Asphalt Contractor November 2016 by ForConstructionPros.com

Unique warm mix design for failing freeway Page 30

Latest Technologies for Production, Paving & Preservation November 2016

30 CELEBRATING

Years

How to Manage Your

RAP

Tips & tricks for getting the most from this recycled material Page 20

Walsh & Kelly expands its L asphalt operation A N with new O I location T Page 64 www.ForConstructionPros.com/Asphalt

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, ER

L VI

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RECON™ helps you stay informed RECON™ monitor helps you stay informed about the status of asphalt storage tanks and hot oil heaters at your HMA plant. It is a web-based system that uses your smart phone, tablet or PC.

VISIT US BOOTH C30332

H E AT E C , I N C .

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an Astec Industries Company

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

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› TABLE OF CONTENTS NOVEMBER 2016 IN EVERY ISSUE

8 Editor’s Perspective

Study: VMT is the best option for long-term funding.

10 New Products

The latest innovations available for your asphalt business.

18 Technology Update Shedding new light on road construction.

81 Ad Index

COVER STORY

82 The Last Exit

Soybeans are the latest sustainable product being used to help extend the life of asphalt pavements.

20 Best Practices for Managing RAP at the Plant Tips & tricks for getting optimum utilization from this recycled material.

PAVING INNOVATIONS

PAVEMENT PRESERVATION

30 Fast Fix for Failing

54 CIR Around the U.S.

Freeway

Unique warm mix design enables early start, enhanced compaction for urgent rebuild of South Carolina’s I-85.

38 Full-Depth HMA Project Uses Cutting Edge Innovations

The Iowa DOT and LL Pelling utilize infrared temperature monitoring, GPS roller mapping, and E-ticketing on the Highway 100 project.

44 Ajax Paving Takes

PLANT MATTERS

A look at some case studies where cold in-place recycling was successfully used to rehab pavements.

60 Preservation Products

Milling machines, reclaimers, infrared equipment & more.

Its Own Opportunities Indiana-based asphalt company expands its asphalt plant operations to a new location in order to meet potential market demand.

68 Cliff’s Notes

How to plan for winter maintenance.

70 Plant Products

on Coffee Cup Challenge

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

Company tackles extensive paving job that promises drivers the ability to drive down the road and not spill a drop of coffee when completed.

28 Special Report:

Four Tips for Selecting the Right Asphalt Recycling Plant

50 Paving Products

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

64 Walsh & Kelly Creating

Crush your ROI goals with the right machine.

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

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A WIRTGEN GROUP COMPANY

Material Transfer Vehicle: MT 3000-2i Offset PowerFeeder.

TECHNICAL HIGHLIGHTS > High-performance material feeder to empty a 27.5 tons truck in just 60 seconds

> Material conveying system counteracts thermal as well as mechanical segregation

> Pivoting and inclining conveyor for high versatility > Automatic distance control system > ErgoPlus operating system for all-around visibility and intuitive controls

www.wirtgen-group.com/america

WIRTGEN AMERICA, INC. · 6030 Dana Way · Antioch, TN 37013 · Telephone: 615-501-0600 Search: 10075240

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WHAT’S ONLINE www.ForConstructionPros.com/Asphalt

WAYS YOU CAN HELP IMPACT THE FEDERAL HIGHWAY MARKET

CEI OFFERS 2017 CUSTOMER TRAINING SEMINARS

Even with a Highway Trust Fund

held at CEI’s training facility in

in place, the revenue crisis

Albuquerque, NM. Registration

will return. Here’s how asphalt

fee is $1,079, and includes

contractors can help.

hotel, meals and transporta-

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tion to and from the hotel and

NEW JERSEY PASSES GAS TAX HIKE

CEI Enterprises offers its Service Training Seminars that are

training facility Search: 12270132

pay for the state’s expired

CATERPILLAR CHIEF DOUG OBERHELMAN RECEIVES ARTBA’S HIGHEST HONOR

transportation trust fund.

Doug Oberhelman, chairman

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and chief executive officer of

Lawmakers voted to raise the tax by 23 cents per gallon to

[VIDEO] PAVEMENT PRESERVATION SEMINARS BROUGHT TO YOU BY ARRA

WORK HARD & PLAY HARD IN NASHVILLE AT NPE 2017 In this video, National Pavement Expo Show Manager Amy Schwandt takes attendees on a brief tour of all the fun that Nashville offers NPE attendees just steps away from the convention center. Full details and

Peoria, IL-based Caterpillar

registration available at www.

Inc., is the sole recipient of the

NationalPavementExpo.com.

American Road & Transporta-

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tion Builders Association’s

NATIONAL NASHVILLE, TENNESSEE / FEBRUARY 1–4 ALL-NEW LEADERSHIP BOOT CAMP— JANUARY 31

(ARTBA) highest honor — the “ARTBA Award.” Search: 12267768

A quick look at this year’s ARRA seminars which demonstrated various pavement preservation techniques and the importance of attending these regional meetings. Search: 12270120

November 2016 Vol. 30, 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 2016 by AC Business Media Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage or retrieval system, without written permission from the publisher. Asphalt Contractor (ISSN 1055-9205, USPS 0020-688): is published ten times per year: January, February, March/April, May, June/July, August, September, October, November, December, with an additional Buyer’s Guide issue published in August by AC Business Media Inc., 201 N. Main Street, Fort Atkinson, Wisconsin 53538. Periodicals postage paid at Fort Atkinson, Wisconsin and additional entry offices. POSTMASTER: Please send change of address to ASPHALT CONTRACTOR, PO Box 3605, Northbrook, Illinois 60065-3605. Printed in the U.S.A. Canada Post PM40612608. Return Undeliverable Canadian Addresses to: Asphalt Contractor, PO Box 25542, London, ON N6C 6B2. SUBSCRIPTION POLICY: Individual subscriptions are available without charge only in the USA. The Publisher reserves the right to reject nonqualifying subscribers. One-year subscription to nonqualifying individuals: U.S. $45.00, Canada & Mexico $65.00, and $95.00 all other countries (payable in U.S. funds, drawn on U.S. bank). Single copies available (prepaid only) $10.00 each (U.S., Canada & Mexico), $15.00 each (International).

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

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Where the Lab Meets the Road OUR WORLD-CLASS TEAM MEANS YOUR WORLD-CLASS ROAD Ingevity has been customizing unique solutions to fit your needs for over 60 years. We are a team of more than 75 chemists and civil engineers, across five global laboratories, who innovate technologies specifically designed to improve the performance of your roads. Whether at your plant or on the jobsite, our team is by your side from mix design to project completion. Let us introduce our lab to your road. Choose EvothermÂŽ and we can build world-class together. Contact us today at evotherm@ingevity.com.

WARM MIX ASPHALT TECHNOLOGY

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November 2016 • Vol. 30, No. 9

EDITOR'S PERSPECTIVE

What's the Best Option for Long-Term Funding?

Published by AC Business Media Inc.

Lisa Cleaver, Editor

lcleaver@ ACBusinessMedia.com

ighway funding is still a struggle for most states today. New Jersey became the 19th state since 2013 to raise or reform its gas tax when Gov. Christie signed a 23-cent hike. More than a dozen states have considered similar moves over the past few months as they scramble to fix their crumbling transportation infrastructure. Raising the gas tax, however, may not be the best way for local transportation officials to raise funds for highway infrastructure. Revenue from gas taxes has plummeted in recent years due to more fuel-efficient cars, the growing numbers of electric, hybrid and other alternative fuel vehicles, and the fact that most states don’t index their gas tax to inflation, and as a result, their funding for roads, bridges and public transit hasn’t kept up with rising costs. A recent study that forecasts state and federal fuel tax revenues based on different fuel taxation policies found that the adoption of a vehicle mileage tax (VMT) would best meet highway construction needs in the long run. The study, "State and federal fuel taxes: The road ahead for U.S. infrastructure funding," was completed by Indiana University and will be published in January 2017. A VMT is a policy of charging motorists based on how many miles they have traveled. Several states have considered the use of a VMT, with Oregon launching a limited program, OReGO, for 5,000 volunteers in 2015 and California launching a pilot program this past summer. Illinois has also considered legislation to move in this direction.

