CT. The ports concern me much less than the highways.” A deeper Panama Canal will give the East Coast a chance to seize more market share; unfortunately, the inadequate, broken highway system could hurt the region’s ability to compete. Michael Landsburg, vice president of real estate at NFI Industries, another logistics provider, agrees. “As distribution gets closer to end markets and customers, traffic congestion and volume of trucks and cars on the roadway will continue to be a limiting factor,” he says. Anxiety over whether our gridlocked highway system can handle the influx of post-Panamax goods is a clear example of what experts have been saying all along: Our highway infrastructure – and lack of a long-term funding bill – is limiting our ability to grow here in the U.S. and to compete internationally.
201 N. Main Street | Fort Atkinson, WI 53538 800.538-5544 • www.ACBusinessMedia.com www.ForConstructionPros.com/Asphalt
Publication Staff Publisher
Amy Schwandt
aschwandt@ACBusinessMedia.com Editor
Lisa Cleaver
lcleaver@ACBusinessMedia.com
Associate Editor
Jessica Stoikes
jstoikes@ACBusinessMedia.com
Ad Production Manager
Patti Brown
Art Director
April Van Etten
Sr. Audience Development Mgr
Wendy Chady
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Advertising Sales (800) 538-5544 Sean Dunphy sdunphy@ACBusinessMedia.com Jill Draeger jdraeger@ACBusinessMedia.com Erica Finger efinger@ACBusinessMedia.com Tom Lutzke tlutzke@ACBusinessMedia.com Amy Schwandt aschwandt@ACBusinessMedia.com Eric Servais eservais@ACBusinessMedia.com Denise Singsime dsingsime@ACBusinessMedia.com
ForConstructionPros.com Digital Operations Manager
Nick Raether
Digital Sales Manager
Monique Terrazas
Editor
Larry Stewart
Managing Editor
Kimberly Hegeman
Change of Address & Subscriptions PO Box 3605, Northbrook, IL 60065-3605, Phone: (877) 201-3915 • Fax: (800) 543-5055 circ.AsphaltContractor@omeda.com
Reprint Services For reprints and licensing please contact Denise Singsime at (800) 538-5544 ext. 1245 dsingsime@ACBusinessMedia.com
List Rental Elizabeth Jackson, Account Executive, Merit Direct LLC, Phone: (847) 492-1350 ext. 18 Fax: (847) 492-0085 • ejackson@meritdirect.com
AC Business Media Inc. Chairman
Anil Narang
President and CEO
Carl Wistreich
Executive Vice President
Kris Flitcroft
CFO
JoAnn Breuchel
Vice President, Content
Greg Udelhofen
Vice President, Marketing
Debbie George
8 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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THE UNIFIED “UF” SERIES DRUM
SINGLE DRUM COUNTERFLOW
PROS: RUGGED! SKID MOUNTED or PORTABLE Built to last WARPAGE Resistant
NO
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 Soilworks Enhances Durasoil New production method creates a high-performance, ultra-pure and ecological dust suppressant that remains active for long periods of time
S
oilworks, a supplier of dust control and soil stabilization products, has been awarded a second U.S. Patent for its revolutionary gas-to-liquid (GTL) technology-based dust control product, Durasoil. The newest GTL Durasoil produces the purest, greenest and only synthetic dust suppression fluid that remains active over long periods of time. Until now, petroleumbased dust suppressants and synthetic fluid derivatives lacked durability and offered short-term effectiveness when they were implemented. With the new Durasoil formula, Soilworks has developed a synthetic compound that offers long term durability. The result is a safe, virtually non-toxic composition that is capable of reducing the generation of airborne and suspended
particulate matter for long periods of time. Created with nonpetroleum properties, Durasoil is designed to control dust in a variety of worksites by “wetting out” soil. The outcome is a re-workable solution that coats and clusters dust particles and weighs them down. The product is diverse and engineered to withstand the most extreme weather and environmental conditions. “Our newest Durasoil will drive the industry to new heights,” says Chad Falkenberg, founder of Arizona-based Soilworks, “The product is proven to work effectively and to handle the most severe dust control challenges for an extended period of time.” Other dust suppressants have attempted to address dust control issues and suppress the negative effects associated
with uncontrolled and suspended particulates, says Falkenburg. They have lacked durability and long term effectiveness, however. In order to move toward something more exceptional, Soilworks has created an innovative and effective dust suppressant that is even more environmentally friendly and performs for extended lengths of time.
“It’s important to us, as a company, to move toward a future where the dust control industry is driven by genuine results and environmental efficiency,” Falkenberg says. “The newest Durasoil technology, is designed to provide a high quality dust control solution.” Search: 12104918
MMD Lynx Lite Pro 8 Light Tower The Lynx Lite Pro 8 light tower features a durable, efficient Kubota D-1105 Tier 4 engine and a 36-gal. fuel tank that enables a 72-hour runtime. • Lighting fixture incorporates four 1,000-watt metal halide lamps and is fully adjustable and multi-directional with 360° rotation • Fully hydraulic cylinder can rise to 28 ft. in just 24 seconds • Eight-event programmable timer with auto start and warm up/cool down features enables easy automatic operation • The unit includes an 8-kW generator with 120V GFCI duplex outlet Search: 12094967
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!
10 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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A FULL LINE OF EQUIPMENT & PRODUCT SUPPORT SOLUTIONS FOR ALL YOUR ROAD BUILDING NEEDS. PAVERS | MTVS | COLD PLANERS | STABILIZERS BROOMS | COMPETITIVE PARTS | GUARDIAN
roadtec.com 1.800.272.7100 423.265.0600
© 2015 ROADTEC.INC. ALL RIGHTS RESERVED Search: 10074458
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NEW PRODUCTS Allmand MAXI-HEAT MH500iQ
Case Tier 4 Final 621F and 721F Wheel Loaders The 162-net-hp 621F and 179-net-hp 721F meet Tier 4 Final using a 6.7-liter engine with a selective catalytic reduction (SCR) that treats emissions separately with diesel exhaust fluid (DEF) and does not require the engine to re-circulate exhaust gas, meaning no diesel particulate filter regeneration or maintenance. • Both machines feature quick, powerful hydraulics and four programmable power modes to match machine output to available engine power • Heavy-duty axles with auto-locking front and open rear differentials allow for optimal traction in most conditions • Optional “Efficiency Package” includes a fivespeed transmission with lock-up torque converter, axles with auto locking differential and advanced system programming Search: 12075802
The Maxi-Heat MH500iQ features MCS dual heat exchangers that produce a maximum of 1,000,000 combined BTUs, or they may be operated independently depending on heating requirements. • 16-in. heater outlet flanges and optional flexible ducting provide various heat distribution options • iQ analyzer detects environmental temperature and pressure, suggests correct burner setting and automatically configures the nozzle, eliminating need to change nozzle as altitude changes • 250-gal. fuel tank capacity that provides over 30 hours of continuous operation without refueling • A CAT or optional Isuzu liquid-cooled 1,800-rpm diesel engine with 9-kW transformerregulated generator provides power to operate heater blowers and safety systems Search: 12095008
Elevance Clean 1000 Asphalt Degreaser Designed for asphalt/tar removal and degreasing applications, Clean 1000 from Elevance Renewable Sciences is easily formulated with d-limonene because the HLB requirement of Elevance Clean 1000 is 11–13, very similar to that of d-limonene. • Boosts performance when used with d-limonene in formulations for asphalt/tar removal and degreasing • Performs as well or better than d-limonene in traditional formulations—in fact, in the industry standard Gardner Cleaning test (ASTM D4488-95), Elevance Clean 1000 has demonstrated 3x the performance of d-limonene • Offers price stability, a large secure supply and economy • Targeted for removing greases, asphalt, tarand bitumen • Outperforms d-limonene at neutral pH, obviating the neeed for highly caustic cleaning products, and the need to preserve sensitive metal substrates Search: 12099029
Renova Asphalt Recycler The RENOVA Asphalt Recycler is the sustainable solution for making asphalt pavement repairs. • 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-person crew is required to operate • 1-ton batch capacity
Trail Ox Series Scrap Trailer from Ox Bodies Ox Bodies offers a rugged Scrap Trailer as part of its end dump trailers series. • For residential and commercial demolition projects with large debris, such as concrete, brick, asphalt or stone • Hardox steel construction • Capacity of up to 60 cu. yds. • Frameless design available in lengths up to 40 ft. and side/end heights up to 72 in. • Standard front mount hoist • Swing gate style tailgate • Various configurations and options are offered to meet specific hauling needs Search: 12115387
Search: 12117571
12 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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THE FACES OF ASTEC PARTS
SHE’S ALWAYS YOUR PARTS PERSON When parts tech DONNA FLOYD is not helping her customers, you’ll find her camping in a matador red replica 1961 Shasta Airflyte. And when she gets back to the office and takes your call, she takes as much care to find the part you need as she does to find the perfect campsite, because she’s always your parts person.
An ASTEC parts tech knows that being successful in her job means that you count on her to deliver when needed. So when she takes your call she takes care to find exactly the part you need and then gets it to you as fast as possible. She’s always your parts person.
Anyone can stock parts and ASTEC stocks the world’s largest inventory of parts for asphalt plants. But ASTEC doesn’t just stock parts. With a team of 35 parts professionals, ASTEC delivers the industry’s best customer service.
Any part, any brand. We can help.
Search: 10072061
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NEW PRODUCTS EZ Road Lightweight TempRamps
Sakai GW750-2 Pneumatic Roller The 20,370-lb. GW750-2 vibrating pneumatic-tire roller develops a dynamic gyratory action that combines the kneading action of a pneumatic tire roller with the high forces generated by a vibratory roller. • Seven 16-in.-wide pneumatic tires include three vibrating tires positioned on the front axle and interspersed with four on the rear, providing a total overlap coverage and rolling width of 77 in. • Unique switching system allows the operator to select from five force settings ranging from 20,580 lbs. of static force to over 55,000 lbs. of total applied force, switchable from the operator’s station • Powered by a 123-hp Isuzu 4jj1XDIA watercooled, turbocharged engine Search: 12113133
New lightweight TempRamps cost 30% less than the original rubber TempRamps. • Can be used at butt joints, bridges, steel plates and endof-day joints • Made from recycled materials • Mill one day placing TempRamps at joint, when crew paves, all they need to do is back out anchors, put them in pickup and take back to yard for the next time • When paver picks up at end of day, lay TempRamps down and roll off joint, next morning pick up TempRamps for a clean straight edge Search: 12114970
Wacker Neuson 80 Series Compact Loaders
Utilicor Minicor-2 Coring Attachment The 48-in.-wide keyhole coring attachment fits all skid-steer loaders with a rated operating capacity of 2,000 lbs. and hydraulic flow rate of 16 gpm. • Cuts keyhole cores up to 24 in. in depth through asphalt, concrete or reinforced concrete pavement • Accommodates coring drums from 8 to 24 in. in diameter • Compact size and mobility enables fast, accurate work in tight spaces • 100-gal. water tank Search: 12114762
Trimble 3D Grade Control System for Bobcat Grader Attachments The GCS900 3D grade control solution is now available for Bobcat all-wheel steer, compact track and skid-steer loaders, allowing small contractors to work faster and more effectively on complex projects that require digital designs and 3D machine control. • Large contractors can also benefit by using 3D machine control to complete the finish phase of projects more affordably and accurately with their Bobcat machines Search: 12114304
The 10,472-lb. 8085 and 12,236-lb. 8085T with telescoping boom feature a standard travel speed of 12.4 mph with 19-gpm auxiliary flow or an optional Ecospeed highspeed/high-flow configuration with travel up to 25 mph and 30-gpm high-flow auxiliary hydraulics. • 8085 high-flow edition includes automatic ride control • Two-wheel drive, all wheel drive and crab steering modes with automatic synchronizing to the selected mode • 74-hp Deutz 2.9L, Tier 4 Final diesel engine with maintenance-free DOC aftertreatment • 8085 offers an 8,047-lb. tipping load and 10-ft. 10-in. reach height and the 8085T has a 6,435-lb. tipping load and 15-ft. 5-in. extended reach • Hydraulically operated universal attachment plate • Standard deluxe cab with extra space and storage, air-ride seats, premium HVAC and a panoramic view Search: 12127069
Global Barrier Coatings ARA ARA is used in almost all aspects of asphalt material handling and is designed to reduce equipment maintenance and energy costs, including reduction in manpower times spent cleaning equipment. • Designed to reduce contamination through the displacement of hazardous chemicals, including diesel fuel • Provides a unique releasing barrier • Does not negatively effect the asphalt mix design • Provides results with all types of asphalt types and mixes • Proven effective with rubber modified mix designs • Provides a lubricating action • Removes residue from equipment • Ready to use - no dilution or mixing required • Does not freeze at low temps orevaporate at high temps Search: 12122865
14 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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TURN GREEN INTO BLACK. USE LESS FUEL.
GENERAL COMBUSTION OFFERS A FULL LINE OF HY-WAY HEATERS HY SERIES · HYT SERIES · MKVO SERIES · ELECTRIC TANKS · SA ELECTRIC SERIES HEATERS · PI ELECTRIC SERIES HEATERS
All Hy-Way heaters deliver the highest efficiency by way of their unique turbocoil design. In fact, it’s the most energy efficient heater in the market with lower stack temperatures than competitive units. Which means your profit isn’t being wasted up the stack. With over five decades of unrivaled experience in efficient heat transfer, General Combustion helps you make more black. No other system saves you more. 5201 N. Orange Blossom Trail ∙ Orlando, FL 32810 ∙ 407.290.6000 ∙ GeneralCombustion.com Search: 10073093
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WATCH THIS TRUCK COME TO LIFE.
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Competitive financing available through Daimler Truck Financial. For the Freightliner Trucks dealer nearest you, call 1-800-FTL-HELP. www.freightlinertrucks. com. FTL/MC-A-1152 Specifications are subject to change without notice. Copyright Š 2015. Daimler Trucks North America LLC. All rights reserved. Freightliner Trucks is a division of Daimler Trucks North America LLC, a Daimler company.
Search: 10073061
10/26/15 2:39 PM
The Freightliner 114SD truck enables these guys to handle demanding paving jobs with greater efficiency. It offers a 114-inch BBC cab made of corrosion-resistant aluminum, reinforced with e-coated steel. It has a contoured hood slope for superior visibility and a 50-degree wheel cut for better maneuverability. Add key weight-saving components and our proprietary SmartPlex™ Electrical System, and you’ve definitely got the latest and greatest equipment for any construction job. To learn more, visit FreightlinerTrucks.com/WorkSmart.