Many states that have done studies on VMTs wonder what the most efficient method of data collection is – GPS, on-board smart cards, relying on drivers’ honesty, etc. This dovetails with one of the biggest concerns with VMT – privacy, as drivers fear a “Big Brother” or “nanny state.” According to the study, however, fuel tax revenue will decline by up to 50.5% between 2015 and 2040 in states that do not adjust fuel taxes to inflation. For states that currently neither adjust for inflation nor impose any sales taxes, charging a vehicle mileage fee would increase tax revenue by 54% with a median change of 62% by 2040. "Our results indicate that although a mileage fee is politically and technologically difficult to achieve, it is the only measure that avoids a declining tax revenue in the long run," says co-author Jerome Dumortier, an assistant professor in the School of Public and Environmental Affairs at Indiana UniversityPurdue University Indianapolis. We need to keep an eye on these initial VMT programs to see how successful they are. While raising the gas tax is a quick fix, it’s not a sustainable fix, and with infrastructure funding stymied at the federal level, states need all the help they can get.

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

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aschwandt@ACBusinessMedia.com Editor

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To read the entire report, visit sciencedaily. com and search “vehicle mileage tax.”

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Anil Narang

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Get fast, relevant product information in the Buyers Guide at ForConstructionPros.com 8 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2016

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THE UNIFIED “UF” SERIES DRUM

SINGLE DRUM COUNTERFLOW

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

SACRIFICES COMPROMISES

CONS:

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

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NEW PRODUCTS New Technology Helps Prepare Roads for a SmoothRide Topcon develops a solution for faster construction and better quality asphalt roadways By Jessica Stoikes, Associate Editor

raditional road mapping is a long process that includes manual labor over an extended amount of time with lane closures and traffic delays. In an effort to streamline the lengthy process from surveying an existing road to the actual milling and/or paving of the new asphalt surface, Topcon has developed the SmoothRide system. SmoothRide is comprised of a vehicle-mounted scanner that collects data at driving speeds to map the road surface, custom software to model the data and create a smoother riding road and patented sonic tracking technology with GPS to provide variable depth milling and paving. “In most cases, it’s inconvenient or impossible to shut down a road and map its surface using traditional survey methods,” says Jan Mennink, product manager for paving products with Topcon Positioning Group. “Now with SmoothRide, it’s possible to eliminate the need for lane closures and map road conditions at highway speeds.” By scanning roads instead of surveying them, you’re eliminating the need for crash trucks, escorts or any other typical road survey collection obstacles. “With the new RD-M1 scanning unit, the system maps the existing surface elevations — with many more points captured versus what can be expected with traditional tools — which provides more accurate data needed to confidently estimate materials, as well as form the basis of the final design surface,” Mennink says.

“Using the SmoothRide solution, the contractor has tighter control over the material used at each location. Also on resurfacing jobs, material management is very important because contractors generally must stay within yield limitations,” he says. “In effect, SmoothRide provides the best of both worlds as it offers the ability to use the same amount of material and end up with a smoother road. “The time saved from start to finish, without the need for lane closures, could be enough reason alone — but the accuracy of the system also produces a much smoother end-result than with traditional methods.”

How it works SmoothRide is a workflow solution that touches all aspects of a milling or paving job. It requires a revolutionary combination of core Topcon technologies. The RD-M1 vehicle mounted road resurfacing scanner is required for SmoothRide. It is used for collecting surface information, processing and design software to create a design and machine control and GNSS components for the milling machine or asphalt paver. “Whether the contractors would have to purchase all of the other components depends on various factors,” Mennink says. “For sure the machine control and GNSS components are required (display, controller, antennas and sonic trackers). The RD-M1 and processing and design software might be in the hands of a separate organization such as an engineering agency.

These agencies might find the RD-M1 and the software useful for other applications.” Once the road information is gathered, operators can Collect, Design, Control use Mobile Master Office point data The SmoothRide system makes your processing software to projects safe, easy and more efficient. recreate the existing The need for traffic lane closures is gone, quick 3D scanning has replaced surface. MAGNET days of cross-section measurements, Office with Resurfacand intuitive software now delivers ing is then used to better results throughout the paving digitally create a highand milling process. resolution model of Collect - Plan and conduct detailed the required finished road surface scanning sessions withmat. The resurfacing out the need for costly lane closures or re-work. The easy to install scanner module allows operacollects millions of data points safely tors to create a design from the cab of the truck. So surveying using specific regulathe road surface is as simple as presstory requirements such ing the start button on your laptop. as minimum thickness, Design – Make your job come alive desired cross-slope and and efficiently create and manage overall smoothness. large point cloud information with our intuitive “Mobile Master Office” softThat information ware. Once done, a seamless transis taken to the milling fer into MAGNET Office software’s machine first resulting unique “Resurfacing” module brings in a perfectly smooth out the full array of software features surface that translates needed to meet smoothness and to a smoother paving cross slope requirements while adjob. In case of overlay hering to any minimum or maximum thickness specified for the job. paving jobs, the builtControl - At the project site, results in capability to comare real and immediate enabling you to pensate for differential continue with paving or milling on the compaction will result same day that scans were collected. in a smooth surface after compaction of the first lift, whereas says. “The result is a much smoothcurrently multiple lifts would be er road than with traditional paving required. concepts and is a breeze compared “With the SmoothRide system, to conventional methods. It all adds contractors can maximize work up to faster completion times.” hours and materials, eliminating the Search: 12265234 need for multiple lifts,” Mennink

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

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roadtec.com 1.800.272.7100 423.265.0600

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NEW PRODUCTS

Road Science ArrMuls Tack Technology

Vögele Super 1800-3i SprayJet

Road Science ArrMuls Tack Technology is designed for eliminating tack coat tracking for faster traffic return to the roadway, while improving pavement layer bonding for better, longer-lasting roads. • Formulated to prevent the tack coat from being picked up and tracked away by vehicle tires, resulting in significantly improved pavement structure and strength. • Decreases tack coat drying time to less than 15 minutes • Extends pavement life and eliminates costs to remove tracked tack coat and replace traffic paint, while eradicating the safety liability of reduced friction roads • Can be formulated to meet typical specifications including AASHTO M-140 and ASTM D-977 for slow-setting (SS-1h)

The new Super 1800-3i SprayJet paver from VÖgele is designed for the placement of thin bonded overlays. • ErgoPlus 3 includes important spraying functions integrated into the menu of the large color display on the paver operator's console • With the spray module removed, unit may be used as a conventional asphalt paver • Maximum spray width of 19 ft. 7 in.; as a conventional paver without spray function, it can pave widths of up to 29 ft. 6 in. • Equipped with five spray bars • Maximum possible pave speed is displayed for the paver operator as a function of the set rate of spread

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XL 80 Power Tail Trailer from XL Specialized Trailers The XL 80 Power Tail trailer is designed for transporting medium-duty construction equipment, such as paving equipment, personnel lifts, rollers and forklifts. • Hydraulic fold-under flip tail ramp for quick loading and unloading of equipment • 10° load angle • 4- or 53-ft. lengths • Rated at 80,000 lbs. overall; 50,000 lbs. concentrated in 10 ft. • Tail has a lifting capacity of 25,000 lbs. for loads centered on the main platform • 18,000-lb. hydraulic winch with a two-function wireless remote and an air kick-out for hauling inoperable equipment or static loads • Raised Apitong and quarter-inch self-cleaning star traction decking, D-ring stake pockets, chain slots and a work light included Search: 12247950

Avant 755i and 760i Multi-Purpose Loaders The 755i and 760i multi-purpose loaders are engineered to deliver maximum power and torque with optimal fuel economy and low emissions. • 57-hp Kohler KDI turbocharged diesel engines meet Tier 4 Final emissions regulations without the use of a diesel particulate filter or the need for diesel exhaust fluid. • 755i has a single speed drive and reaches a maximum 10.5 mph; 760i offers dual speed drive and achieves a maximum of 19 mph • Standard telescopic boom with a 3,810-lb. lift capacity and a lift height of 122 in. Search: 12253890

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

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THE FACES OF ASTEC PARTS

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

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

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

Any part, any brand. We can help.

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NEW PRODUCTS Continental Heritage Vulkan Conveyor Belts Continental introduces its newly developed modular system to control hot materials for ContiFlex Vulkan, a line of Heritage conveyor belting for heated applications. • Designed to carry materials with temperatures of up to 1,000° F • Modular system allows for mixing & matching components for high heat solutions • Available in widths up to 126 in. with a broad portfolio of belt constructions • Tensile strengths range from 220piw to 2,000piw and cover thickness can be selected to match application Search: 12255858

Gencor Trifecta Drum Mix Plant Gencor's Trifecta is a fully integrated counterflow drum mix plant reduced to just three transportable loads. • Patent-pending concept that comprises everything needed to make hot mix quickly and efficiently • Unit requires no cranes and no ductwork to be in production quickly • Vehicle 1 comprises the Ultraflo baghouse filtration system and four large feed hoppers, with variable-speed drives and individual scalping screens to accurately control the flow of varying sizes of aggregates for any specification; each of the aggregate feeders discharges onto an integrated vibrating screen to remove any over-size material or debris prior to the weigh scale • Vehicle 2 is a high-efficiency counterflow drum mixer and silo batching system that couples directly to the Ultraflo baghouse, without any ductwork • Vehicle 3 is a “state-of-the-art” fully automated control van and motor control center; Ultralogiks plant control automation manages every aspect of the operation including burner, motors and loadout functions Search: 12260023

Applique Technologies Dragon Asphalt Mixer The Dragon asphalt mixer provides the ability to produce a variety of asphalt-based products as needed and eliminates the need for trips to the asphalt plant or use of a hot box. • Can produce virgen HMA, HMA from millings, highperformance cold patch, water-cured cold patch and even asphalt slurries, all on site in three to five minutes • Onboard carrying capacity is 4,000 lbs.; when towed by a typical municipal-sized dump truck or a mason dump, carrying capacity can be increased an additional 10,000 lbs. for a total of 14,000 lbs. or 7 tons of on-the-road patching material Search: 12263067

ACTIVATE Reclaimed Asphalt Pavement Restoration Agent ACTIVATE is a 77% biobased solution that restores reclaimed asphalt pavement (RAP) millings to like-new asphalt perfect for filling potholes, edge ruts, shoulders and other paved surfaces. • With its patented chemistry, ACTIVATE introduces new polymers to the mix while reducing oxidation in the RAP • Ultra-low carbon footprint and does not require heating or additional oil • Mixing with conventional equipment takes only 20 minutes and the material cures in three hours with no tracking of raveling Search: 12254712

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

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SO FUEL EFFICIENT, IT MAKES YOUR HYBRID LOOK LIKE A MONSTER TRUCK.

GENERAL COMBUSTION OFFERS A FULL LINE OF MULTI-FUEL BURNERS GENCO ULTRA II · EQUINOX · ULTRA FLAME · ASTRAFLAME

Nothing can compare to fuel efficiency of the Ultra II burner. Unbelievable power, unshakable reliability and faster response make it the most dependable burner available. It also runs on almost any fuel making it the greenest burner on the planet. Just one of the many brilliant systems from General Combustion. 5201 N. Orange Blossom Trail ∙ Orlando, FL 32810 ∙ 407.290.6000 ∙ GeneralCombustion.com Search: 10073093

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Long Drying Time Plus Long Mixing Time Equals

High Quality

MIX

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

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DILLMAN UNIDRUM Features

• • • • •

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

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TECHNOLOGY UPDATE

Shedding New

LIGHT

on Road Construction

Granite Construction increases its use of The Halo Light to keep workers safe on the job By Lisa Cleaver, Editor The Halo Light helps employees see and recognize hazards and makes them more visible to motorists.

few years ago, Granite Construction was awarded the resurfacing and repaving project on I-90 a few miles east of Snoqualmie Pass. This stretch of road endures some of the harshest wear conditions of any Washington state roadway due to extreme temperature fluctuations and heavy truck traffic. A unique part of this project was that the east- and westbound lanes were resurfaced using different paving techniques, so Washington State DOT (WSDOT) could study conditions over the next few years and determine the best system to use going forward. The project involved nighttime to early morning open road cracking, grinding and repaving of a major interstate highway at the

top of a mountain pass. Heavy equipment moved slowly down the single closed lane, while dump trucks cycle back and forth from the asphalt plant. The trucks entered the lane in-between cones directly from the moving lane of traffic.

Using your head Light stands were used on the main paving machine and light towers were in place at the very beginning of the lane closure. However, the highway itself had no lighting and there was no ambient lighting, making this an extremely dark and dangerous environment and requiring the best and brightest personal lighting solutions. This jobsite presented a real need for workers to be able to both see and be seen while they worked around moving

equipment, with the motoring public moving past at 60 mph just a few feet away. Granite was looking for the best means to illuminate its workers. After a first field trial of The Halo Light, Illumagear was invited back for a second. Granite placed an order for the units based on the results of the field tests. "Working on a roadway job site can be scary," says Bob Johnson, VP and director of safety for Granite Construction. "There are a lot of moving parts: the traveling public, heavy equipment, trucks traveling in and out of the work zone. It can be even more frightening at night, when workers are at a greater risk of not being seen. My workers feel safer when wearing The Halo Light, and I'm more confident that they are visible to others." Almost every job type used The Halo Light at some time, including personnel directing and running the dump trucks, density checkers, QC inspectors and the prep cleaning crew. Different workers used different light modes depending on their specific tasks. The equipment director used the hard hat light Task and Halo modes, and the density checker most often used HI-Alert, while the QC and prep cleaning crews primarily used Task mode. Using The Halo Light, workers were able to see their task areas better and said they felt safer by being more visible to both the heavy equipment operators and civilian traffic. Granite has since equipped multiple jobsites with the product.

18 Asphalt Contractor â&#x20AC;˘ www.ForConstructionPros.com/Asphalt â&#x20AC;˘ November 2016

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DOTs recognize the benefits Looking to improve the safety of their workers, more than half of the U.S. Departments of Transportation (DOT) have deployed The Halo Light, according to Illumagear CEO Max Baker. As of today, DOTs in 27 states are now using The Halo Light to help improve visibility on construction sites, with over 10,000 units now deployed on high-risk job sites. “The growing adoption of The Halo Light by our country’s The Halo Light Personal Active Safety DOTs is good news System is a 360° system that attaches for worker safety in to any hard hat and produces a halo construction zones,” of light around the wearer enabling says Baker. “It’s our the worker to see and be seen in all mission to help keep directions. workers safe on the job. As we continue • Illuminates task area without shadows to stress to the • Personally visible over 1/4 mile away industry, traditional in all directions personal protective equipment is, in • Unique tension spring-mounting sysmany ways, outdated. tem connects securely to any hard hat New personal active • Single button functionality safety systems are • Four light modes: high alert, normal, the future, and we task and dim are pleased that our nation’s DOTs are • International Protection (IP) rating of embracing The Halo 67 to protect against dust, dirt and Light to protect their water workers.” • Rechargeable battery lasts a miniThe state of Ohio mum 12 hours on full power is just one example of • Breakaway quick-release battery cord a DOT recognizing the benefits of improving the safety of workers on road construction sites. More than 150 Halo Lights are currently deployed among Ohio DOT workers, and, to date, there have been no reports of any accidents or injuries involving those wearing the system. Izzy Ciptak, Safety & Health Program Consultant with the Ohio DOT, says, “Some of the biggest safety concerns our employees face are not being able to see hazards and being struck by a motorist. The Halo Light provides light in dark conditions to increase employees’ safety and awareness, helps employees see and recognize hazards, and makes them more visible to motorists.”

The Halo Light

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

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SPECIAL REPORT ASPHALT RECYCLING & CRUSHING PLANTS

Best Practices for Managing

RAP at the Plant

Your

Tips & tricks for getting optimum utilization from this recycled material By Lisa Cleaver, Editor

ccording to the FHWA, there are approximately 2.8 million miles of paved public roadways in the U.S., which have used approximately 18 billion tons of asphalt mixes.

Approximately 99% of asphalt pavement material that is removed from a roadway is recycled back into infrastructure-related materials and products. The practice of using reclaimed asphalt pavement (RAP) in new asphalt mixtures has increased in recent years because of its economic and environmental benefits. Recent NAPA surveys of the asphalt pavement industry have reported that across the U.S., the average RAP content in new asphalt mixes is now around 20%. The percentage of RAP used in new plant mix varies considerably by state, however, only a few currently use more than 25% RAP in the design, production and construction of asphalt mixes.