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PAVING INNOVATIONS
The airport had to be closed completely during runway reconstruction, which was completed during two 61-hour stints over consecutive weekends.
18 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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How to Fix an
Airport Runway
Planning, jobsite logistics and crew support land Summers-Taylor a NAPA award for the Tri-Cities Airport Project by Allan Heydorn, Contributing Editor
A
ll contractors have worked under tight deadlines at one time or another, but last year’s runway rehabilitation by Summers-Taylor Inc., Elizabethton, TN, of Tri-Cities Regional Airport was an extreme case. And Summers-Taylor did such a great job on the two-weekend job, the contractor was recognized by the National Asphalt Pavement Association (NAPA) with a 2015 Quality in Construction Award. And while many contractors do work on airports, the nature of this job required a large, experienced contractor operating full-force during two 61-hour weekends. Even then, because of the narrow work windows and an unexpected weather delay, the outcome of the job was uncertain until the crew pulled off the site for the final time. “This project was unique because the airport is big enough to have a good size runway, but not big enough to have the redundancy of a second runway to keep it open while we did the work,” says Grant Summers, fourth generation president of Summers-Taylor Inc.
The project
The job centered on the 8,000-ft.-long, 150-ft.-wide Runway 5-23, which had a number of issues including surface cracking and drainage problems that needed to be taken care of through milling and overlay. In addition, Summers-Taylor corrected drainage issues and milled and paved taxiways, constructed 25-ft.wide paved shoulders on each side of the runway, and adjusted 350 runway lights. Ultimately Summers-Taylor crews placed 53,000 tons of mix over the two 61-hour weekends. The project was a year in the planning and Summers says they needed all that time to orchestrate the tight logistics the job required. Had they missed the deadline either weekend, the contractor would have been subject to a penalty of $10,000 for every 15 minutes it was late – a potentially catastrophic hit on the project’s profitability. “It certainly had the potential to be a profitable job, but basically it was going to be either good for us or really bad,” Summers says. “If we got done what we planned to get done, then it was going to be good. But if not then we were going to be paying liquidated damages
of about $1 million a day and obviously we didn’t want to do that.” Summers says the contractor has done a number of jobs under tight schedules — bridges and night work, for example, “but nothing like this with such significant liquidation damages, with the demands and specifications which the FAA requires. It was a certainly a challenge,” he says. But Summers-Taylor knew how to tackle it. A turnkey highway & heavy contractor, Summers-Taylor was started in 1932 and today employs 350 people and operates four hot mix plants and six concrete plants to serve its road, commercial and airport work. The contractor “sticks pretty close to home,” working in eastern Tennessee, western North Carolina and southwestern Virginia. “Our crews were all very excited to do a great job,” Summers says. “We explained how this was really a once-ina-lifetime opportunity and we just said ‘let’s show people what we can do’.” “Both weekends we started at 7:00 p.m. on Friday and by 9:00 a.m. Monday, we had to be off because there was a plane scheduled to land at 9:05
(Continued on next page.) November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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PAVING INNOVATIONS
Summers-Taylor milled 4 inches across most of the runway, and paved back in two lifts. A 2.5-in. binder course was placed the first weekend and a 1.5-in. surface course was placed the second weekend.
Early focus on milling set the stage for the remainder of the job, ensuring not only that the quality was there and specs were met, but easing and speeding production as well. “Getting the milled surface correct was a very important aspect because once you do that you can just get on with the paving and you’re all set,” says Grant Summers. “Otherwise you’re always chasing grade. We got a high degree of accuracy from the GPS mills in front.”
Monday morning,” he says. “On the final Monday we pulled off the site and a plane landed almost immediately.”
Redundancy & shoulders first Summers says the contractor began planning for the work a full year out. He says the complexity of the work combined with the narrow working window, tight FAA specifications and potential penalties required even more thorough and detailed preparation than the contractor normally makes. One of their decisions was to begin work on the shoulders months in advance of the weekend shutdowns. But even then Summers-Taylor crews had access to the airport only five hours a night starting at midnight, so even that work had to be well coordinated. Shoulder construction required cutting 2 ft. deep alongside the runways,
then filling the cuts with stone and lowering 350 lighting cans beneath grade. Lighting cans were each marked with a GPS coordinate so the cans could be located once paving was done. Then the shoulders were paved with a 3-in. surface course 25 ft. wide during the weekend shutdowns. Another key part of the planning was to create redundancies at the jobsite. “The amount of risk involved required that we create redundancies. We couldn’t afford to shut down at all,” Summers says. And the first backup was in hot mix asphalt production. Summers-Taylor ran the job out of two plants, both set up about a mile from the airport. “The quarry we’re in is right next to airport and our flagship plant is there. We also moved a portable drum plant next to our flagship location,” he says. “That enabled us to run trucking from
the same place and it also meant we were able to use the same aggregate throughout the job and that helped us with consistency.” He says both plants ran nonstop for 50 hours each weekend, producing an average of 300 tons per hour (portable plant) and 350 tons per hour. Two other Summers-Taylor HMA plants — in Watauga, TN (20 miles away) and Greeneville, TN (40 miles) — were ready to go in case Summers-Taylor needed mix from another source. In addition to backup HMA plants, Summers-Taylor readied backups for every piece of equipment on the job. The subs hired also had backups for their equipment. Summers-Taylor kept its mechanics on site with a variety of the more common replacement parts, and its dealers were at the ready to provide whatever else was needed.
20 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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PAVING INNOVATIONS
Milling to specification Because of the tight timeline, SummersTaylor front-loaded the schedule to get as much work done the first weekend as possible. “The plan always was to do all the milling and install all the base the first weekend, then pave the surface course and the shoulders the second weekend,” Summers says. “It turned out it was a good plan because we got unlucky with a weather front moving in from the Gulf the second week that cost us 12 hours. Luckily we had more fluff built in for that second week.” He says a 200-person Summers-Taylor team swarmed the airport job starting at 7 p.m. Friday that first weekend, with milling the first step. Milling was done on the runway, on taxiway joints and on some areas of the taxiways that were cracked and past their serviceable life. They also milled across a smaller Runway 927 to make it easier to tie the two runways together. “The taxiways were milled where areas were cracked and past their serviceable life, but mainly we just milled enough to make them flush with the runway,” Summers says. Summers-Taylor relied on
a milling subcontractor, Delta Contracting Co., Paris, TN, which operated five Wirtgen 210 mills that cut 7 ft., 2 in. wide — just about a perfect overlap for milling a 150-ft.-wide runway. Summers says using five of the same machines provided a consistency that helped the project. He said the mills were staggered with a slight overlap. “The width just worked out with 7 ft., 2-in.-wide mills covering the entire 150-ft, width of the runway in four passes of the whole milling train,” Summers says. Three mills — each equipped with GPS — led the way and two remaining mills followed to clean up the joint areas. The three GPS mills enabled SummersTaylor to bring the grade to the appropriate specification. Summers-Taylor also brought in milling specialists Banks Construction who used the Topcon system to provide an even greater degree of milling accuracy. Banks managed the satellite, base
station and lasers, leapfrogging down the runway ahead of the mills to help mill operators know their targets. And a surveyor followed right behind the mills to verify that the tolerances were achieved. One area with drainage and cracking issues required 6 in. of milling, but for the most part pavement was milled 4 in. deep. Summers says the early focus on milling set the stage for the remainder of the job, ensuring not only that the quality was there and specs were met, but easing and speeding production as well. “Getting the milled surface correct was a very important aspect because once you do that, you can just get on with the paving and you’re all set,” Summers says. “Otherwise you’re always chasing grade. We got a high degree of accuracy from the GPS mills in front.”
Playing catch up Once the milling was well underway, the paving began. Crews placed a 2.5-in. binder course over the project the first weekend, then placed a 1.5-in. surface course the second weekend (slightly Strategic use of lighting enabled the crews to easily work through the weekend nights.
Four paving crews operated in two shifts of 12 hours each. Each crew used a Roadtec 190 paver and Roadtec 2500 Shuttle Buggy, which was kept fed by 850 trucks delivering hot mix to the site nonstop throughout each weekend.
22 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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PAVING INNOVATIONS Work on the Tri-Cities Regional Airport project was front-loaded on the first weekend with time allotted for unexpected challenges the second weekend. A good plan considering work was shut down for 12 hours by a heavy storm the second weekend.
All rollers were vibratory (though not always used in vibratory mode) to provide added redundancy in case any roller went down. Six rollers were on the job at all times, three for each paving train.
thicker in areas milled 6 in.) Summers-Taylor opted to run four paving crews in two shifts of 12 hours each. Each crew used a Roadtec 190 paver and Roadtec 2500 Shuttle Buggy, which was kept fed by 850 trucks delivering hot mix to the site nonstop throughout each weekend. Planning, organization of the trucking, and use of the shuttle buggy and experienced crews enabled Summers-Taylor to keep up with the combined plants production of 650 tons per hour. “On the second weekend we did add a third paving crew out there to pave taxiways to catch up.” Summers says. “That’s about the only major adjustment we had to make as a result of the rain.” He says a standard roller operation using Caterpillar and Hamm rollers was used, a three-roller rolling pattern leading with the breakdown roller followed by a vibratory roller and a static finishing roller. All rollers were vibratory (though not always used in vibratory mode) to provide added redundancy in case any roller went down. Six rollers were on the job at all times, three for each paving train. Summers-Taylor staggered the two pavers a few hundred feet apart so they
weren’t crowding each other. Pavers were set up using fixed screed extensions to pave 15 ft. wide “because that gives us perfect multiples to pave 150 ft. wide,” Summer says. Ski poles (50 ft.) with sonic sensors were used for joint matching.
Coordination is key Summers says that coordination of the milling trucks and stockpiling trucks was a challenge and a lot of planning went into the logistics, scheduling and routing of trucks into, through and out of the airport. Specific entrances and exits had to be used and thus, traffic patterns had to be followed so milling trucks and mix delivery trucks didn’t get in each other’s way — or in the way of working crews. And trucks had to be routed so they didn’t cross any recently paved areas. Once the trucking plan was set, the contractor held multiple coordination meetings to make sure trucking ran smoothly and on schedule. SummersTaylor brought in the primary trucking subcontractor, Claiborne Hauling, to help with logistics and even to direct truck traffic on site. “We had a number of people working
essentially as air traffic controllers for 80 to 90 trucks because that was something that could easily get out of control if it wasn’t taken care of,” Summers says. He says the contractor conducted multiple coordination meetings with the “traffic controllers,” who were upper level management with the company. “We relied on superintendents and others who we felt could handle a fast-paced operation,” Summers says. “They did a great job. “This was definitely an all-consuming job and was pretty much all hands on deck, so we didn’t do other work during those weekends. During the weekend we pretty much had the whole company out there.” Only 25% of each crew changed shifts at any one time so the work never stopped. While crews were scheduled 12 hours on and 12 hours off, by the second week some crew members were working 14, 16 and even 18 hours a day because the company knew they had to finish the job on time. And company management caught some shut-eye for an hour or so in the cabs of their trucks. “This is a once-in-a-lifetime project that we want to be able to point to,” Summers says. “This is definitely a marquee job for us. We’re real proud of all our guys and the vast amount of work with the high level of quality needed. They did a great job.”
24 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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PAVING INNOVATIONS
Paving a Small Town in
ASPHALT The mayor of a small town in central Iowa achieves his goal of paving all the streets with asphalt without raising taxes on the citizens
C
hristopher Columbus was a man with a vision. Meriwether Lewis and William Clark were men with a vision. Brian Devick, mayor of Woodward, IA, is a man of vision. And the citizens of a small, central Iowa town will be benefiting from this vision for decades to come. In the summer of 2015, the vision of Devick and the Woodward City Council was completed — they paved the whole town with new asphalt streets. Devick was elected Mayor of Woodward in 2012 after serving on the city council previously and working on the Planning & Zoning Commission both in Des Moines and Dallas County.
“I remember being at an early city council meeting when one of the citizens, very angry at the time, shouted at the council, ‘If you are going to spend money on anything in this city, fix the damn streets!’ That really struck me and I never forgot it,” he says. In the fall of 2013, Devick and council members began researching the possibility of paving the city. They began with doing the right legwork: they called a local contractor and member of the Asphalt Paving Association of Iowa (APAI), Des Moines Asphalt & Paving (DMAP), and asked for a budget price to put two inches of asphalt over all their streets. In early 2014, they invited the estimator from DMAP, along with Bill Rosener, execcutive vice president of the APAI, and Tony Bellizzi, vice president of Veenstra & Kimm (V & K) Engineers and City of Woodward Engineer, to a fact-finding city council meeting. The meeting allowed the city council to ask myriad questions that concerned them. The meeting ended with a consensus — the project should be professionally designed. In June 2014, the city sent V & K a contract to design the town’s paving project with special emphasis on improving drainage. While Bellizzi and Co. began work on the plans, the Mayor and city council took the plan to the streets and asked the citizens for their input.
Public input The City of Woodward is a typical small town in Iowa. The city has a population of 1,400, including the state hospital which accounts for approximately 350 residents. It has 400 households, with about 30% of the residents of retirement age combined with a strong group of young families. “This is a blue collar town, we’re not a wealthy town by any stretch of the imagination,” Devick says. “We are primarily residential. Our two biggest commercial business are the hospital and the school, both of which are tax exempt.” The city held two town hall meetings, attended by approximately 80 people.
28 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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Search: 10072820
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PAVING INNOVATIONS
According to Devick, over 90% wanted to see the road work done. Of those, 50% wanted to see it get done no matter what, the other 50% said only if they could get the project done without taxes going up.
The design In the fall of 2014, Bellizzi presented the initial findings with a draft plan for overlaying the city’s streets and addressing the drainage issues. The project called for overlaying the existing sealcoat streets with hot mix asphalt (HMA) at a depth of three to four inches, strengthening pavement edges with HMA base repair, three linear blocks of concrete curb and gutter, 172 handicap ramps, storm sewer, culverts, ditch improvements, and a large 8’ x 5’ box culvert. “We cut a lot of cores in the existing streets to determine what type of structure we had,” says Bellizzi with V & K Engineers. “The city had made an investment in their chip seal streets and a strong rock base.
“It was great to see all the kids come out with their bikes, skateboards and roller skates as soon as the road was finished.”
Left to right: Tony Bellizzi (V & K), Mayor Brian Devick and Matt Yonker (Grimes Asphalt & Paving Corp.).
or do a mill and fill operation in the future. They have the basis of a perpetual pavement design. It will serve the taxpayers for decades to come.” As with all things, the Woodward project came down to money. V & K estimated the job at $3.2 million: $1.4 million for drainage remediation and $1.8 million for the base repair, curb and gutter and paving. The mayor and council went to work.
Finding funding “We were able to use an asphalt design that we have had success with in many small towns,” he continues. “With a good base and good drainage, we were comfortable specifying a three- to four-inch overlay. We can add structure
$
Mayor Devick is a believer in his city. He is also a pragmatic man. Woodward could not put itself into a financial hole with this project. He discussed the city’s expenditures on the upkeep of the sealcoat streets with Woodward’s Public
30 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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PAVING INNOVATIONS The project, which was completed near the end of July 2015, placed over 20,000 tons of asphalt on Woodward streets.
Works Director, Chris Newland. “In the 10 years previous, we spent upwards of $640,000 on maintaining our sealcoat streets. It was not sustainable,” Newland says. The city of Woodward had just finished paying off a bond for the rehabilitation of Main Street. The bonding capacity offered them $1.8 million at historically low interest rates, the remaining $1.4 million came through a private loan against future Road Use Tax Funds. “To do this project piece by piece would have been too costly,” says Devick. “I told our citizens that asphalt will never be cheaper than it is right now.” By extending the bonding capacity and rededicating the dollars spent on yearly maintenance of the sealcoat roads, Woodward was able to fully fund the project without raising taxes. The project letting was set for the spring of 2015.
The project Grimes Asphalt and Paving Corp. was the low bidder on the project with a bid of $2.9 million. The project was divided into five phases to limit inconvenience to the townspeople. Drainage work began in early May with two crews getting the project ready to pave.
“We had some complaining to start with,” Newland says. “But that quit as soon as the paving started.” Matt Yonker, project manager from Grimes Asphalt, says coordination and sharing information were key to a smooth project. “We had to do a lot of coordination on this project,” he says. “We handed out notices when we would be working on their streets. The people of Woodward are very nice and appreciative. We did a smaller, similar project for the Metro — I took 20 calls a day on that job. We have paved this whole town and I have had four calls to date.” Of course, not every project is perfect. “You are always going to have some issues,” says Bellizzi with V & K. “There was a lot happening here all at once. The big benefit of asphalt is that you can open the streets as soon as you are done paving. You can’t do that with concrete.” The project was completed near the
end of July. Over 20,000 tons of asphalt were placed. Residents are pleased with the outcome. “I’m very happy with the streets,” says Woodward resident Deb Gilbert. “It’s great to see all the kids come out with their bikes, skateboards and roller skates as soon as the road was finished.” The three men are also pleased with how the vision they created has become a reality. “I’m extremely proud of this project,” Devick says. “We were able to address the number one issue in this town without raising our citizen’s taxes. This is how a city should do a project — we are getting the best product, the best pricing and the best quality.” Wise words spoken by a man of vision.
Article provided by the Asphalt Paving Association of Iowa; visit apai.net for more information.
Grimes Asphalt and Paving Corp. was the low bidder on the project with a bid of $2.9 million.
32 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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PAVING INNOVATIONS MEL-DEK from W. R. MEADOWS MEL-DEK is a roll-type waterproofing membrane composed of a nominally 53 mil thick layer of polymeric waterproofing membrane on a shrink-resistant, heavy-duty, 12 mil thick polypropylene woven carrier fabric. • Two components are laminated together under strictly controlled production procedures • MEL-DEK is easy to install and requires no protection from hot asphalt overlays • It is flexible and can be used on bridges, parking decks and various other structures • Available in rolls which are 60 ft. long and 38.5 in. wide Search: 12096243
LeeBoy Legend Electric Screed The electrically heated Legend Screed System is available for commercial class pavers in the 16,000-lb. and under range. • Available for the 8500 and 8515 models with an 8- to 15-ft. paving width, and on the 24,000-lb. 8816 model with an 8- to 15.5-ft. paving width • Bull-nose screed plates, angle of attack controls, frontmounted screed extensions and crown/invert control Search: 10079337
Weiler P385A Asphalt Paver The 18,000-lb. P385A paver includes a 3,000-lb. electrically heated screed with angle-of-attack adjusters on the extensions. • Screed can be extended to pave 15-ft. 8-in. widths with a single slide point on two 2 3/4-in.-diameter slide tubes for rigidity • 83-hp Cat C3.4 diesel engine Search: 10246380
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34 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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Vögele MT 3000-2i Material Transfer Vehicle The 56,000-lb. MT 3000-2i is powered by a 215-hp Deutz water-cooled, Tier 4i engine, has an 18-ton storage capacity and can move 1,300 tph. • Active remixing is achieved by two 16-in.-diameter conical augers in the receiving hopper, and passive remixing is achieved via a 17- or 22-ton “receiving insert” in the paver hopper • Auto feed function automatically slows or shuts down feeding when the paver hopper insert is filled, while a maximum delivery override switch will deliver material at maximum throughput for instant filling of the hopper insert Search: 12113037
Carlson Joint Density Attachment Through use of a higher angle of attack and an electrically heated element, the 4” bolt-on forces increased material into the side cut, greatly reducing voids and yielding higher density numbers at the joint. • Enables contractors to hit specific job requirements by increasing the overall density of joints creating longer lasting and more dense joints while maintaining consistent heat with the main screed and extensions • The electronically heated element maintains consistent heat of the element, allowing greater extrusion of material while preventing cold spots • While increasing angle of attack, 4” bolt-on does not lift the screed giving operators ease of mind while paving • Easily adjustable through use of a wrench on the exterior of the screed attachment • Can be fitted on the right or left hand side • Combined with Carlson’s new side load attachment, contractors are able to increase joint density while decreasing operational downtime Search: 12041568 Search: 10073374
November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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PAVING INNOVATIONS Atlas Copco Dynapac CP2700 Pneumatic-Tired Roller The CP2700 pneumatic-tired roller tackles soil compaction, in addition to asphalt finishing and sealing applications. • Spacious platform, ergonomic controls and a rotating, sideway-sliding seat and steering assembly • Tier 4i engine • Dual-circuit braking system maintains full braking effect even if one circuit is disabled • Compacting width of 7.55 feet and a maximum operating weight of 59,000 pounds • Optional temperature sensor and DCA-A analyzer can play back the rolling pattern and produce a printout of all relevant information Search: 12051951
Roadtec RP-195e Asphalt Paver The rubber-track highway class RP-195e paver is powered by 230-hp Cummins QSB 6.7 Tier 4 Finalcompliant diesel engine. • Anti-segregation design encompasses the feed tunnel, feed tunnel discharge and rear augers • Fully oscillating bogies and smooth tread aide in laying a smoother mat • Includes the Clearview FXS fume extraction system and Guardian remote telematics and diagnostics system Search: 12055680
Dynapac F800T Paver The F800T 8-ft. tracked paver has a working width of 8 to 19 ft. and paves to 12 in. thick. • 13.5-ton material hopper • Safe-impact push-roller system • EZIV08-15 front-mounted electrical screed powered by a tractor-mounted 34-kV hydraulically driven generator • Independently controlled, dual-bar feed conveyor system with 17-in.diameter auger flights • 173-hp Cummins Tier 4 Final engine Search: 11322495
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36 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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WBI Delta S RAP Rejuventor and WMA The Warner Babcock Institute for Green Chemistry and Collaborative Aggregates announce the commercial availability of Delta S, an easy-to-use liquid additive that reverses aging and oxidation in reclaimed asphalt. • Non-toxic, worker safe and environmentally friendly • Can be used in any traditional hot mix, recycling, in-place recycling or warm mix asphalt applications • Single tank storage • Can be added during any phase of production • Enables the use of higher ratio RAP and RAS to virgin asphalt and aggregate without affecting pavement performance • Lowers paving temp, reducing energy usage and extending paving season Search: 12080760
Topcon 3D Mobile Mapping System The IP-S3 3D mobile mapping system employs the integration of an Inertial Measurement Unit (IMU) and GNSS receiver with a vehicle’s onboard electronics to offer high-density mobile digital imaging. Compact, lightweight and scans at a rate of up to five times faster than previous models. • 39-lb. weight makes it light enough for a single person to mount it on a car, truck or SUV without assistance • Rotating LiDAR sensor scans at 700,000 points per second, • Six-lens digital camera provides data-rich results with panoramic Search: 12082633
Wacker Neuson RD 27 Series The redesigned RD 27 2.5-ton doubledrum vibratory roller incorporates a multi-functional lever that contains buttons for all vibration options. • Tapered front frame for optimal visibility to the front drum • 5,470-lb. RD 27-100 comes with a 39.4-in. drum width and and produces a low/high total centrifugal force of 15,589/16,860 lbs. • 5,950-lb. RD 27-120 has a 47.2in. drum width and produces 15,285/20,232 lbs. of low/high centrifugal force • Single or dual drum vibration • 37.5-hp Kubota diesel engine Search: 10085573
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November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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PAVEMENT PRESERVATION
Rigorous Maintenance Keeps Milling Machine with High Hours Cutting a Path
Koss Construction Co. is determined to keep its historic W 2200 going via standard service intervals
A
milling machine with over 15,000 hours is still grinding pavements across the fruited plain, and the men who manage it are determined to keep it going. The W 2200 from Wirtgen America is special for another reason: this W 2200 – serial number 0821100181340039 – is
the first Wirtgen mill in the United States with a 12-ft. 6-in. standard drum. The mill operates 10 to 12 hours every work day, and its long-time performance is emblematic of the care that the owner and crew provide for it. Now, instead of it becoming a museum piece – in late spring at 15,136 hours and counting – the owner of Koss
Koss Construction’s W 2200 cold mill with over 15,000 hours was the first Wirtgen mill in the United States with 12-ft. 6-in. drum.
Construction Co., Topeka, KS, is determined to keep its historic W 2200 going via a rigorous maintenance program that sees servicing at standard intervals.
38 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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PAVEMENT PRESERVATION
Historically high hours The W 2200 hit 15,136 hours in mid-May. That number represents nearly two years of nonstop work, day and night, without pause. The gear box is original, and is serviced every 500 hours. The mill itself is serviced every 200 hours. Koss has installed two clutch assemblies, the first at 5,000 hours, and the second at 10,000 hours. Two drive couplers have also been replaced. And the cutter drum with Type III holders was upgraded to the HT-11 holder system last year. Koss replaces cutting tool holders about every two years. Three years ago the leveling system was upgraded by Wirtgen America to a current Level Pro system. Moreover, all the seals and bearings in the sheaves, and all track drives, have been replaced. Track assemblies have been replaced three times. Wear items like primary and discharge belts have been replaced six times in its 15,136-hour lifetime. History means a lot to Koss. They’ve been in business for 103 years and their slogan is the ‘Hard Roaders’ since 1912. Koss also owns a “younger” Wirtgen W 2000. It takes a lot of loving care to keep a workhorse like this W 2200 in operation over the years — since 2002. Crew
foreman Steve Hart has been with the mill for 11 years and operator Scott Brixley for four years. They report to division manager Kelly Moore. “We will do everything from profile milling to concrete,” Hart says. “It depends on the season, but we work upwards of 300 days a year. “The full-lane drum is a big advantage over half-lane machines, considering what we do,” he continues. “Occasionally a 7-ft. machine may be an advantage in doing shoulders, but we usually make it work with this one.”
Hart maintains a daily log of the machine’s use. “I keep it for my own benefit, so I can go back and answer questions later. We’ve worked in Iowa, Minnesota, Nebraska, South Dakota, Arkansas and Oklahoma and take her everywhere we go.” Furthermore, the W 2200 is the only mill that the crew has. “We don’t have a At the I-40 jobsite in Sidney, NE, are Scott Brixley, operator; Steve Hart, foreman; James Barrett, water truck driver; and Tom Ellis, broom operator.
Regular maintenance is key to pushing W 2200 performance to the limit.
40 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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250T Tack Tank
•
1000F Paver
7000B Paver
400T Roller
8500C 15,800 lbs
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74 HP Kubota Tier 4i Engine
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8’ – 15’ Heated, Vibrating Legend Screed System
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7 ton Receiving Hopper
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Under Auger Cut-Off Gates
To find your local dealer, go to: www.
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ASTEC
PAT E N T E D S TA C K T E M P Run dense graded mix, warm mix, high RAP and OGFC all with no flight changes and no loss of production rate or fuel efficiency.
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M P E R AT U R E C O N T R O L S Y S T E M “The V-Pack stack temperature control system is the most important improvement to asphalt production since long-term storage.�
Dr. J. Don Brock
Founder, Astec Industries, Inc.
Search: 10072061
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PAVEMENT PRESERVATION Koss has been using Wirtgen W7/20x bits in this mill for about five years.
back-up mill,” Hart says. “We count on this one. It’s been dependable in every way. We’ve had very, very little lost time on this machine. We do keep a good inventory of parts ourselves in our parts trailer. The service truck we have now has a small crane on it. Very seldom do we run into something we don’t have. We do all of the maintenance and most of the repairs ourselves. Of course we can’t carry a complete mill with us.” One secret to cutting bit longevity is to keep the machines supplied with water, said Rhino Parts salesman Tom Sanders. “If you run them without water, you’ll burn them right off,” he says. “These mills are like big drill presses; If you operate a drill press without water, you’ll burn it up.”
Cutting Nebraska I-10 When visited, Koss was using the venerable W 2200 to mill pavement in the reconstruction of I-80 near Sidney, NE, in the Nebraska panhandle. Koss’ crew was using its full-lane machine to plane asphalt off a 3-ft. shoulder. The unit would run left side on cross slope, and right side a little above grade. “That way we can get all the material we possibly can off this narrow shoulder without cutting into the concrete slab,” Hart says. “The reason we have to cut it like that two different slopes are present: shoulders are going one way, and the main line the other. We will be daylighting on one side, and 3 to 3½ in. on the other. We will be watching for the outside of the concrete slab as we don’t want to cut into it.” After the asphalt is removed and stockpiled, the RAP will be crushed and sized by a mobile crusher, and will go right down as a base for a new pavement. “Koss Construction has been using Wirtgen W7/20x bits in this mill for about five years now,” Sanders says. “They like that the carbide and the bodies work together well in all the applications.” For concrete, Koss will go to the W113-G/20 cutting tool, with carbide imbedded in the body.