With the increase in the amount of RAP used in modern mix design, good RAP management practices need to be employed to ensure the greatest economic benefit for RAP and the highest quality of recycled asphalt mixes. “The management of RAP is important because it holds many resources with high value to the end user, such as oil and sometimes scarce aggregate sizes,” says Patrick Reaver, product development manager for Astec Mobile Screens. “If RAP is not managed properly, you can create contamination or lose control of what mixture of these resources were used, thereby decreasing the value of the RAP.”

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When possible, store processed RAP stockpiles under cover, or at least in an area with good drainage.

Let’s take a look at managing your RAP at the plant and the role crushing and screening equipment plays.

Inventory management RAP combines a high residual asphalt cement content with aggregate that has already been acquired, permitted, shot, processed to meet state specifications and then transported. This makes RAP a valuable product to the asphalt producer. But the transportation, storage and utilization of RAP is always a logistical challenge. “Producers apply different monetary values to recycled asphalt,” says Joe Schappert, technical trainer for Kleemann. “Some value RAP the same as other aggregates, $8 to $10 per ton; others as high as $41 per ton. This is why it is so important to manage recycled asphalt materials at each stage.” Once milled asphalt is crushed and reclassified by size, the asphalt producer can use 15% to 25% recycled material in its new asphalt mixes. This helps the producer save money on new raw aggregate products, as well on purchase of asphalt cement.

When asphalt millings are removed from the road surface, the contractor needs to find a place to store the millings or waste products until they can be RAP is a valuable product and needs to be reused. treated as a very profitable component in the According to NAPA’s “Best asphalt producer’s inventory. Laboratory charPractices for RAP and RAS acterization of RAP in terms of residual asphalt Management,” poor management content and other physical attributes creates of RAP stockpiles is commonly — from a raw unprocessed waste product — an cited as a reason agencies are engineered material which will behave predictreluctant to increase allowable ably in asphalt mixes, possibly leading to higher RAP contents in asphalt percentages of RAP allowed in mixes. mixtures. For production of quality mixes with high RAP contents, excellent materials management • Whether or not the state or other primary practices are essential. local agency requires captive stockpiles The single most important "best practice" or allows continuous replenishment of is to treat RAP the same way you treat a virstockpiles gin product, says Reaver with Astec Mobile • The space available at the plant site for RAP Screens. “This means keeping the RAP processing and stockpiling ‘clean,’ dry, separated by job and returning the • The target RAP percentages in the asphalt product back to its original size.” mixes to be produced Whether or not to put all incoming RAP • How much RAP comes from a single materials into a single pile or to create separate project stockpiles for RAP obtained from different Some agencies’ specs allow only RAP from source is a big decision and may depend on their projects to be used in their mixes. Other several factors: agencies allow the use of RAP from multiple • Components in the RAP, such as special sources, including “unclassified RAP,” that classes of aggregate, steel slag, or asphalt has been combined and processed into a single rubber, that warrant handling the material uniform RAP stockpile. separately from other sources When possible, store processed RAP • Whether the state or primary local agency stockpiles under cover, or at least in an area allows RAP from other sources in asphalt with good drainage. Stockpiles of crushed and mixes produced for its agency specifications classified RAP have a short lifespan before

What is characterization of RAP?

Once milled asphalt is crushed and reclassified, an asphalt producer can use 15% to 25% recycled material in its new asphalt mixes.

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

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SPECIAL REPORT ASPHALT RECYCLING & CRUSHING PLANTS further reprocessing is required. RAP re-use within two to three months is recommended. Longer storage periods may be expected when the material is under cover. Also, avoid driving loaders on RAP stockpiles, which leads to premature compaction of the processed RAP. “RAP should be placed on a slope paved surface to drain the water, and the loader should charge material from the high side of the slope,” says Reaver. “Where possible using fabric buildings or other methods of covering RAP creates great benefit from reducing moisture content to also minimizing the amount of sunlight that RAP is exposed to, therefore minimizing how much it sticks back together.”

Processing RAP There are several best practices to follow to process the RAP into a finished product where it can to be introduced to the hot asphalt plant. The first is actual classifying (correctly sizing) the material to the appropriate size. “This may sound like common sense, but daily inspection of your screen media is crucial,” says Schappert. “Any oversized material in your RAP can lead to oversize material in your plant mix, and eventually, oversized rock on the actual road surface (in the mat).

The effects of weather Moisture and temperature can affect crushing and screening of RAP. When the RAP is wet and/or temperatures are hot, RAP will be stickier and tend to build up in feeders and crushers, blind screens, stick to belts, and accumulate under conveyors. Not only does this require more maintenance of RAP processing units and RAP feeder systems for mix production, it can also affect the gradation and asphalt content of the RAP. Information from NAPA’s “Best Practices for RAP and RAS Management”

“Oversized material on the surface can lead to financial penalties from the state or agency customer, and the contractor may be required to remove all the new asphalt because of the inconsistency of the mix,” he warns. The most widely used sizes are ½ x 0-in. to 5/8 x 0-in. Some states also allow producers to used 3/4-minus RAP in subbase and binder. “As much as 60% of millings are 5/8 x 0-in.,” says Schappert. “At Wirtgen America, we recommend the use of an impact crusher. Use of this impactor allows the use of a 5/8-in.

screen in the bottom deck of its prescreen to remove some of the already-sized material. This material is then conveyed to the finished pile and blended with the crushed material.” This not only reduces the amount of material actually being delivered to the crusher, but reduces the wear in the crushing chamber and increases the capacity of the crusher for more material that needs to be reduced in size, he continues. “If additional sizes are required, we can place a two-deck or three-deck tracked screen plant behind the crusher and make the additional products.” Another best practice is to crush only what you need for a two- to three-month period. After this time, the RAP will begin to gather moisture and re-bond to itself. This results in large chunks and further processing before it can be used in the asphalt plant. If possible this period can be extended by storing the RAP under cover.

The role of equipment “RAP processing is a very different process from that of traditional aggregate crushing, and requires equipment to match these demands,” says Reaver. “Many times it is one of the last things thought about in the overall production of asphalt pavement; however, where producers try to use equipment previously designed for aggregate

Daily inspection of your screen media is crucial. Any oversized material in your RAP can lead to oversize material in your plant mix, and eventually, oversized rock on the actual road surface.

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

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SPECIAL REPORT ASPHALT RECYCLING & CRUSHING PLANTS production, maintenance, production and efficiency will suffer.” The role of crushing and screening equipment in managing RAP is to take the product back to its original size without over crushing or generating excess dust, he says. “Features that are important include efficient crushing and screening and units sized to match job requirements,” Reaver continues. “Also equipment should be capable of operating in the harsh environments associated with processing RAP and have features such as remote-mounted radiators, pre-filtering gensets, minimizing shelves for material to build up, and conveyors capable of handling ‘slabby’ material.” A variety of crusher types are used for crushing RAP. According to NAPA’s “Best Practices for RAP and RAS Management,” many contractors have found that the best type of RAP crushers are horizontal-shaft impactors (HSI). “One of the more efficient ways to process RAP is utilizing HSI and High Frequency Screens due to their ability to vary many operating parameters, thereby creating an overall greater efficiency for the system,” says Reaver. HSI crushers typically use a three-stage impact bar arrangement that can be set to size material according to the desired top-size. However, crushing to smaller top sizes will increase the percentage of material passing the No. 200 sieve, which often limits how much of the RAP can be used in mix designs while still meeting VMA and dust-to-binder ratio criteria. The term crushing is a bit confusing. “We aren’t really crushing and reducing the size of the aggregate in the RAP,” says Schappert. “We are separating the binding material from the aggregate. The impact crusher has been found to be the most cost-efficient way to perform this task.” Since crushing RAP will create more aggregate fines, it is best to set up the crushing operation so that the RAP is screened before it enters the crusher. This will allow the finer RAP particles that pass through the screen to bypass the crusher.

The role of crushing and screening equipment in managing RAP is to take the product back to its original size without over crushing or generating excess dust.