“That’s so the carbide won’t fracture prematurely while milling the concrete,” Sanders says. “You get tremendous forces and quite a bit of vibration while milling concrete, and this is the ideal bit for it.” The mill has dug as much as 11 in. of concrete in one pass, Hart says. “It’s a lot harder than asphalt on the machine, teeth and holders,” he says. “Last year we dug a lot of concrete in Arkansas on I-40.
“It was a stringline job and we had to run grade off the stringline while using cross slope,” he continues. “The concrete varied from 4 to 6 in., and it was hard.” For another memorable project, Hart’s crew cut asphalt in single-digit temperatures. “Water freezing can be a problem in those situations,” Hart says. “But the these mills have a good water system on them, and you can drain them. They’re equipped to have air blown through the system, and we treat lines with antifreeze at night so it’s ready to go in the morning.” While Koss is willing to reinvest in the machine to keep it going, there is more to it than meets the eye. “You’ve got to put a little love back in the machine,” Hart says. “You have to love it and take care of it, and keep the maintenance up. “This old mill still digs 11 in. on both sides,” he says. “It still has a lot of power, it’s a good mill. The way it’s performed and has lasted has exceeded everybody’s expectations. Within the entire company, I would say it’s the best piece of equipment they’ve got.” On the Nebraska I-80 project, the crew used its full-lane machine to plane asphalt off a 3-ft. shoulder.
44 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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UNBEATABLE TEAM.
The Wirtgen Group owes its strength to the excellence of its four product brands – Wirtgen, Vögele, Hamm and Kleemann – with their unique wealth of experience. Put your trust in the Wirtgen Group team.
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PAVEMENT PRESERVATION
PPRA Fall Meeting Offers
New Ideas, Perspectives
O
ver 300 pavement preservation specialists descended on Niagara Falls, ON, Canada for the PPRA (Pavement Preservation & Recycling Alliance) 2015 Fall Conference. The final registration count set a record for the conference at more than 330 people from at least six countries. PPRA is the unifying voice of the preservation industry. Throughout the three-day conference, contractors, agencies, manufacturers and consultants attended informative and engaging sessions offering new ideas and perspectives from the three main associations representing PPRA: ARRA (Asphalt Recycling & Reclaiming Association), ISSA (International Slurry Surfacing Association) and AEMA (Asphalt Emulsion Manufacturers Association). Attendees listened to presentations from transportation agencies, contractors, suppliers and other industry experts. Buzz Powell with the National Center for Asphalt Technology (NCAT) discussed the most recent NCAT Pavement Preservation Research and Results. Powell also updated attendees on the NCAT partnership with MnRoad and discussed reviews of the Pavement Test Track, Lee Road 159 and US 280 WB outside lane, which are the sites for testing various types of preservation treatments. For more information and updates on the progress of the track, visit www.pavetrack.com. David Peshkin with Applied Pavement Technology presented The Role of Preservation in Managing Pavements and began with a review of the benefits of integrating pavement preservation into existing pavement management systems. Becca Lane from the Highway Standards Branch of Ontario’s Provincial Highways Management offered her Summary of Performance Data over the Last 25 Years for Recycled Pavements in Ontario. Lane detailed the history of the use of the recycled processes and their
increased use over the past 25 years. The processes identified were CIR, CIREAM (CIR with Expanded/Foamed Asphalt), FDR and FDREAM (FDR with Expanded/ Foamed Asphalt). Since the mid 1980s, there have been 669 projects completed in her district with PCI ratings over 85 and minimal rutting.
Buzz Powell, National Center for Asphalt Technology, updates attendees on the latest pavement preservation research. Photos provided by FP2 Inc.
There was also a panel of six members discussing Owner’s, Contractor’s and Equipment Manufacturer’s Perspective on Method vs. Performance Specification. Both Method Spec and Performance Spec perspectives were represented and the benefits of each were identified and examined. The overall indication at the end of the discussion seemed to be that what has proved most common to date has been a combination of the specification types and that it is most likely for the immediate future that this practice will remain as such. Other presentation included: • Chip Seals & Surface Treatments – A Northern Experience with Antoine Boucher, director of Public Works and Engineering for East Ferris. While the northern climates could prove challenging in trying to find ways to apply and maintain chip seals, East Ferris has found a way. Through an approach that utilizes different chip
seal “systems” based on the existing conditions, anticipated traffic loading and performance expectations, the municipality has created a program that has successfully endured the harsh winters. Components of their program include RAP emulsion mixes over granular surfaces, implementation of geotextile fabrics and recycled asphalt mixtures. Upon review in 2014, the rehabilitated road surfaces were in excellent condition. • Stephen Lee of the Ministry of Transportation of Ontario spoke of the Evaluation Manual on Recycled Pavements — What We Need to Know. This presentation was intriguing as a manual has been developed to identify and assess the types of distresses associated with HIR, CIR and FDR. • During Recycling Around the World with Ayrton Senna Highway Brasil & USA, Mike Marshall of Wirtgen America detailed the work on the Ayrton Senna Highway in Sao Paulo, where prior to recycling, the surface had to be replaced as frequently as every three months. He discussed milling, CCPR with foamed asphalt, multiple lift placements on the successful project. • Gary Foux of Suit-Kote presented CIR: NYDOT’s Success, where he identified how his company frequently uses rock and types of emulsions (high floats) that are commonly used. • Randy Dobson from Caterpillar discussed Fine & Micro-Milling – High Performance Specifications – A Perfect Pavement Preservation Technique. Dobson reviewed the places where micro-milling may be most effective within pavement management programs and the benefits that the planing processes provide. The 2016 AEMA-ARRA-ISSA Annual Meeting will be held Feb. 23-26 in Bonita Springs, FL. For more information, visit ppralliance.org.
46 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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Meeker has installed more of these RAP-PAK systems than any of our competitors AND we have the reputation and quality to back up each and every one. • Allows batch plants to add up to 30%-40% RAP in high quality mixes
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PAVEMENT PRESERVATION
Dynapac PL2000S Cold Planer from Atlas Copco The Atlas Copco Dynapac PL2000S hydraulically powered, high-capacity cold planer features four-track steering, a front loading system and a mechanical belt-driven cutting drum. • For removing both asphalt and concrete pavements • Working width of 79 in. and a 13-in. cutting depth • Automated sequential processes for conveyor belts and water system • 600-hp Cummins QSX 15 diesel engine • 977-gal. water tank Search: 10078174
Kennametal Road-Ready Milling Drums
Wirtgen 3800 CR
The Road-Ready milling drums feature ProFit or Quick-Change block systems, and are balanced to reduce machine vibration. • Drums designed to specific customer parameters • User-selectable design elements include cutting pattern, diameter, width, advance rate and rpm • Drum configurations also available for a number of pavement conditions and road machine OEM specifications • Maintenance tool kit consists of two wedge pullers, a flex drill, bucket spare sleeve and sleeve-removal tool Search: 10087727
The 3800 CR is able to CIR a full lane of pavement in one pass, stabilizing with foamed asphalt “green mix” or any other stabilizing medium. • With a conveyor mounted, it will also serve as a full-lane cold mill • Uses the same platform as the 2200 CR, but is supplied with a full-lane, 12-ft.-6-in.-wide drum and uses a screed width to match • In recycle mode, the full-lane working width is complemented by a recycling depth of up to 6 in • In the cold milling mode, it will mill to 13.75 in. deep in the upcut mode Search: 10282012
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48 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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VSS Macropaver 12B The VSS Macropaver 12B truck-mounted slurry/microsurfacing machine offers an average output of 3 to 4 tpm. • 12-cubic-yard maximum aggregate capacity • EZ-OP Monitoring System included • Hydraulic fail-safe automatic materials sequencing • Seal Lock hydraulics • Fines feeder power and drive system offers increased power and a simpler, robust design • Tier III Low Emissions John Deere Engine • 850-gal. water and emulsion tanks • Options include CALTRANS material monitoring and control system; truck speed control on operator platform; stainlesssteel additive tank/pump system; high-pressure washer/ reel; and more Search: 10085540
Caterpillar RM500 Rotary Mixer The RM500 is designed for both asphalt reclamation and soil stabilization applications. • Three available rotor options • Tier III-compliant Cat C15 engine with ACERT Technology • 96-in. cutting width • 16-in. reclamation; 20-in. stabilization cutting depth Search: 10091330
Roadtec SX-2e Stabilizer-Reclaimer The SX-2e stabilizerreclaimer features a standard 50-in.diameter cutter drum that allows it to achieve a cut depth of 18 in. and a cut width of 78 in. • Tractor towed cutter housing for increased maneuverability • High-efficiency hydrostatic drum drive • 380-hp Cummins QSL-9 Tier 4 final engine • Options include an injection system for water or emulsion and a fully enclosed cab with AC and heat Search: 11322498
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November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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PAVEMENT PRESERVATION Rayner PavementSaver II
ChipSpreaders
The PavementSaver II by Rayner Equipment Systems is designed for squeegee or spray application. • 300 to 500 gal. • 42-hp, diesel powered engine • Three-wheel drive, full hydrostatic brakes • Fail-safe emergency braking system Search: 10092362
Asphalt Transports
Live Bottom Trailers
E.D. Etnyre Centennial Black-Topper Asphalt Distributor
Asphalt Distributors
Etnyre Centennial Asphalt Distributors provide one-person operation. • Fingertip control of distributor functions • Computer-controlled spray • Available with cab controlled variable width or standard spray bar Search: 10147283
BIORESTOR Asphalt Rejuvenator
Heavy Duty Trailers
E. D. Etnyre & Co.
www.etnyre.com 800-995-2116 email: sales@etnyre.com
BIORESTOR is a family of USDA Bio Preferred products to enhance asphalt pavement. • Testing in the field has shown that BIORESTOR makes a difference in surface ravel • Accelerated aging in the lab has shown that BIORESTOR can eliminate up to 90% of the loss of binder characteristics (penetration, viscosity and Marshall Stability) • BIORESTOR contains no harmful carcinogens as do most petroleum products • USDA Bio Preferred
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!
Search: 11299278
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50 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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ALL PLANT PARTS. ALL ADM QUALITY.
Bergkamp FP5 All-In-One Pothole Patcher The FP5 flameless pothole patcher come standard with InPave Technology, which monitors material usage, performance and location of each pothole, patcher and crew through multiple data-reporting sensors strategically engineered into each unit. • Insulated 5.1-cu.-yd. electric-heated hopper keeps asphalt at a constant temperature and pliable for an extended period • Damaged area removed and squared off using the onboard, hydraulically driven pavement breaker • Air and tack wand blows out any remaining debris and applies the tack coating • Material chute delivers fresh hot asphalt to the prepared area • Onboard compactor consolidates the material evenly with the existing pavement Search: 12055457
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 zero to 1.6 gpm to the cutter housing Search: 12095029
ADM customers have long known about our excellent parts quality and availability. Now, users of non-ADM equipment can get that same level of confidence in replacement parts. At ADM, we stock a huge inventory of industry-standard parts and components for all major manufacturers’ systems and can have them most anywhere for next-day delivery and installation. You’re up and running and we’ve made another satisfied customer. It’s what we do best.
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November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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PLANT MATTERS
The Latest Trends in
Asphalt Plant Automation Technology helps asphalt producers gain control, harness data, increase profits By Jessica Stoikes, Associate Editor
T
he asphalt industry is more competitive and complex than ever before. From the demands of a quality mix to the ever growing desire for sustainability, asphalt plants need to have every tool at their disposal to reduce costs and grow profits. With the use of new technology and plant automation, asphalt producers have more options available for them to do just that.
Total system control Having complete control over your plant is what automation was designed to do. In 2002, the first asphalt automation system with highly configurable software was introduced to the industry. PC/PLC based systems provide complete control and monitoring of an entire facility on any type of plant. Motor control, flows, temperatures, sensors and all other components of the plant are monitored, controlled, trended and alarmed to
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Not too long ago, it was common to only blend two or three aggregates and one RAP with the liquid AC. This could easily be accomplished with a basic control system or almost manually if the plant operator was well trained and adept at timing sequences. Now, there are often eight to 10 or even more ingredients that must all be accurately combined at the right point to achieve the proper mixture, making manual or simplistic controls obsolete.
individual needs. This gives plant operators the ability to constantly monitor all their values — watch the numbers move — and tell if there is a problem before there is wasted mix. Automation lets you watch targets, actuals and movement. If you see where the equipment is trying to adjust, it can help you pinpoint the problem and diagnose it. Automation helps you stay on top of the quality of your mix and minimize waste. “Systems control centers like these are designed specifically for the asphalt industry with an emphasis on rugged construction, operator comfort and logical integration of the plant controls” says Kenneth Cardy, president of Libra
Astec’s V-Pack Stack Temperature Control System extends the range of mixes that can be produced without requiring that the flights be adjusted. The system’s ‘V-flights,’ unique drum flights with a deep V-shape, and its use of variable frequency drives (VFDs), which provide control of the drum rotational speed, are keys to the control system managing an asphalt plant’s exhaust gas temperature and increasing overall efficiency.
Systems. “These systems run and monitor all plant functions from a standard PC, including blending operations, plant motors, motor currents, mix and plant temperatures, material inventory, silo levels, energy usage and alarm status.” Lien Gangte, controls engineer at Astec Inc. adds, “A conscious decision to use industrial grade computers for the central user-interface is a step in meeting the overall objective of automation. In addition to meeting rigorous technical specifications, the advantages of using these machines lie in their production stability and long-term availability. In a world of constantly changing computers and operating systems, it is extremely important to offer systems that can be controlled more effectively to avoid any surprises.” Producers also have the ability to mold these systems to their unique business processes. This includes the ability to add fields, layout printing on delivery tickets, add or modify reports, add special logic, create their own pricing schemes, etc. “These systems are designed to primarily provide a solid platform that supports the most robust, flexible and dependable automation architecture,” Gangte says. “The modular design allows the upgrade or integration of components (burner, silos, motor control, blending, tank farm, double barrel green, etc.) in stages or all at once. This means that we only move when the customer is ready; there are no forced choices. Consistent emphasis on backward compatibility in the design process
November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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PLANT MATTERS
means that all of the new developments can be retrofitted with older modules even as new ones are added.” Whereas custom software of years past had the effect of locking producers out of new versions, the configurable and modular design of today’s software allows users to receive new releases and features, while maintaining the configuration settings that make the software unique for their specific business requirements.
Mix design drives innovation The latest innovations in asphalt plant automation can be attributed to the demand for more mixes using more types of ingredients that need to be carefully blended together in the process. “A reliable controls system is an absolutely necessary component in producing high quality mix today,” Gangte says. “It is not sufficient by itself but without it, quality becomes a dicey game at best.” Since some of these mixes are being designed for government agencies that require strict compliance, automation systems assist the plant operator in keeping the plant running and also for the company owner to combine all the ingredients and ensure the mix meets the required specs.