Crush only the RAP you need for a two- to three-month period, otherwise RAP will begin to gather moisture and re-bond to itself. This can result in large chunks and further processing before it can be used in the asphalt plant.

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

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SPECIAL REPORT ASPHALT RECYCLING & CRUSHING PLANTS The primary advantage of fractionating RAP is having stockpiles of different RAP sizes to provide more flexibility in meeting mix design requirements.

“We feel that all RAP should be screened first prior to crushing, this takes advantage of the milling machine and the fines that have already been generated and removes them before creating additional fines at the crusher,” says Reaver. (Continued on page 26) Some RAP crushing units are set up so that all of the RAP is conveyed from the feeder bin into the crusher, followed by a recirculation circuit after the crusher. The recirculation circuit is designed to return larger particles that do not pass through the screen back to the crusher. Because all the material must go through the crusher in the first pass, however, there is a good chance that breakdown will occur for some smaller particles that did not need to be reduced in size. There are times when finer aggregate products are required for specific projects. Some of these can be 1/8 x 0-in. and 1/4 x 0-in. For these sizes, “screen media takes a major role in making these fine products,” says Schappert. Thinlays are a suite of thin asphalt overlay mixes designed to be placed at thickness as thin as 5/8-in. on an existing milled or unmilled road surface, require finer sized products including RAP. Fractionating uses a high-frequency screen to classify finer aggregate products less than 1/2-in. The primary advantage of

Sloped storage areas are crucial for keeping moisture out of the RAP pile.

fractionating RAP is having stockpiles of different RAP sizes to provide more flexibility in meeting mix design requirements. “We feel RAP should always be processed to the point of taking it back to its original state,” says Reaver. “This is especially true when mixes utilize greater than 20% RAP.” Follow these best practices for processing

and stockpiling RAP, and you’ll be sure to produce a better quality product. “In the field, every material and application must be analyzed to see what best works for your application,” says Schappert. “Many factors contribute to a successful RAP program. Partner with your local dealer to see what is best for your application.”

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

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SPECIAL REPORT ASPHALT RECYCLING & CRUSHING PLANTS

FOUR TIPS for Selecting the Right Asphalt Recycling Plant Crush your ROI goals with the right machine

elf-diagnosing a health issue can lead to incorrect treatments, prolonged recovery and perhaps an even more costly outcome. The same applies in the asphalt recycling industry. Operators shouldn’t select an asphalt recycling plant before carefully sorting through the options and thoroughly evaluating what they need. A short visit with the manufacturer, a couple of questions and a thorough evaluation of an operation saves an operator from the turmoil that comes with selecting the wrong plant. Not only that, but the right machine sets an operator up for achieving a fast return on investment. Here are a few things to

By Sean Donaghy consider to ensure you select the equipment that’s right for your operation and ROI goals.

Profit from portability The obvious appeal of mobile crushers is the ability to move the unit closer to where it’s needed. Even with this advantage, it’s important to inspect a mobile crusher to see just how portable it is. Ask the manufacturer how long it typically takes to set up the machine. Some models are designed to only take an hour or so, but other models take days to set up because they require extended use of a crane to move the equipment in place. Not only does this require the extra

costs of renting the crane, but also labor costs to have someone operating that crane. In addition to setup time, consider transportation. Often, operators have to transport the hopper feeder separately and break the plant into multiple pieces to meet Department of Transportation weight regulations. Unfortunately, this means more workers are needed to transport and lift the equipment, which results in greater labor costs as well as higher fuel expenses. Look for a plant with a lightweight, easy-to-remove hopper that one operator can install within minutes, or for a plant that is compact and light enough to be transported without removing the hopper. You’ll save time and labor costs.

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Mobile plants with a double-deck screen and conveyor have the ability to automatically return oversized material from both screens back to the crusher for sizing. This can reduce expenses and increase production by as much as 20%.

Follow your production prescription Properly sizing your equipment to expected production capacities is critical to the success of a business. Think of it like a patient following his or her doctor’s prescription. To achieve a full recovery, the patient listens to the doctor’s orders. In the same way, asphalt recycling plant managers must take certain steps to meet their production goals, the first being to determine those goals before making a purchasing decision. A crusher that is too small fails to produce the desired tonnages, which limits profits and caps the organization’s growth potential. On the other hand, a machine that’s too large costs more to maintain and doesn’t add value to the operation. Before buying a machine, calculate the desired output. For example, if an operation can sell 450,000 tons of material per year, its plant needs to produce 37,500 tons each month. If the crusher is set up to run two days per week for nine hours per day, the operation will require a machine capable of processing just over 400 tph.

Compare apples to apples It’s easy to get caught up in price. While saving money on the initial purchase price is important, so are the extras that will save time and money in the future. Understanding how certain features can impact operating costs is critical before buying a unit. See if the unit has an onboard power source as well as auxiliary outlets. These allow you to run a complete crushing operation from one source, eliminating the need for separate generators to power multiple pieces of equipment, such as individual crushers and screeners. Consider a machine that can recirculate material. For example, a double-deck screen and conveyor automatically sends oversized material from both screens back to the crusher for sizing. This eliminates an extra person and an additional loader or excavator to pick up the material and manually re-feed the crusher, which reduces expenses and can increase production by as much as 20%. In addition, some double-deck screens also enable contractors to crush and classify as many as three different sizes of material. This offers contractors the versatility to size their products for the best sale potential and appeal to multiple customers.

Defensives up Crushers need to withstand daily abuse. That’s why investing in quality equipment and components up front will save money in the long run. Take, for example, a crusher’s discharge point. This area of the machine is under a lot of stress for the majority of the machine’s run time, and as a result, it requires regular maintenance such as wear-liner replacements. Some machines, however, have a specially designed Units that incorporate catwalks make it easier to change out the screen and provide convenient access to crucial maintenance and cleaning points.

discharge Rock Box that eliminates wear-liner replacements. The specialized design uses a shelf system with an abrasion-resistant wear bar that allows crushed material to build up and act as a wear liner. The result is dramatic cost savings on labor and wear parts. Be sure other components, such as conveyors, bearings, rollers, shafts and drives, are

Machines with hydraulic power packs, designed to be removed or installed in minutes, make for convenient transportation and feeder setup by one person.

robust and built for high wear. For example, some manufacturers design blow bars that are better in different applications and will last longer than other types of bars. To reduce cleaning and maintenance requirements, some units will even feature a dust suppression system. Catwalks are also a good feature to consider. These make it easier to change out screens and provide convenient access to crucial maintenance and cleaning points, which saves time and enhances safety. A fast recovery is part of every patient’s goals, but it’s more important to have a lasting recovery. In the same way, stop and consider all elements of the crusher and the operation’s needs, as these can have a huge impact on long-term costs. After all, the right machine will make every job easier and more profitable today and beyond — just what the doctor ordered. Sean Donaghy is the national sales manager at IROCK Crushers. He has more than 25 years of experience in the crushing business and has been with IROCK for more than 10 years.

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

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PAVING INNOVATIONS

FAST FIX for

Failing Freeway

Unique warm mix design enables early start, enhanced compaction for urgent rebuild of South Carolina’s I-85

unique design for warm mix asphalt (WMA) enabled the South Carolina DOT (SCDOT) and its contractor Sloan Construction to get a mid-winter start early in 2016 on urgent reconstruction of failing I-85 in the northwestern corner of the Palmetto State. Because WMA can be compacted to required density at lower ambient temperatures, it can lengthen the paving season by enabling winter paving. The warm mix additive also served as a compaction aid that permitted Sloan to quickly get specified density on twin lifts totaling 9-in., in time-limited night work, to avoid severe penalties for failure to reopen the highway in time for the morning rush in the busy Spartanburg-Greenville corridor. On this project, in a single one-night shift,

as much as 9-in. of delaminated, failed pavement would be milled, and the warm mix additive – Evotherm – allowed placement of two 4-in. and 1/2-in. lifts in that single shift, rather than the three, 3-in. lifts that would have been required under standard specs, making it impossible to open the pavement by morning rush hour. The I-85 work was taking place between mile marker 56 to 68, milling out left and center lanes from 5- to 9-in., and for the right hand lane, milling out 10-in. and putting 9-in. back. Pavement preservation techniques like thin asphalt overlays and mill-and-fills prolong a pavement's life, however, as lower layers of I-85 experienced stripping and delamination over decades, use of additional preservation treatments would have done nothing to improve the pavement.

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

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Warm mix modifier enables swift placement of deep lifts, allowing urgent traffic to return to I-85 in time for morning rush hour.

This is why the SCDOT bid an emergency $51 million reconstruction project in October 2015, and started work immediately in January 2016. The project involves 12 miles of three lanes each north- and southbound. There, the DOT decided to mill out the entire driving course 10-in. deep, replace the milled trench with two consecutive lifts, and in 2017 place an open graded friction course (OGFC). The state favors OGFC for high volume driving courses. The job is scheduled for completion in 2018.

Cold milling reveals flaws Originally, the project started as a typical mill-and-overlay of a deteriorated surface layer, but the cold milling revealed a damaged pavement that would require emergency action. "The original plan was to mill off, let

traffic run on it, and switch over to another lane until the whole roadway is complete," says Dennis J. Garber II, P.E., C.P.M., District 3 construction engineer, SCDOT, Greenville. "The problem was, as soon as traffic started running on it – we weren't even gone a weekend – the underlying layers started to ravel. I got an interstate that was quickly falling apart. We had to shut the project down and develop a new plan of attack." "The DOT realized that, in starting the project last year, the structure of the road didn't hold up the way they wanted it," says Dennis Ayers, senior project manager for Sloan North Region. "They re-let the contract to put in a new base course and reconstruct the road to handle the traffic." "When we first started we were going to do a 2- or 4-in. mill-and-fill," says Chad W. Hawkins, P.E., C.P.M., state materials engineer, SCDOT, Columbia. "But some of the milling process got down into delaminated areas, and that's when the project was put on hold, and we thought 'what do we do now?'" The pavements in this section were constructed in the 1950s and 60s, so finding out what went wrong is problematic. "Realistically, our 2-, 3- and 4-in. mill-andfills over the last 50 years have caught up with us," Hawkins says. "It's time to do a major reconstruction, and that's what were finding on a lot of our interstates. We're having to do more than put a 4-in. 'band-aid'." Cores taken at half-mile intervals showed the extent of the failing asphalt layers. "We found delamination of layers 5-in. down in

In July 2016, intermediate B warm mix is placed 4.5 in. deep and will be covered with another 4.5-in. lift by 4:30 a.m.

the left and center lanes, and in the right lane, where heavy trucks run, we found delamination up to 10-in. down," Hawkins says. "The scope of the work began to change at that point," says Cliff Selkinghaus, asphalt materials manager, SCDOT, Columbia. "We found we needed to go a lot further down into the road." The change in the project between Spartanburg and Greenville opened up investigation of the entire length of I-85 in S.C. "We're studying all of I-85 now, from the North Carolina line to the Georgia line," Hawkins says. "We're studying in pieces and sections. Some of it is just riding the road, finding surface cracks and it's our job to determine how far down the cracks go. Some cracks are going 8-, 10-, 12-in. deep.”

Leveling courses first Because all lanes must be kept available for traffic, each night shift crew was milling approximately 1,000 feet, and then coming back with two lifts. This created an intermediate or leveling course which would serve motorists until the final driving course could be placed late in the season. On a night in the northbound lanes in July 2016, crews were milling out 10-in. of failed pavement, and were replacing it with two 4 and 1/2-in. lifts of leveling course pavement.

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

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PAVING INNOVATIONS

Sloan's QC and design lab manager Mitchell Dodd samples outgoing warm mix for analysis at plant lab.

They paved 1,000 feet in a single night shift, leaving room for the final driving course. There, Evotherm warm mix modifier from Ingevity enabled Sloan to get density on the first lift, and place the second 4 1/2-in. lift right on top of the first. Both lifts cooled rapidly to permit timely opening to traffic on the second lift. As milling would begin at 9 p.m., and paving at about 11 p.m., Sloan crews did not have the luxury of allowing the mats to slowly cool to the point where traffic could be allowed. "We're finished and out of the road by 6 a.m.," says Mitchell Dodd, quality control and design lab manager for Sloan Construction, North Division, Duncan, SC. "To do that we need to stop paving no later than 4:30 a.m. Evotherm lets the lifts cool faster, permitting overlay sooner, and that was one of its benefits. We could produce the mix at a cooler temperature, which allows the mat to be compacted at a cooler temperature, letting us back up and put the second lift on in the same night." While SCDOT does permit motorists to drive on milled surfaces, it will not allow more than a 1-in. sheer vertical drop from lane to lane. "We're not going to allow traffic to drive in a 9-in. trench," SCDOT's Hawkins says. "What we're milling out at night has to be

SCDOT needed an additive that allowed them to pave two 4-in. and one 1/2-in. lifts in a shift instead of three 3-in. lifts.

put back by morning. Our challenge with the mix was how to construct, at night, as fast as we can, using an asphalt mixture that can be placed 9 in. at a time." This was a problem, as DOT specifications require lifts to be placed at no more than 3-in. at a time. "That's why we looked for an additive that would allow us to pave two 4-in. and one 1/2-in. lifts in a shift, instead of three 3-in. lifts," Hawkins says. "This would allow us to speed up construction and lengthen how far they could pave in a night." That was done by issuing a provisional specification, WMA Intermediate B Special, that requires that a chemical warm mix technology be used for the two 4-in. (or deeper) lifts. "The Intermediate B Special mix was developed for this particular job," Hawkins says. "It's based on one of our old surface mixes, with one-halfinch nominal maximum aggregate size, and that's why we chose this design, as it will be the riding surface for about a year until we place the final surface, which will be our Surface A, topped with an OGFC." In the meantime, the existing cross slope of the adjacent pavements would address any concerns with standing water during construction, as both the new and existing pavements have a cross slope to facilitate drainage off of the interstate. Sloan's Mitchell Dodd measures mat temperature at screed; mix was being produced at temps of 270° to 275° F, but at the screed, measured 255° F.

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

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PAVING INNOVATIONS Of a total of 340,420 tons of asphalt to be placed, there are 131,752 tons of Intermediate B Special being placed, 116,976 tons of Surface A to be placed, and 31,453 tons of OGFC, plus an additional 60,239 tons of other mixes. Other special considerations in the mix are use of a liquid warm mix modifier (in this case, Evotherm), and a lowered target air voids in such thick lifts. The design does not specify Evotherm, but the mix cannot be foamed warm mix, it has to be a liquid warn mix additive. The PG 64-22 liquid binder is not polymer modified, and is incorporated at 5.7% or 5.8%, instead of 5.5%. Target densities were being met on site and in test strips. "Typically, our specifications on interstates are 92.2 to 96 percent," Selkinghaus says. "We would have been happy to get in the lower range, considering it's something new in 4- and 1/2-in. thick at a time, but the numbers we got in our test section were close to 96 percent, so we are really happy to see them in the upper limits." Also, Sloan was getting 93% density on the cold longitudinal joints, which go down 9 in.

"We definitely had concerns about the vertical joints that we were going to create by cutting the delaminated asphalt out, but we were very, very satisfied with the 93s," Selkinghaus added.

Improved mixes with WMA WMA is not a single proprietary process, but a variety of technologies that reduce the temperatures at which asphalt mixes are produced and placed, and enable the complete coating of aggregates at temperatures 35°F to 100°F lower than conventional hot mix asphalt (HMA). Conventional HMA production takes place from 275°F to over 330°F and compaction temperatures are between 260°F and 300°F. Before mixing with hot liquid asphalt, fine and coarse aggregates are heated to high temperatures to drive off moisture, to ease coating of the mineral aggregates with the liquid asphalt, and to keep the complete mix fluid enough to be workable during placement. In addition to consumption of huge amounts of fuel, heating of liquid asphalt to these temperatures produces undesirable

volatile organic compound (VOC) fumes which may either be vented to the exterior, or collected with fume enclosures and vented back into the process. Today’s warm mixes have the potential to all but eliminate such emissions, giving a plant owner a powerful tool to use in the permitting process. Warm asphalt mixes produce emissions at a greatly reduced level from conventional HMA plants, thus potentially enabling the permitting of asphalt plants in air pollution nonattainment areas, or where there is local opposition. One such lower-temperature technology is Evotherm, produced by Ingevity, an easyto-use additive that adds lubricity to liquid asphalt. The additive creates “slip planes” which let the asphalt particles move more easily, requiring lower levels of energy. Because the energy is lowered, Evotherm WMA has the same viscosity properties at lower temperatures as does conventional HMA. As a result, more and more contractors look to Evotherm as a compaction aid. In general, at the microscopic level, aggregate surfaces have a lot of mountains, ridges, hills

RAP from I-85 project is processed with impact crusher; Sloan was returning RAP back to the highway in Intermediate B and Surface A mixes.