“The major developments in plant technology have more to do with the increasing number of ingredients that are now being required by both contractors and governmental agencies to make a variety of mixes and the ability of the plants to blend all the ingredients in a consistent homogeneous manner to make a good asphalt product,” says Gregg Gilpin, director of electronic control systems for Stansteel/Hotmix Parts. “In recent years, we’ve seen the addition of fractionated recycle with multiple feed bins along with recycled asphalt shingles (RAS),” Gilpin says. “The growing use of multiple liquid ACs have necessitated the need for modifying the ACs at the plant with inline blending and mixing. A large number of chemical additives is now being used to condition the liquid AC to make foamed and warm mix, allowing for lower energy asphalt, and to meet environmental requirements to aid in sustainability and recycle ability.” Monitoring all these ingredients is vital to the reputation of your mix. “With the advent of in-place density or end result mixes, it can potentially be a costly practice to risk making mix that is not in compliance,” Gilpin adds. “There are many systems that do not have the capability to combine all of the necessary materials. The major developments in plant technology have more to do with the increasing number of ingredients that are now being required by both contractors and governmental agencies to make a variety of mixes and the ability of the plants to blend all the ingredients in a consistent homogeneous manner to make a good asphalt product.
In previous times, it was common to only blend two or three aggregates and one RAP with the liquid AC. This could easily be accomplished with a basic control system or almost manually if the plant operator was well trained and adept at timing sequences. Now, there are often eight to 10 or even more ingredients that must all be accurately combined at the right point to achieve the proper mixture, making manual or simplistic controls obsolete. “Control platforms helps the quality of mix by controlling the entire production process with precision and accuracy,” Gangte says. “This design empowers the user to set up the system for optimal
A Contractor’s Perspective: According to Pete Grangaard of Systems Equipment, the push for plant automation is coming directly from asphalt producer company management in an attempt to lower their costs per ton produced. However, some companies are still reluctant to add automation components. “It is tough to add more to keep track of when asphalt producers are already juggling many variables,” Grangaard says. However, when Florida-based P&S Paving looked to build its Daytona, FL, asphalt plant from the ground up, technology was at the forefront of design. Tim Phillips, president of P&S Paving, knew that the latest technology would give his plant an edge. Phillips was pleased that the new Daytona plant was ready-made to incorporate the latest in operations and control systems to better assist preventive maintenance. “After 20 years of operations, we know where the high-maintenance areas in a plant are, so it was important that we made them very accessible,” Phillips says. “We also placed 16 cameras throughout this plant. “With eyes right there in the control house, it means that a couple of ground personnel are now free for something else,” he explained.
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If a control signal is sent to a material feeder that is not functioning correctly, the contractor can unwittingly make a large quantity of mix without blending the right ingredients. With closed loop control, the feeder is monitored to make sure the conveyor is turning at the proper speed and the material is flowing and, in fact, combining with the other ingredients.
“In fact, the first time the plant fired up, we were able to use one of the cameras to identify where a belt was tracking off a recycle conveyor. This is something which a normal operator can’t see inside the plant, but the cameras were able to spot it and allow us to address it immediately. With that catch, the cameras paid for themselves within the first five minutes of operation.” Another Florida asphalt producer, Duval Asphalt, agrees that the benefits of automation outweigh the initial costs. “The upfront costs of automating your asphalt production doesn’t matter,” says TJ Young, plants manager at Duval. “We needed to be automated to compete in our market. Automation is really priceless. “It’s like having a crystal ball — it allows you to see what’s going to happen before it happens,” he continues. “By the time you get feedback from the lab that there’s a problem, it’s too late. By that time, you’ve produced thousands of tons — it’s too late to fix the mistake and now you’ve wasted time, mix and money. “A consistent mix at a consistent temperature equals paving success,” he concludes. “And all that starts at the plant. In today’s world, close is not good enough. Automation helps you stay on top of the quality issue from the beginning.”
blending and provides numerous tweak points to achieve desired goals. If any deviation is detected from the calibrated targets, it has the ability to immediately notify the operator through audio and textual messages. The meticulous tracking of data from the raw material bins to the storage units also enables the user to reject mixes and exercise tight quality control.” “Total plant control must not only coordinate the blending of the numerous ingredients, it must offer closed loop control features that independently monitor the plant components to ensure the equipment is operating correctly,” Gilpin continues. “For example, if a control signal is sent to a material feeder that is not functioning correctly, the contractor can unwittingly make a large quantity of mix without blending the right ingredients. With closed loop control, the feeder is monitored to make sure the conveyor is turning at the proper speed and the material is flowing and, in fact, combining with the other ingredients.” Total plant control monitors other critical plant components to give alarms, alerts, or plant shutdowns based upon the complexity of the out-of-tolerance condition. In addition, the operator can set up a procedure to store or print at timed intervals the statistics on how the plant is operating.
Business process integration The ability to monitor and track all the moving pieces of your asphalt plant creates a lot of data. What your company does with that data however, is what’s important to improving your bottom line. “The plant automation must support real-time management decisions by providing up-to-the-minute company-wide data, accessible from anywhere in the enterprise,” Cardy says. This means plant automation must allow office and IT personnel to control business data in real-time, while allowing operators to concentrate on running plants. It must mold itself to fit the unique business processes of the producer without requiring the custom programming that has stunted the agility of past systems.
Mix quality starts with a good mix design from the contractor’s lab or from the governing agency. The asphalt plant must then combine all ingredients in the correct proportion within allowable tolerances and with minimal wasted mix. A good automation system will hold the tolerance to within an average of +.10%.
“Yes, plant automation for the asphalt industry has come a long way to be sure,” Cardy says. “Long a staple of the ready mix industry, dispatch software is now available that is uniquely designed for asphalt producers, helping them to forecast, organize and manage job/truck
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PLANT MATTERS Automation gives plant operators the ability to constantly monitor all their values – watch the numbers move – and tell if there is a problem before mix is wasted. Automation lets you watch targets, actuals and movement. If you see where the equipment is trying to adjust, it can help you pinpoint the problem and diagnose it. Automation helps you stay on top of the quality of your mix and minimize waste.
scheduling to make the most efficient use of resources and thereby improve the bottom line. “The dispatch software is integrated with the controls and self-service kiosks, so operators benefit by knowing the plant production requirements for the day, scheduled jobs, and when each truck will arrive.” New business integration software is also available for transaction review, mass-edits of transaction data, advanced pricing for account customers, management dashboards and help desks.
More data = less work Today, we are accustomed to receiving what we need immediately. With the introduction of smartphones, the world and all its’ information is legitimately at your fingertips. Data about the operations of your asphalt plant should be no different. “The information technology revolution and the age of the internet have brought with it a huge craving for more and more data,” Gangte says. “A younger generation that has grown up with hyperconnectivity all around them naturally insist on being able to gather, store and move data at the click of a mouse or a finger tap. This demand for data has a very compelling effect on plant automation, for there is no other way to satisfy it then to address it at the most elemental level.” Until recently, operators were asked to put in more and more data, when what they really needed to concentrate on was keeping the plants running and making good asphalt. “New developments in centralized management software have changed all that by giving the people responsible for the accuracy and timeliness of the data
Cameras installed around the plant can help ensure all systems are working properly before mix is wasted.
the ability to control it,” Cardy says. “The great benefit to operators is that they now merely pick the data from lists rather than keying it in. The learning curve for operators is very fast because they have less data to maintain and the software is much more intuitive. Inherently, the timeconsuming task of correcting mistakes prior to invoicing is virtually eliminated.” Centralized management software has opened the door to allow real-time access to company-wide data — anywhere, anytime. Up-to-the-minute information is available via wide area networks or the web. Web alerts may be configured to send texts or emails to portable devices — even to end-user customers, thus eliminating time-consuming phone calls.
Thoughtful throughput Even with all this data to keep your plant running smoothly, it will all be for nothing if you have no customers to sell asphalt to. This means that quickly and economically fulfilling customer demand is a must. New automated ticketing kiosks and silo load out and truck ticketing systems are an outstanding combination that can be used to achieve exceptional productivity improvements. These new automation solutions help operators more
efficiently manage points-of-sale and increase capacity without having to assign more plant personnel. “Self-service kiosks allow producers to increase revenue by handling more truck traffic without increasing the number of operators,” Cardy says. “The kiosks increase customer satisfaction by reducing in-yard times, and by allowing the extension of site operating hours.” Outdoor printer terminals are generating greater profits for producers by keeping drivers in their trucks and sending them on their way. The plant software allows virtually unlimited flexibility, such as the ticket layout, number of ticket copies, as well as the capability to retract tickets if not taken. The printer terminals are also designed to withstand the harsh environment. Cameras are also being used to identify trucks and eliminate the delays and other costs of paper signatures. Key ticket text is superimposed on the images and the resultant picture is digitally stored along with the transaction. If a billing dispute, or other need for proof of receipt arises, a billing clerk can automatically retrieve the picture and email it to the customer. The cameras require absolutely
56 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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PLANT MATTERS
no action by the driver, provide more information than a signature, stores the images electronically, and provides easy access to each transaction’s image downt he road if needed. When camera Identification is coupled with a remote printer terminal, post-ticket times are slashed. The driver simply pulls forward to the printer, takes the waiting tickets and leaves.
Ease of operation Along with saving operators time, automation can also assist in employee management. In the past, at a typical asphalt plant, there would be at least three plant personnel on site to maintain and monitor the plant: the plant operator, loader operator and a ground person. Today, it is increasingly more common to have only two people operating the plant, with no ground person. “We have seen some plants that get by with only one person at the plant,” Gilpin says. “In such cases, it is imperative to use AI (Artificial Intelligence), which is
a computer system, to take over and electronically operate the plant. AI can easily monitor the feeding of the baghouse fines and very expensive liquid chemical additives, along with monitoring the filling of the silo system to ensure the bintop conveyors are running and in the correct position to receive a new mix design. The quality and integrity of an electronic control system with AI will permit the plant operator to interface with the outside world of truck drivers, telephone calls, ordering of materials, and much more.” Eliminating personnel may lead to a negative view of these automation systems, however. “Contractors may be concerned these systems would threaten their job,” Gilpin says. “It would be a tough task for an operator to manually combine all of the ingredients that are being used in modern mixes without any mistakes though. With the numerous amount of materials used to make asphalt today, and the complexity of calculating varying amounts of RAP, RAS
“Contractors may be concerned these automation systems would threaten their jobs, but in the industry today, it would be a tough task for an operator to manually combine all ingredients that are being used in these mondern mixes without making any mistakes,” says Gregg Gilpin with Stansteel.
and AC percentages, the need for quality plant automation is a must.” Cost can also play a factor in implementation hesitation. “To install a new automation system requires a substantial investment and a good understanding of the benefits you get in return,” Gante says. “If one has had the experience of working with an unreliable controls system it quickly becomes clear why the choice to install new automation is obvious.”
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58 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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PLANT MATTERS › CLIFF’S NOTES
How Daily Reports Can Save You Money
C li f N ot f’s es
By Cliff Mansfield
R
ecord keeping. We all hate the task but it’s important in a well run business. Without it we wouldn’t be able to track expenses or payroll or our most important asset: profits. Daily asphalt plant reports provide information not always readily available to management, like fuel consumption, oil percentages and plant ‘idle’ time. They also provide an inventory record of oil and fuel in case the plant operator isn’t available to ask. A plant report is also a powerful tool to the alert operator. It can indicate problems with the burner or with the asphalt oil delivery system. For example, in July, a drum plant produced 2,970 tons of hot mix. In doing so it burned 4,455 gallons of diesel for a rate of 1.5 gallons per ton. Cold feed samples indicate a moisture content of 5.4%. The fuel rate seems high to the operator, so he goes back through his plant reports to May when he first fired the plant after its winter maintenance regimen. One day in early May, he produced 2,125 tons of hot mix, burning 2,550 gallons of fuel for a yield of 1.2 gallons per ton. A glance at the report indicates cold feed moisture was 5.9%. It’s now obvious to the operator that something has changed and he needs to look into it. A check of fuel filters on the burner reveals a partially plugged filter which caused a drop in fuel pressure resulting in a higher burner setting to yield the same amount of heat, thus higher fuel consumption. The plugging happened so gradually that the operator never noticed the progressively higher settings he was using on the burner controls. Without the plant reports to reference, he might have soldiered onward, blissfully unaware that he was wasting .3 tenths of a gallon of burner fuel per ton. At $2.70 per gallon that equals $.57 per ton wasted. That’s a total of $1,453.50 for the day.
Finding the source of the problem Daily plant reports can also point out problems in oil content. Let’s use a Stansteel RM-80 batch plant as an example. On August 12, the second day of a major state contract, All State Paving received the results from state sample #4, sub-lot 1. As its predecessor did, the sample shows an oil content of 6.7%, a tenth of a percent out of spec and in penalty territory. The previous day’s samples indicated a range of 6.3% to 6.5%. Since the target value was 6.1%, the plant operator reduced the batch menu oil content by .3%, expecting a 6% on his next test. When this didn’t happen, he fell back of the traditional asphalt plant operator’s defense: the state got a couple of inaccurate tests or the nuke gauge is faulty. In the example above, an investigation later revealed that the oil content listed by the state was correct. This particular plant uses an external oil weigh pot. The problem was traced to a build-up of asphalt/aggregate in the hole under the oil distribution bar where it enters the pug mill. The material restricted the downward movement of the scales as they loaded up, causing the scale outputs to indicate a weight lighter than reality. This forced an excessive amount of oil to be loaded in order to satisfy the batching computer’s demand for a set weight. Since this condition did not occur overnight, it’s a fair assumption that if the operator had kept daily records of oil consumption he would have noticed that his tank stickings were indicating a progressively higher yield than his plant’s computer was requesting.
Saving dollars In both examples, a daily plant report proves to be a valuable asset in operations. While the actual amount of dollars saved by a plant report program can be hard to estimate and likely varies from
plant to plant, few people would argue that the potential is great. The plant report can also contain other useful information, like venturi pressure drop, water pressure and gallons per minute (gpm) for the wet systems. Baghouse data can be substituted where needed. Plant reject and mix wasted can also be tracked. By including a section for operator comments, plant downtime can also be recorded. If the plant’s temperature ‘chart recorder’ disk is included, a very accurate picture of daily operations emerges. These forms are not hard to generate. I suggest creating a hard copy with two carbons. One copy is for the main office, one for the plant superintendent and the hard copy stays at the asphalt plant. In some states, asphalt plants are required to provide asphalt tank measurements and mix produced tonnages to the plant inspectors at the end of each day. For this purpose a third carbon can be added, with inappropriate data like fuel consumption and operator comments blanked out. A word of caution: Only provide the information required. It’s amazing how unnecessary and poorly understood data in uneducated hands may come back to haunt you. I have examples of these forms that can be easily modified to fit your company. To request one, please email me: cmconsulting@hotmail.com. Cliff Mansfield is owner of Cliff Mansfield Inc. and operates C.M. Consulting, an asphalt plant repairing, upgrading and operational training company. He is an asphalt plant engineer with 38 years of experience working with various brands and styles of asphalt plants. For more information on this topic, contact Cliff by calling 541-352-7942 or visiting hotplantconsulting.com.
60 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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PLANT MATTERS Reliable Asphalt Products Used/ Reconditioned Equipment Reliable Asphalt Products offers equipment that can be purchased on an “as-is” basis or reconditioned for specifications. • List thousands of plants and components of all types to meet various requirements • Batch plant, drum plants, parts and components • All listings prequalified for quality” Search: 10084584
Meeker Batch Plant RAP Kit Tarmac Plants, Components and Replacement Parts 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
Deister EMF-Series Vibrating Feeder Deister Machine Co.’s EMF-Series two-mass electromechanical vibrating feeder is designed to allow greater control over high-capacity feed rates and productivity, while lowering costs per ton in a wide variety of rugged aggregate, mining and mineral applications. • High-profile infeed lip • Heavy-duty formed deck with replaceable liners • Simplified drive with easy-access exciter frame houses the single vibrator motor • Energy-efficient pre-compressed steel transmission springs • Heavy-duty spring isolation assemblies for suspension or support mounting • Available in a wide range of deck sizes and capacities Search: 12091215
Astec V-Pack Stack Temperature Control Astec’s V-Pack Stack Temperature Control System extends the range of mixes that can be produced without requiring the flights be adjusted. • “V-flights,” unique drum flights with a deep V-shape, and its use of variable frequency drives (VFDs), which provide control of the drum rotational speed, are keys to the control system managing an asphalt plant’s exhaust gas temperature and increasing overall efficiency • Automatically controls exhaust gas temperature across a range of mix types and operating conditions by making drum speed changes • Keeps baghouse temperature relatively stable as mix temperature changes and even as mix types change from hot mix to warm mix, from virgin to high RAP, and from dense graded to open graded mixes • V-flights produce a uniform veil of virgin aggregate across the entire drum, regardless of how full the drum is, the plant’s production rate, or the RAP percentage used; this enables drum speed changes to be effective as a means of controlling stack temperature Search: 12058427
Meeker’s RAP-Pak Kit 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
AlMix Batch & “Dratch” Plants ALmix batch towers feature a new generation design adapted to handle today’s high percentage RAP and warm mix asphalt requirements. • High speed mixers without the need for timing gears • Insulated aggregate storage and hot mix storage • Fully enclosed tower • Tower may be incorporated into a combination drum/batch plant • Available in capacities from 1- to 8-ton drop • Portable options available • Seamless batch and loadout automation Search: 10280208
November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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PLANT MATTERS E.T. Clancy Asphalt Plants E.T. Clancy Co. has specialized in selling asphalt plants and equipment for 40 years. • Complete inventory of drum plants, batch plants and components • Assist in plant dismantling and set up, as well as trucking Search: 10086122
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 control system • In place of the 50-ton SEB, customers can choose a 100-ton crane erect silo • Four-bin cold feed is standard with the option of adding more bins • A recycle system is also optional Search: 10616687
PHCo Lo-Density Rigid Tubular Drywell Tank Heaters Process Heating Company Lo-Density Rigid Tubular Drywell Tank Heaters provide safe and consistent overnight heat for asphalt emulsion distributor truck tanks. • Allows operators to simply plug the heater in at the end of the day, maintaining the emulsion at the correct temperature overnight or over a weekend • No open flame • Provides even heat distribution throughout the reservoir to prevent coking or damaging of temperaturesensitive emulsion material • Drywell-style elements reside inside the sheath to eliminate the need to drain the tank to service elements Search: 12085197
Gencor Megaplant Gencor designs and builds the biggest installed base of Megaplants across North America each producing over 50% RAP and achieving production levels of over 800 tph. • Incorporates the Ultradrum design which maximizes heat transfer • Use RAP and RAS • Patented positive reclaim system Search: 10860316
Stansteel Hot Mix Asphalt Plants Stansteel’s complete heavy-duty highproduction hot mix asphalt plants include both counterflow drum mixer and batch plants. • Batch plants up to 16,000-lb. batch size • Complete counterflow drum mixers up to 850 tph • Heavy-duty design and construction Search: 10084926
ADM SPL Asphalt Plants The SPL series of hot mix asphalt plants include all necessary components for drum mixing asphalt production, yet can fit on a single trailer frame. • Available in 60-, 110- and 160-tph production rate • Come standard with a drying/mixing drum, wet wash, cold feed bin and surge system • Available in a portable or stationary configuration, as well as automated or manual operation • Only one plant operator and one loader operator needed for operation Search: 12095461
62 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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Libra Systems PlantWise PlantWise Drum Mix Control System offers advanced automation for asphalt drum mix plants. • Adaptability for retrofit or total plant control of nearly any plant • Extensive use of high-speed networking to increase accuracy and reduce wiring • Integral manual control via software control “panels” • Easy calibration of plant equipment • Real-time trending of key process parameters • Fully graphic operator interface • Instantaneous production rate changes • Tracks equipment maintenance and re-calibration schedules • Facilitates future expansion Search: 10565024
WEM Automation offers a full line of PC/PLC based full plant controls for complete drum, batch, loadout, and scale ticketing operations. • Systems include PC/PLC/Ethernet, completely off-theshelf parts, Microsoft OS and database, Allen Bradley PLC, automatic multi-point calibration, built-in redundancy, and energy efficiency tools • WEM also provides control houses, MCC’s, and total plant automation • 24/7 worldwide service and superior office communications utilities included • No charge phone/online service Search: 12085197
Systems Equipment AM-1600
“Hot Mix Asphalt, Paving the Highway to the Future”
SYSTEMS Equipment Model AM-1600 multiple ammeter display allows a quick overview of selected plant motor loads. • Provides an accurate indication of actual loads and visual and audible alarms of overload and underload conditions • Displays incoming or generated power voltage and frequency from up to two sources • Optional zero speed shaft sensors can be interfaced and will display an alarm condition as a flashing white bar graph; an out of tolerance alarm switched output is available Search: 10085072
Maxam California Bulk Sampler Maxam’s California Bulk Sampler was developed in direct response to Caltrans’ requirement to take bulk samples from the plant; the CB Sampler is now approved by Caltrans for this purpose. • Air-operated clam gates are easily chattered to fill a Caltrans approved Gilson sample splitter • Onboard air tank contains enough air to open and close the gates several times • After emptying, the hopper is lowered by battery operated electric winch, and locks easily for transport with cam lock latches • When at the plant site, the hopper is quickly powered to the upright loading position, where it automatically locks into place; once loaded the trailer mounted hopper is ready for transport to the lab site Search: 12096351
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C.M.Consulting
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2006 Cummins 275kWPortable 480v Generator. hours!Control SellingHouse….Call as USED...............Call. 1996 ADM SPL-110 Drum mixer0W/NEW 1996 ADM SPL-110 Portable mixer W/NEW Control 1980s Boeing MS-200 250Drum TPH Portable Drum with SlingerHouse.................Call. & Burner….Call Rebuilt GenCo AF-25 250 Natural Burner,Drum w/newwith controls. Complete 1980s Boeing MS-200 TPHGas Portable Slinger & Burner..........Call. New, used and rebuilt Hauck & Genco burners. Burner Controls….Call 1980s Boeing MS-300 Portable Drum Plant, Wet-Scrubber, No AC Tank......Call. 1999 John Deere 544G Front End Loader. 5,000 hours….Call Rebuilt GenCo AF-25 Natural Gas Burner, w/new controls & Gas-Train. Complete. New, usedMANSFIELD and rebuilt Hauck Burner Controls................Call. CLIFF INC. & Genco burners. OFFICE 541-352-7942
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November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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How to Optimize Telematics with a Maintenance Management Program by John Kane, Contributing Editor
64 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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TECHNOLOGY UPDATE
T
he use of telematics to track fuel use, engine hours, GPS location, fault codes and numerous other metrics is nothing new. What is new is the opportunity to optimize that data by adopting industry standards and a software-based maintenance management program. In recent years, construction enterprises have been moving away from managing and maintaining their fleets solely by e-mail, paper forms and spreadsheets. For many companies, this task has grown too large to be continued in a manual process. Telematics have helped, but managing data from multiple manufacturers in multiple formats has also created new challenges. In many cases, it takes too long and too much manual intervention to extract and decipher this information in order to use it. Construction companies’ cries for help are being heard, and a new streamlined process is taking shape. Equipment manufacturers are moving to standardized telematics data, and maintenance management software is delivering powerful opportunities to use the data to optimize maintenance operations.
Telematics standards are vital Telematics are changing the construction industry and when properly used can have a dramatic impact on a company’s bottom line. There is a high value of telematics for the automation of the service process and for identifying when an asset should be brought in for maintenance. However, a stumbling block remains in the Tower of Babel — the proprietary means by which manufacturers communicate their data. Because each manufacturer historically delivered telematics information differently, most construction companies have been forced to use a variety of means to access, understand and correlate it all. Companies may need to log into web portals of multiple manufacturers to pull this telematics data. First
it’s a visit to the John Deere site, then it’s a completely different site to pull similar information for the Volvo fleet, then it’s onto Caterpillar, and so on. Using an intermediary source to aggregate and reconcile data from multiple equipment suppliers is another option, but that can add another layer of complexity and expenses. An industry-wide standard for telematics data makes obvious sense. The Association of Equipment Management Professionals (AEMP) and the Association of Equipment Manufacturers (AEM) have led the charge in this area and have made great progress. Their current standard — version 1.2 — includes 19 data fields. In addition to this expanded number of data fields, the new standard also changes how this information is accessed in an effort to make it easier to integrate with other systems and processes. This includes standardized communication protocols for transferring telematics information across equipment fleets to end user maintenance management programs. By working closely with manufacturers to develop their own Application Programming Interface (API), the AEMP is helping to ensure that all telematics information is formatted with the same language and style.
Compiling useful data Expanded industry standards and APIs make it easier to export more telematics data, and software-based maintenance management programs are the key to maximizing the obvious potential of that data. It’s a powerful combination that can increase realtime visibility and awareness, automate maintenance processes and improve reporting. Let’s look at work orders for preventive maintenance as an example. Without a maintenance management program, a mechanic or manager must review telematics data manually, identify when a piece of equipment is due for routine maintenance
and then generate a work order. In contrast, a maintenance management program can pull in telematics data for each piece of equipment, analyze it and generate the work order for routine maintenance at the appropriate time – all automatically. Similarly, reports and dashboards used to manage maintenance processes can be automatically populated with telematics data.
The benefits of telematics and your maintenance program Combining telematics and a maintenance management program provides powerful benefits when it comes to cutting maintenance costs and optimizing fleet performance, uptime and safety. But don’t be fooled, it’s not the younger generation who grew up attached to PlayStation, that is leading the charge to advanced technology. In many construction companies, it’s the seasoned pros who are realizing the ROI advantages. Many construction companies are understandably apprehensive about introducing a maintenance management program, fearing resistance from maintenance teams with limited software experience. Most, however, are pleasantly surprised by how fast those teams embrace the technology. There are two primary reasons. These employees want to be successful and they recognize quickly that maintenance software makes it easier for them to be successful. Secondly, the best maintenance software programs are now extremely intuitive and easy to use.
How telematics can save you money Combining telematics and maintenance management programs allows an entire new world to open up. One of the most impressive aspects of this is its Global Positioning System (GPS) ability. Using GPS with fleet telematics enables the monitoring of location, movements and the general status
November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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TECHNOLOGY UPDATE Merging telematics data with a maintenance management program can automate processes, which can increase adherence to preventive programs, leading to lower maintenance and repair costs, increased uptime, fewer breakdowns and a safer fleet.
of a vehicle. This is made possible by a combination of a GPS receiver and an electronic GSM device installed within each vehicle. Collected data provides complete and up-to-theminute status of any vehicle in the fleet — potentially valuable data for the maintenance team. Perhaps even more impressive than GPS abilities are geofencing abilities. A recent report from ABI Research forecast that the provision of geofencing tools will be a market in its own right and will reach almost $300 million in 2017. The research company points to low-cost tools becoming available, and the fact that geofencing is moving beyond traditional locationbased applications For construction companies, geofencing provides geographic boundaries around vehicles that reside on the construction site or that are stored elsewhere. The system sends out automated alerts when a vehicle enters or leaves these specific boundaries. This is extremely valuable information for executives, foremen and other construction workers. In addition it provides an added protection for vehicles that should not be operated due to safety, based on maintenance schedules.
Preventive maintenance The biggest benefit of telematics for many companies, from a financial perspective, may lie in the potential to improve preventive maintenance. As explained earlier, merging telematics data with a maintenance management program can automate processes. That increases adherence to preventive programs, leading to lower maintenance and repair costs, increased uptime, fewer breakdowns and a safer fleet. The construction industry has taken notice of these powerful advances in telematics. Telogis underscores this by recently issuing its five big construction industry trends for 2015 and specifically noted telematics. According to their blog, the trends are: • Assets with built-in telematics will become a lot more common • Managers will be accessing more real-time data on the go • Focus on improving the asset safety and security • Fuel use and potential savings will continue to be critical • Strong growth in off-highway vehicle (OHV) telematics adoption Construction companies are embracing new technologies to combat margin pressure and drive profitability. With telematics, growing pains of dealing with data from multiple manufacturers in multiple formats
are giving way to industry standards that make it easier to access a growing range of data. Vehicle manufactures can do their part by embracing new AEMP Telematics Standards and providing simple APIs for companies to easily pull data into their maintenance management programs. Access, however, is only one part of the equation. With a wealth of data and no way to process it efficiently and make it actionable, companies can be left at a competitive disadvantage. A maintenance management program is the logical companion to telematics and a way to turn that disadvantage into and advantage. The specialized software gives companies a way to optimize telematics data to streamline and automate maintenance processes and manage their fleets from one, unified platform that interfaces across many disciplines — such as estimating, scheduling and field tracking. John Kane is a product manager with B2W Software.