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

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WITH YOU FROM THE GROUND UP The work may be under your feet, but you’re looking ahead—to the next challenge and the next deadline. We’re right there with you. You can count on our equipment to handle every task on your site, on our dealers to keep it running efficiently, and on our real-world training to help you master the latest techniques and technologies. Get the tools to tackle whatever challenges come your way. Visit our online resource center for mobile apps, calculators, application guides and more. Resources supporting you from the ground up—that’s what we’re built to deliver.

Unlock the resource center at www.cat.com/AsphaltContractorResources ››

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

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PAVING INNOVATIONS and valleys. Evotherm additive acts to smooth out those hills and valleys to help the two surfaces glide past each other. It provides enhanced lubricity, or optimized internal shear, without reducing viscosity. “By lowering the temperature of production we also are avoiding some of the potential degradation to binder that can occur at higher production temperatures,” says Everett Crews, Ph.D., technical manager for Ingevity. “On the S.C. I-85 job, at the plant, mix was being produced at temperatures of 270°F

to 275°F. In the paver, the WMA measured 265°F, but at the screed it measured 255°F,” says Sloan's Dodd.

the milling was stockpiled at the Duncan plant, and after processing with an impact crusher and analyzed, eventually was added to the warm mix and taken back out to I-85 for placement. "We acquired an impact crusher RAP system and we are processing the RAP off I-85 as it comes in," Dodd says. "Directly after processing, we test it, send it to the plant and put it right back in the Intermediate B mix." Ultimately, this section will be topped with 2-in. of S.C. Surface A mix, and one inch of OGFC after compaction, bringing the total depth of the rebuild about 1- and 1/2in. above the existing pavement. This allows the OGFC to drain surface water out to side ditches. RAP also will go into the Surface A mix, according to Dodd. The OGFC will be all virgin aggregate. Lastly, for the OGFC driving course, warm mix can be used at the contractor's option. "Statewide, 95 percent of our contractors use WMA in their OGFCs," Hawkins says. "A lot of our contractors are selecting Evotherm to put into their warm mix OGFC. It's used to eliminate stabilizing fibers and improve workability of the mix." That is, Evotherm has the ability to stop liquid asphalt drain-down in a fresh OGFC placement. Because they lack fines, there is little to keep liquid asphalt in place in the open grading of aggregate essential to OGFC. Typically, and at additional expense, fibers have been added to OGFCs to forestall this liquid asphalt drain-down. But Evotherm also stops drain-down, permitting removal of fibers from the mix design, at substantial savings, while permitting placement of the OGFC at reduced temperatures and with reduced premature aging of the binder at the plant due to high production temperatures. "The job is going well," says Todd K. Carroll, P.E., resident construction engineer, SCDOT, Spartanburg County. "They are able to produce a lot of mix every night, very efficiently. We've had a good project so far."

I-85 RAP returned to interstate Every shift, two mills and two paving crews worked the north- and southbound lanes, respectively. The volume demands of the two crews permitted better utilization of the nearby Sloan plant at Duncan to produce warm mix for the night work. Reclaimed asphalt pavement (RAP) from

Evotherm warm mix modifier from Ingevity is introduced to PG 64-22 liquid binder as a terminal blend at Sloan's Union Terminal.

Load out of intermediate B warm mix at Sloan's Duncan plant, a short distance to I-85 paving. Blue smoke is absent with lower production temperatures.

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

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Search: 10074806

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PAVING INNOVATIONS

Full-Depth HMA Project Uses

Cutting Edge Innovations The Iowa DOT and LL Pelling utilize infrared temperature monitoring, GPS roller mapping, and E-ticketing on the Highway 100 extension project By Lisa Cleaver. Editor

n September, the Asphalt Pavement Association of Iowa (APAI) held an open house to highlight the Highway 100 Extension project near Cedar Rapids, IA. Highway 100 is a state highway located in Linn County, IA. The route is located primarily in Cedar Rapids and Marion and is known locally as Collins Road. It begins at Edgewood Road NE in Cedar Rapids and ends at U.S. Route 151/Iowa Highway 13 in Marion The project included HMA perpetual paving a four-mile stretch of Highway 100 mainline from Covington Road to just east of Edgewood Road. It included the construction of HMA and PCC shoulders and longitudinal grooving of dual Highway 100 bridge decks over Old Ferry Road, Cedar River and Ushers Ferry Road. The contractor was LL Pelling headquartered in North Liberty, IA. The full-depth perpetual asphalt was 12.5-in.-thick HMA on 15.5-in. rock subbase.

38 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2016

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This was a new section of highway, and field modifications were made to provide a strong and drainable support for the pavement. “This project was designed to meet the predicted traffic volume,” says Greg Mulder, P.E., director of Iowa DOT’s Office of Construction and Materials. “Parts of the design included drainage, subgrade, subbase and pavement thickness.”

In order to help improve fatigue cracking resistance in the lower lift, reclaimed asphalt pavement (RAP) was not allowed, says Roger Boulet, District 6 materials engineer with IDOT. “The target for lab voids was decreased to allow an increase in binder content in the lowest base lift,” he explains. “The RAP percentages were submitted by the contractor and

approved by the IDOT for the mix designs for the upper lifts.” A total of 120,000 tons of HMA was placed. For mix design specs, see the box on page 41. “This was a unique opportunity for us,” says Joel Gryp, general manager with LL Pelling. “We were able to construct a full-depth pavement in a rural, four-lane highway setting. IDOT predominately designs new and reconstruction pavements with PCC.”

New technologies = continuous improvements IDOT used the Highway 100 project to pilot several innovations. “This was a typical HMA paving project,” says Mulder with IDOT. “From the continuous improvement viewpoint, however, different instrumentations were used to evaluate the potential improvement on quality, simplifying the work, and providing better safety for workers.” Infrared temperature monitoring was piloted on this project to run a correlation on the temperature and roller coverage monitored versus the measured in-place densities of the compacted mixture, with the hope of studying the information for a possible thermal segregation specification. “The intention is to be able to someday use technology to assist in quality assurance for the required compactive effort needed to build a quality product,” says Mulder. Roller mapping was also used on this project to track station-to-station pass counts and mat temperature readings for each roller in the train. “This tool will provide the information needed to compare the mapping results to actual field cores,” says Gryp with LL Pelling. “Ideally it should allow the contractor to fine-tune the pass counts for optimum field densities.”

E-construction enhancements In order to help improve fatigue cracking resistance in the lower lift, reclaimed asphalt pavement (RAP) was not used in its mix design. Photo by Rick Zettler, Z-Comm

E-ticketing is not entirely new to IDOT. The first E-ticketing pilot project was on Highway 69 near Ames, IA, in 2015. The pilot was successful in that it provided verification of materials being loaded from a certified plant and delivered to its intended destination.

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

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PAVING INNOVATIONS

Roller mapping was also used on this project to track station-to-station pass counts and mat temperature readings for each roller in the train. Photo by Rick Zettler, Z-Comm

Earthwave’s Materials Delivery Solution Using Earthwave’s Materials Delivery Solution, cycle times are tracked and analyzed by the contractor for opportunities to improve their trucking costs per ton and move materials more efficiently. There are GPS devices installed in all trucks and pavers/mills that update real-time. Moving geozones set up around the paver captures the time trucks unload their material. Each time a truck is loaded at the plant, Fleetwatcher electronically records in its software the Ticket Number, Date, Plant Source, Weighmaster, Truck Number, Trucking Company, Project Name, Contractor Name, Tonnage, Material Type, Phase Codes and any Voided Tickets. For more information, visit earthwavetech.com.