66 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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Gencor Provides Superior Product Support Gencor established itself as the leader in rugged dependable equipment and superior after sale support, over a century ago, with a philosophy of hands-on training, innovative technology and common sense solutions to your needs. Whether at a one of Gencor’s legendary annual training schools, a turnkey installation, or a parts order at 2 am, no one offers you better 24/7 support than Gencor. When you need dependable support, look to the leader Gencor. Search: 10073090
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Advanced Paving Technologies to Develop
“ 3D PAVER ”
Crowdfunding campaign hopes to raise $60,000 for R&D by Allan Heydorn, Contributing Editor
O
n October 15, Advanced Paving Technologies Inc. (APT) launched a crowdfunding campaign to generate $60,000 for what it expects to be the first step in bringing what the company terms a “3D asphalt paver” to the market. Still in the research phase, the paver is called the Multi-Dimensional Asphalt Delivery and Compaction System (MADCS) and will be intended for paving overlays, not for new construction. “Informally, it is the world’s first 3D asphalt paving machine,” according to APT. John Smith, CEO, says the $60,000 will fund core research and development on MADCS. APT is working in conjunction with Dr. John Harvey and his team at the University of California-Davis, where research funded by this crowdfunding campaign will be performed.
“Our stretch goal is to do the mechanical engineering for the 3D paver and the final design for a prototype,” Smith says. “Once we get positive results from our research we can then reach out to capital investors to finance and build a prototype.”
What 3D paving is trying to solve According to APT, current pavers that rely on screeds have only a single flat surface, which can’t compensate for the bumps, dips, depressions and ruts found in most roads. For example, if used to overlay an existing surface that has typical depressions or ruts, and without any preparation work, APT says current pavers deliver too much material over the bumps and not enough material over the depressions, resulting in what is commonly referred to as differential compaction.
“When the heavy roller comes along the material around the depression compacts first, causing the heavy roller with its flat compacting surface to bridge over the depression and the asphalt material doesn’t fully compact,” according to APT. Smith says that to compensate for this, the industry currently has no choice but to turn to pavement milling, which does even out the surface to be paved. “Unfortunately, this method reprocesses 100% of the road surface to address a much smaller percentage of problem areas. Structurally, nothing is wrong with the majority of all asphalt that is reprocessed in this manner. “This process is very time consuming and costly as well as greatly contributing to the carbon output of the project,” he continues. “It also causes more and longer lane closures, which
68 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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TECHNOLOGY UPDATE
In theory, the MADCS approach could eliminate the need for multiple lifts. “In one pass we expect to be able to provide enough material that is shaped it in a way that will eliminate ‘bridging’ around defects and also solve the problem of thermal differentiation between layers because in many cases multiple layers won’t be needed,” Smith says. He says once their research demonstrates the ability to accurately shape and deliver asphalt as they expect, additional benefits will include the ability to improve drainage issues on the go and improve joint and edge density.
adds to traffic congestion and causes even more carbon output. Often it is milled for no other reason than to provide a uniform flat surface for current 2D asphalt paving machines to be effective.” The industry rightly calls this practice a “recycling” effort, however it is anything but a green process.
How the 3D paver works The MADCS uses a remote sensing technology (LIDAR) that essentially bounces a laser off a target (in this case the pavement surface) and analyzes the reflected light. Smith says this scanner, when combined with APT’s new asphalt paver design, will be able to scan a road surface, map out its defects, and then design and deliver “on the move” a shaped asphalt mat that provides a smooth and long-lasting pavement surface. “Mapping the surface is only part of the solution. The other part is that instead of using today’s typical flat screed, we will be using a multi-segmented variable screed that incrementally delivers asphalt material across the entire width of the paving pass,” Smith says. “The variable screed works completely different from current
screeds that measure and provide initial compaction of the asphalt material at the same time. “Instead we first form an overly thick uncompacted layer of asphalt that is then introduced to the variable screed, which incrementally strikes off the unneeded material, leaving only the asphalt required to form the 3D-shaped asphalt layer.” Smith says the individual blade elements of the variable screed do not move straight up and down, as that would distort the oncoming asphalt layer. Instead, the plurality of screed blades are held at an angle in order to bisect the oncoming layer of asphalt and minimize distortions. Smith said the excess material moves up and out of the inner chamber and comes into contact with a return conveyor that grabs the excess material and delivers it back to the feed hopper, to be reintroduced back into the system. The shaped asphalt layer immediately comes into contact with an angled vibratory sled positioned at the back of the paving machine to compress the high spots into the depressions they are designed to address. Final compaction is performed by a typical heavy roller to form the designed smooth planar surface. “That will enable us to deliver an asphalt mat that accounts for and corrects any surface irregularities underneath and provides a smooth even wearing surface on top,” Smith says. “And we can do that without having to
mill the entire surface.” In essence this method utilizes the effects of “differential compaction” and uses it in a positive way. He said under ideal circumstances the company is looking at roughly a three-year timeline to bring the unit to the market.
NPE 2016 Offers Technology Insights
At National Pavement Expo, Jan. 27-30 in Charlotte, NC, Guy Gruenberg, Grow Consulting, will present “How to Use Today’s Technologies to Manage Your Contracting Business,” outlining the variety of technologies available to help contractors improve them management side of their business. According to the description, “You’ll learn about the new and different ways contractors are deploying technology to win contracts, reduce costs, and generate more profit.” Technologies covered will include lead generation through online research, customer tracking with CRM, job costing with integrated spread sheets, data collection and analysis, aerial measuring, and how to create compelling proposals. Plus learn how digital photography and video are instrumental in communicating and cataloging what happens on your jobsites. This seminar won’t solve all your technology problems, but it will open your eyes to new cost-effective tools that will improve the management side of your business — and your bottom line. For details visit www.nationalpavementexpo.com. Individual blade elements of the variable screed do not move straight up and down, as that would distort the oncoming asphalt layer. Instead, the plurality of screed blades are held at an angle in order to bisect the oncoming layer of asphalt and minimize distortions.
November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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TECHNOLOGY UPDATE
How Wearable Technology is Saving Lives Integrating wearable tech into site safety procedures is a win for construction contractors By Jessica Stoikes, Associate Editor
M
obile construction jobsites are busy places. There are workers on the ground, workers operating heavy cons truc tion equip ment and traffic from both workers and the travelling public to consider. When these workers aren’t aware of each other, that is when accidents happen. According to OSHA, over 10% of all construction fatalities are related to workers being struck by an object. But what if that could change through the use of new wearable technology? SiteZone Proximity Warning System (PWS), is an audible and visual warning system designed to reduce the risk of vehicle personnel collisions and can be used anywhere the proximity of people and vehicles working together is of concern. The devices use Radio Frequency Identification (RFID) to transport data. These tiny electronic chips transfer information from a transponder to a receptor. Pedestrians wear a small RFID transponder on their hard hat or sleeve, and a small unit is fitted to the vehicle. SiteZone PWS then produces a detection zone, or bubble, around a vehicle, machine or even a restricted area. This invisible radio frequency field completely surrounds the vehicle and is used to detect the presence of the wearable transponders.
“Don’t Burst the Bubble” SiteZone uses the analogy of a “safety bubble” to help relay the message of their technology to contractors. The bubble is the danger zone that pedestrians should avoid to prevent accidental collision. When the detection zone is breached, the personnel wearing the SiteZone transponder has “burst the bubble.” The machine operator is immediately
alerted to their presence and can take the appropriate action. When this occurs, both the driver and the operator receive warnings through vibration, audio or visual alerts. This two-way alarm is important since it is the responsibility of both the driver and the pedestrian to avoid a collision. SiteZone also offers optional external alarms that can be placed on top of equipment to sound in the event of a breach.
The “Don’t Burst the Bubble” message provides an easily memorable reminder to workers not to breach the danger zone of any vehicle or heavy plant, useful in staff inductions and training programs. Importantly, if a pedestrian does breach a safety zone, SiteZone automatically logs the incident. SiteZone’s developer, OnGarde, has launched OverSite, which transfers logged data to a secure website. Since each RFID transponder can be individually identified, managers can identify repeat offenders and target further safety training. Through use of this technology, workers are becoming more aware of the risks they encounter every day and are adapting their behavior to protect themselves from potentially dangerous situations. The Sitezone PWS can be deployed onto a wide range of vehicles and machinery across multiple disciplines. It can
also be used to tag critical or valuable assets to prevent vehicle collisions or create exclusion zones around no entry areas and hazardous machinery.
Future of Safety Vests
Researchers at Virginia Tech’s Bradley School of Electrical and Computer Engineering have created prototypes of construction safety vests incorporating radio sensors that alert workers of potential hazards and prevent potentially fatal roadside accidents. Head of research Tom Martin and Ph.D. student Kristen Hines are working to use short-range communication to provide construction workers with collision avoidance, which could give workers a few extra seconds to get out of the way of a possible collision. The InZoneAlert vest uses GPS tracking and short-range communication — something that many cars will have in the future. It sends an alert to the worker and driver the moment danger is Dr. Tom Martin detected. The and Ph.D. student vest currently Kristen Hines also features LED with the newest lights, speakers prototype of and vibrations to the InZoneAlert determine which construction vest. mode of communication is most effective. Early tests of the technology anticipate a 90% success rate for future incidents. Virginia Tech Transportation Institute is planning real-world trials of the vests in actual highway traffic environments.
70 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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TECHNOLOGY UPDATE MOBA PAVE-IR Scan System MOBA PAVE-IR scan system provides a nondestructive 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
HCSS GPS Feature The HCSS GPS feature is integrated with The Dispatcher Resource Management Software to provide a mobile geofence for asphalt pavers and other equipment. • Yields accurate cycle-time information for individual machines • Pinpoints real-time movement on the equipment • Does not require daily input and modifications • GPS data “draws” the geofence automatically throughout the day as equipment moves from job to job Search: 10280008
Trimble TrimFleet Mobile App Roadtec Guardian Telematics System The Guardian Telematics System consists of software, on-machine viewing screens and wireless signal boosters to send and receive data at the machine. • Numerous functions such as engine data and fuel consumption can be viewed at the machine or on your computer screen from a remote location • Standard on e-series cold planers and e-series pavers • Software automatically updated when a new version is released • Machine circuits and systems shown as live schematics so issues can be solved instantly • Guardian Production reporting will allow customers to see in real time or at the end of a day what production is on that machine; available for RX-600, RX-700 and RX-900 milling machines Search: 10913506
TrimFleet Mobile is an Android app that tracks the position, speed and direction of heavy construction, ready mix, aggregate and bulk materials vehicles with real-time updates on location and events. • Uses a combination of automated geo-based statuses for arrive and depart site and driver-initiated statuses for load and unload events • Allows drivers to communicate via two-way text messaging, Driver Initiate Messaging (DIM), voice-totext and text-to-voice capabilities and Radio over IP (RoIP) voice calling • Active Navigation feature enables use of CoPilot Truck Navigation, a truck-specific GPS navigation solution that notifies drivers where to reroute from truck-restricted and prohibited roads • Ticket and delivery information accessible by the driver with dispatch integration • Electronic proof of delivery with signature capture and time-stamped record of receipt Search: 12017009
Caterpillar Grade and Slope System for Asphalt Pavers This 2D system allows paver operators to place the exact amount of mix on the surface for better compaction performance, optimal material usage and improved mat quality. • Can be equipped with single or dual LCD displays with text-based menus offering multiple language options • Can be configured to control elevation to one or both sides of the screed, cross-slope and elevation plus cross-slope • Can be equipped with sonic or contacting grade sensors • Can also be configured with an averaging beam Search: 10983751
72 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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International Cybernetics ACCU-SLOPE The ACCU-SLOPE is designed to rapidly and accurately measure and check cross-slope readings during the paving process. • Fully automated with single-person operation • Lightweight, portable and cost effective • Eliminates the need for multi-person measurements • Made with traditional rod and level equipment Search: 10713898
Topcon Magnet Software The Magnet cloud-based enterprise solution and cloud-enabled software applications combine all facets of managing a company’s precise positioning projects, data and assets. • Basic products include Field, Tools, Office and Enterprise • Connects every user within a company within the productivity application used or by simply logging in using a web browser • Visualize projects, job files, equipment assets and plot job points, lines and areas on a familiar map interface Search: 10430791
WEM Maintenance Log The Maintenance Log helps to increase plant availability by tracking device usage and producing work orders. • Schedule downtime • Product work orders for preventive and routine maintenance based upon calendar time, hours of run time, total tonnage or number of device actuations • Parts lists and photos can be displayed to aid in performing maintenance tasks Search: 10226318
Navman Wireless Qtanium Connect Telematics Portal The Qtanium Connect telematics portal merges data from all OEM and Navman Wireless-tracked heavy equipment to simplify management of mixed fleets. • Provides one-stop fleetwide visibility without adding thirdparty hardware to machines, and supports integration of data into the enterprise office system • Allows fleet operators to request data access credentials from each OEM represented in their fleet • Data securely transmitted to operators’ servers and aggregated for use in the portal’s widgets, dashboards, maps and reports • Data captured includes machine location, fleet utilization, fuel burn, geofence and curfew violations, preventive maintenance schedules and more
Bergkamp InPave for Pothole Repair The InPave System is an option on Bergkamp’s Flameless Pothole Patcher to help government agencies and contractors better monitor and manage pothole patching performance. • Multiple data reporting sensors strategically placed throughout the patcher monitor production, performance and locations of your patcher and crew • Data automatically gathered and transmitted back to the office as potholes are repaired • Data can be turned into easy-toread reports to assist in evaluating current and historic production to verify patching performance and material usage, troubleshoot and reduce inefficiencies Search: 10796982
Search: 11364434
November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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TECHNOLOGY UPDATE Zonar Fuel-Based GPS Tracking Technology
Niveltronic Plus Technology Vögele’s Niveltronic Plus is a fully integrated system which provides the perfect match of the paver’s technology to its grade and slope control system. • All settings are made on the screed console • Allows the screed operator to understand and safely control all major functions • Requires no extra training • A wide variety of sensors permits use of Niveltronic Plus in all applications • Automatically recognizes every sensor connected • All wiring and connections are integrated into the tractor and screed Search: 10720075
The Fuel-Based GPS Tracking Technology reports latitude, longitude, time, odometer and fuel wirelessly from vehicles in a fleet. • Determine sample rates based on geographical data and fuel consumption • Identify routes and lanes over which vehicles are most and least fuel efficient • Transmit engine fault codes and verified electronic vehicle inspection data in real-time • Capture and transmit driver performance metrics including accelerating too quickly, hard braking, excessive idling, anti-lock brake system activation, roll stability control activation and more Search: 10656133
Spectrum Equipment Field Entry Mobile App The Equipment Field Entry app is a simple, powerful tool for gathering and analyzing equipment data in the field. • Select a job and view all equipment assigned to it or view the location of equipment in the field • Enter data such as usage hours and odometer readings and track fuel transaction or amounts of fuel dispensed • Track scheduled maintenance tasks • Equipment Field Entry app connects directly to Dexter + Chaney’s Spectrum Construction Software suite • Bluetooth capability enables it to automatically connect and communicate with fuel tank flow meters • Works with tablet devices and iPhone and Android smart phones, and is available at both the Google Play and iTunes app stores Search: 12011614
Case SiteSolutions
Volvo Density Direct Intelligent Compaction System
CASE SiteSolutions brings together the company’s precision construction services, including all telematics and machine control technologies, under one name. • Select equipment available as factory-ready for machine control solutions with all three primary machine control brands • Number of machine parameters transmitted via the SiteWatch telematics system increased from 12 to 40 • Added satellite connectivity for telematics services in areas without cellular network coverage
The Volvo Intelligent Compaction (IC) system for select Volvo asphalt compactors is available in two packages — Volvo IC and Volvo IC with Density Direct. • Offers pass mapping, temperature mapping and data storage features; Volvo IC with Density Direct includes real-time density mapping technology • Produces a density calculation that is accurate to within 1.5% of core sampling, providing a real-time reading of density values over 100% of the mat • Reduces the occurrence of inadequate densities and time spent taking core samples, improves quality, and leads to much greater uniformity • User interface depicts a density map, showing each square foot of rolled asphalt in a color representing density, and also provides a real-time numerical density reading displayed in the corner of the screen
Search: 12092954
Search: 12058450
74 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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CLASSIFIED ADVERTISING
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Late model Terex E225P Counterflow Drum Mix Plant 5 Bin Cold Feed, Self-Erect Silo, Baghouse, 20,000 G. A/C Tank CMI Impulse II Controls, Complete MCC and Control House
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November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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CLASSIFIED ADVERTISING
LIME ADDITIVE Pugmill Systems manufactures top-quality portable and stationary pugmills for lime additives, soil cement, and stabilized base. 100-1500 TPH. Durable, low maintenance design.
Wanted: 12x30 Stationary asphalt Control House ➤ Late model in good condition. Able to be mounted on concrete block or poured walls
FOR SALE
➤ 360 degree view preferred
✔ 2000 Roadtec, SB-2500B Shuttle Buggy ✔ 6000 hours approximate – POR – South Central USA
Reply to:
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➤ 1600 amp MCC 262-269-8473 marks@wolfpaving.com
Servicing OLD & NEW Batching Systems since 1984 Batching Loadout Truck Scales Okidata 320 Printers
Clark Loney 888-220-1277 • Fax 707-929-0569 Email: clark@asphaltequipment.us www.asphaltequipment.us
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In Stock: New 500 and 750 Pugmills Conveyors, Belt Feeders
PUGMILL SYSTEMS, INC. Manufacturers of Davis Pugmills (931) 388-0626 COLUMBIA, TN www.pugmillsystems.com
PUMP PACKING Stop your pumps from leaking!
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OPPORTUNITY AWAITS! Contact Denise Singsime at 1-800-538-5544 ext. 1245 Fax: 920-542-1133 dsingsime@acbusinessmedia.com
Astec Relocatable 300TPH Double Barrel Plant ®
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an Astec Industries Company 4101 JEROME AVENUE • CHATTANOOGA, TN 37407 USA • 423.867.4210 • FAX 423.867.4636 • www.astecinc.com
76 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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CLASSIFIED ADVERTISING
November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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CLASSIFIED ADVERTISING
RAP-14719 Gencor style 2-Bin Stationary Recycle System
• 10’ x 15’ Bin Openings • Grizzly and air cannon • 5hp chain drive RAP-14645 H&B 10,000 LB. BATCH PLANT
• H&B 10K Batch Plant • Cedarapids 10028 Dryer w SJ360 natural gas
RAP-14687 DILLMAN STATIONARY CONTROL HOUSE
• Start/ Stop panel, • Systems GUI Windows Silo Burner control Loadout • Systems ADP100 • 5 Bin Cold Feed System drum controls - Herman Grant RAP-14686 DILLMAN 88,000 CFM • Single RAP Bin BAGHOUSE w Grizzly
RAP-14682 RELIABLE ASPHALT PRODUCTS RECYCLE SYSTEM
• Three Bin setup, NEW in 2008 • 9x14 bin opening • 5hp DC
• Bin Extensions • One bin equipped for shingle use. Sitting on load cells
RAP-14676 500 TPH DILLMAN SILO SYSTEM
• (2) 200-ton Dillman Silos • Dillman Main Drag Slat Conveyor • (2) Dillman Transfer Conveyors
• Silo System Switchgear Panel • Truck Scale Not Included
RAP-14700 HEATEC PORTABLE AC TANK
• 784 - 6-1/4in x 13ft6in bags • 17,320 sq ft of cloth • Dillman uses 5.1:1 air to cloth ratio • 88,332 ACFM
• HT25P/HCS100 . SN HO1- 119 • Date - 2001 • Coiled for Hot Oil heat
• 25,000 gallon capacity • Tandem axle portability
RAP-14701 CMI PORTABLE AC TANK
• CT25P - sn 189 • Coiled for hot oil heat
• Gooseneck mounted unloading pump • Tandem Axle portability
RAP-13915 ASTEC 60K CFM BAGHOUSE
• RBH-58:DB 98-007 • Horizontal Cyclone • Skid Mounted Arrangement
• 10,843 sq ft - 5.5 to 1 = 60,000 cfm
78 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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CLASSIFIED ADVERTISING
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November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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CLASSIFIED ADVERTISING
E
JBKP.O. ENTERPRISES INC. Box 369, Georgetown, TN 37336
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TempRamps pay for themselves in two uses. No Clean-up—No Trucking—No Disposal of Cold Patch No safety Claims
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Come see us at the World of Asphalt Nashville, TN March 22-24, 2016 Booth 3216
We stock Parts for Barber-Greene, Cedarapids, Cummer, H&B, Littleford, Madsen, McCarter, CMI, Simplicity, Standard Steel, Warren Brothers and other makes. Contact us for all your parts needs for Batch & Drum Mix Plants at
423-476-9900 or 1-800-441-9528 www.JBK-Enterprises.com
DRYER/DRUM SPECIALISTS “Serving the rock and asphalt industries since 1985” WE ARE SECOND TO NONE IN SERVICE AND SATISFACTION ALIGNMENT
Just as your vehicles need proper alignment, so does your dryer. Nearly all external dryer problems are caused by trunnion and frame misalignment. Long-term mis-alignment causes damage resulting in downtime and costly repairs. Even units that seemingly float properly can in reality be drastically out of alignment.
SIGNS OF MIS-ALIGNMENT
✔ Metal flakes from tires or trunnions ✔ Trunnion mis-location and trunnion bearing failure ✔ Poor wear/contact on tires and trunnions ✔ High drive motor amperage ✔ Excessive vibration ✔ Thrust roller and bearing damage ✔ Tire pad and keeper wear ✔ Lack of proper floatation Evans & Daniels uses precision laser and sighting techniques to restore your unit to proper alignment settings.
RESURFACING
Evans & Daniels uses highly specialized grinding equipment that can fit into the tightest of spaces. We resurface tires, trunnions, thrust rollers and tire thrust faces. We don’t require cranes, lifting assistance, or steel framework. In most cases, we can grind during regular production conditions.
COMMON WEAR PATTERNS ✔ Tapers ✔ Washboard ✔ Concave / Convex ✔ Shoulders ✔ Lumps / Divots / Cracks ✔ Rollover
TIRE & TRUNNION RESURFACING — TRUNNION ALIGNMENT — PREVENTIVE MAINTENANCE
www.evansanddaniels.com — 570-779-1982 80 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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CLASSIFIED ADVERTISING
OIL DISTRIBUTORS 2015 RENTAL RETURNS
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milling machine via CAN Bus, Digital Valve, or Proportional Control. • With the IntelliMatics system now fully integrated. The entire system can be monitored remotely by our technicians and your own office as well.
Etnyre 2000 Gallon Centennial • 16’ Spray Bar – 1’ Increments • Computer Controlled • 2 Diesel Burners • Mounted on 2015 Freightliner and Ford Trucks • 33,000 Lb. GVW • Diesel Engines • Auto Transmission – 2 Speed Rear End • Live PTO – Air Conditioning
CALL JON AT (701) 293-7325 • www.swanston.com
Toll Free 1 800-719-PAVE
The Ace Group
77
Aggregate Designs Corp.
75
Almix
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Aqua Foam
31
JBK Enterprises Inc.
80
Asphalt Drum Mixers Inc.
26-27, 51
K-M International
34, 48
Astec Inc.
13, 42-43, 76
LeeBoy
41
Atlas Copco
37
Libra Systems Corp.
36
Carlson Paving Products Inc.
83
Meeker
47
Caterpillar Paving
7
NAPA
59
Clarence Richard
79
National Highway Maintenance System Ltd, LLC
75
Clear Span Fabric Structures
79
NPE
71
C. M. Consulting
63
Pavesmart
81
Dillman
4-5
Process Heating Company
48
Eager Beaver Trailers
29
Pugmill Systems Inc.
76
E. D. Etnyre & Co.
50
Reliable Asphalt Products
78
E. T. Clancy Company
75
Road Widener
34
Evans & Daniels Inc.
80
Roadtec an Astec Industries Co.
11, 84
EZ Road, Inc.
80
Sealmaster
23
FastMeasure By KTP Enterprises
75
Swanston
81
Freightliner
16-17
Systems Equipment Corp.
21
Gencor Industries Inc.
3, 67
Tarmac International Inc.
49
General Combustion
15
Transtech Systems Inc.
39
Heatec Inc.
2
Volvo Construction Equipment
25
Ingevity
33
Weiler
57
Innophos
35
Wirtgen America
45
ADVERTISERS’ INDEX
November 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor
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THE LAST EXIT
Teaching Old Asphalt Delta S Asphalt Rejuvenator restores New Tricks binder to its original functionality,
extending the life of an asphalt pavement
T
By Jessica Stoikes, Associate Editor he primary cause of failure in a pavement is oxidation. Asphalt binder, which is the material used to keep aggregates together, weakens over time, becoming brittle and breaking apart. Water then penetrates into the asphalt base, causing it to shift and settle, leading to further cracking and depressions in the surface. This oxidation process is what the team at Collaborative Aggregates sought to change. “The Massachusetts DOT was looking for an environmentally friendly product that allowed them to use higher percentages of RAP and RAS in their mix design,” says Jay Bianchini, vice president of operations at Collaborative Aggregates. “The principles of green chemistry required us to ensure that any rejuvenator we developed was sustainable. From the very beginning, that was our goal. It was just a matter of developing a formulation that truly rejuvenated aged binder and met our green initiative.” The result was Delta S, an asphalt rejuvenator that was designed to chemically reverse the oxidation that takes place in asphalt as it’s heated at the plant and subsequent aging after it’s been paved. “The key here is that it was designed to chemically reverse the oxidation,” Bianchini says. “There are a lot of rejuvenators out there that simply soften the aged binder. Other products came about as a waste material that companies wanted to turn into a commodity product, so again, they do not chemically alter the aged binder.” Delta S is environmentally friendly, worker safe and all the components come from renewable feed stocks. Oxidation is reversed through a carrier matrix which solvates aged asphalt in order to allow the antioxidant properties of the
suspended small molecules to react with the oxidized components of the aged binder. That allows their antioxidant properties to reach the damaged elements and ameliorate their effect on the final pavement product.
Mix it up Just like any other additive, Delta S can be added into the binder before mixing or directly to the recycled material. “Since the idea is to recycle aged binder, we often suggest dosing directly to the recycled material, to ensure the target of interest is receiving the maximum dosage,” Bianchini says. “Experiments have shown, however, that performance does not differ to a meaningful extent with pre-dosing, so the choice of application method should be largely driven by customer convenience.” Unlike other products though, Delta S can be introduced at any point in the production of pavement: it can be added to the binder in the asphalt storage tank, where it will remain incorporated in the asphalt without ongoing heating or agitation, applied through a spray bar over the belt or bin for whichever recycled product is being used/treated. It can also be in-line blended with the liquid asphalt using an injection system (such as those used for liquid anti-strip aids or latex, or a basic pump skid). It can be sprayed directly into the plant through its own metered injection port. “Delta S has successfully been introduced through every method commonly used in the trade,” Bianchini says. “Delta S has been tried and shown success with both RAP (upwards of 45%) and RAS (upwards of 5%). The dosage rate differs, however, due to the greater stiffness of RAS binder. “The purpose of rejuvenator use, in our view, is to produce pavement that
meets or exceeds performance targets for high-quality engineered mixes, and to do so in an economical and environmentally conservative way.”
Green means clean This product is not only good for the asphalt it’s helping to keep in prime performance, it’s also good for the environment, your crew and those around the paving process. “Reducing the chronic exposure of paving crews to carcinogenic or otherwise harmful compounds by replacing the elements you feasibly can with safer alternatives is the responsible thing to do, both on a human level, and in terms of reducing long-term costs to society,” Bianchini says. “In terms of greater environmental impact, increasing the amount of recycled content you can use, and increasing the lifespan of pavement, reduces the consumption of non-renewable resources, so the more effective a rejuvenator is, if it is itself produced from renewable sources, the lower the environmental footprint of paving a given roadway will be,” he says. And it isn’t just your workers that can be exposed to material used in the production of pavement. “Those nearby during production, or even thereafter, should be spared any unnecessary harmful exposure,” Bianchini says. “Every time water rolls off the top or makes its way through pavement, it’s worth considering what it may be taking with it.” Delta S has just been paved on a test section of the National Center for Asphalt Technology (NCAT) track. “We’re using a very aggressive mix design of 25% RAP (upper fail temp 110°C) and 5% RAS (upper fail temp of 189°C) along with a 67-22 virgin binder,” Bianchini says. “Delta S was dosed at 10% to the recycled binder content.”
82 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2015
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