Infrared temperature monitoring was piloted on this project to run a correlation on the temperature and roller coverage monitored versus the measured in-place densities of the compacted mixture, with the hope of studying the information for a possible thermal segregation specification.

On the Highway 100 pilot, the DOT wanted further verification of tonnage and mix-type to automate contractor pay and a method for on-site inspectors to record waste and notes for auditing purposes, says Mike Schulz, business development manager with Earthwave Techologies Inc. “On the Highway 100 project, Earthwave integrated with LL Pelling’s Astec WM2000 Load-Out System out of Plant 17 in Cedar Rapids,” he explains. “With this new capability, Earthwave’s Materials Delivery Solution software records each truck’s load-out ticket electronically in real-time, providing inspectors remote access to easy-to-use mapping and

reporting features that allow them to focus more on quality inspection checks instead of collecting paper tickets throughout the shift.” Each truck has a GPS unit installed which is then tracked through a series of geozones setup at the plant site and the jobsite. Tracking of each load consists of the following: • The time spent entering and exiting the plant • The precise time the truck was loaded with tonnage, material type and other pertinent data specific to the project • Travel time, distance and route from the plant to paver and back • Amount of wait time spent (if any) on

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

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Mix Design Specs Mainline: • 12.5-in. total of Hot Mix Asphalt (HMA) with Performance Graded asphalt binder, PG 64-28 • 2-in. 10 M Equivalent Single Axle Load (ESAL) ½” Surface course 15% RAP, steel slag used as friction aggregate, target lab voids 4.0% • 2-in. 10 M ESAL ½-in. Intermediate course 14% RAP, target lab voids 4.0% • 5.5-in. 10 M ESAL ½-in. Base course 15% RAP, target lab voids 4.0% • 3.0-in. 10 M ESAL ½-in. Base Course no RAP, target lab voids 3.5% Ramps: • 10.5-in. total of HMA with Performance Graded asphalt binder, PG 64-28 • 2-in. 3 M ESAL ½-in. Surface course 15% RAP, steel slag used as friction aggregate, target lab voids 4.0% • 2-in. 3 M ESAL ½-in. Intermediate course 15% RAP, target Lab voids 4.0% • 3.5-in. 3 M ESAL Base course 15% RAP, target lab voids 4.0% • 3-in. 3 M ESAL base course No RAP, target lab voids 3.5% Shoulders: • 12.5-in. total of HMA with Performance Graded asphalt binder, PG 58-28 • ½-in. 1 M ESAL Base 20% RAP

the jobsite and the precise time the truck entered a customized geo-radius of the paver indicating material delivery “Travel and idle times are recorded in real time for every aspect of the trucks daily routine,” says Gryp with LL Pelling.

Benefits of E-ticketing Gryp says there are many benefits to using the E-ticketing process: • Measures and reports exact HMA quantities delivered paperless • Frees up the DOT inspector to actually perform quality control and inspect the job instead of time-consuming paper shuffling (HMA tickets) • Allows the paving superintendent the ability to see where every truck is located with realtime tracking and actual load weights • Creates an electronic trail every minute which is available on the software dashboard. “The Earthwave software is a great tool to help in trucking efficiencies as a whole and not just this project,” says Gryp. “With multiple projects happening within a 20-mile radius, we’ve found it not only to be a cost effective way to manage our own fleet, but it’s helped in decreasing the need to hire trucks outside of the company.” Probably the biggest benefit of using E-ticketing is safety. “With E-ticketing, the DOT is assured the certified product is being delivered and used in the project, without having to have an IDOT inspector verify each individual delivery truck,” says Mulder. “The safety aspect comes from not having to have an inspector maneuver through truck traffic to collect paper tickets from each truck. This ticket taking can now take place remotely from a safe distance through the cloud-based information

in the delivery system using an app on a mobile device.” Schulz says the E-ticketing process also helps save money. “Inspectors can record waste and notes for individual tickets in the field using smartphone and tablet applications and easily tabulate tonnage and mix type totals for contractor pay, cutting out days of processing time when calculated manually. When factoring implications for lost or misplaced tickets, the efficiency gains extended to both the contractor and DOT are even greater.”

The Highway 100 project was a 12.5-in.thick full-depth perpetual HMA on 15.5in. rock subbase. Photo by Rick Zettler, Z-Comm

Gryp with LL Pelling notes that IDOT had the Highway 100 project budgeted at $18 million and the bid came in at $15 million. Despite above-average rainfall during the project, the Highway 100 project can be viewed as another successful step toward implementing new innovations and E-construction methods into IDOT projects. To read the about IDOT’s first E-ticketing pilot project near Ames, IA, visit ForConstructionPros.com and search: 12164619.

On the Highway 100 pilot, IDOT wanted further verification of tonnage and mix-type to automate contractor pay and a method for on-site inspectors to record waste and notes for auditing purposes

November 2016 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor Search: 10072820

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PAVING INNOVATIONS

Ajax Paving Takes on

Coffee Cup Challenge Company tackles extensive paving job that promises drivers the ability to drive down the road and not spill a drop of coffee when completed 44 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • November 2016

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hortly after 2010, a problem that had been growing along the streets of North Port, FL became too cumbersome to be ignored. Originally paved in the 1960s, roadways had fallen into severe disrepair. Each year, the city was working to keep up with maintenance and rehabilitation, but the job was becoming too big to manage against budget constraints. On November 6, 2012, nearly 60% of voters approved a referendum authorizing the city to obtain a bond up to $46 million to upgrade 266 miles of substandard roads in the city. The funding from the bond would be used to upgrade substandard roads over the course of three years, with current resources re-directed toward a viable, ongoing road maintenance program to improve North Port’s overall road quality. In addition, 210 additional miles of roads would receive maintenance. To jump-start the six-phase project, more than 8,300 postcards were mailed to community members educating them about the first three phases. The postcards promoted the project as the “Coffee Cup Test.” Once done, you should be able to drive down your neighborhood roads with a coffee cup in hand and not spill a drop the postcards stated. The community also hosted a neighborhood celebration on June 28 to kick-off the project. While the neighborhood was celebrating, road repair teams were firing up their own coffee cups, preparing for some early mornings and hot afternoons. One such team was Ajax Paving Industries of FL, LLC.

— expanding the company from its roots in Michigan to opening the doors of a second operation in Florida. Now, it was time for that philosophy to be put to the test tackling the North Port “coffee cup challenge.”

Reliable performance, consistent support Under a hot Florida sun, the Ajax team is working on a milling and resurfacing project as part of the referendum — it’s a 120,000ton project, and part of phase four of the sixphase project. The team isn’t taking the responsibility lightly. The days kick off at 7 a.m., heating up the screed, and within 30 minutes, the first

“Any guy in paving knows that machine has to be reliable first and foremost,” Bengford says. “When Dan and I sat down, we wanted to talk through performance, sure, but we were also working to build a plan that included extendable warranties and walked through how we manage preventive maintenance.” Maitland says deciding on the Volvo 7170 came down to a few things, but among them was plain math. “I look at the cost of ownership throughout the life of a paver. We typically run a 5-year lifecycle, about 5,000 to 6,000 hours. I’m tracking our repair costs, our maintenance costs, and when I run analysis, for every meter hour of run time, the Volvo consistently ranks better than the majority of competitors.” Beyond cost of ownership, Maitland says

The right company, equipment for the job Founded 65 years ago by Herb Jacob, the company received its name — Ajax — solely so it would be listed first in the phone book. But, it soon made the top of the list for other reasons. Word of mouth spread and the quality of work the company was producing moved the company to first choice on its own merits. One of the things for which Jacobs credited the company’s early success was machine selection. Jacob believed in the following philosophy: If I provide my employees with the best tools to get the job done, they will provide the highest quality pavement work for our customers. It’s a philosophy that has provided the foundation for continued expansion

load is arriving. Currently, Ajax is tacking the existing road, putting an1-1/4-in. of SM-9.5 overlay down. Over the course of each day’s nine-hour shift, the team lays between 750 and 800 tons of asphalt. Sticking true to Herb Jacobs’ philosophy of providing the best tools for his employees, there are several high quality machines helping Ajax get the job done. One such piece of equipment is a Volvo 7170 paver. Dan Maitland, equipment operations manager for Ajax, says the Volvo Million Ton Guarantee encouraged him to connect with the local Volvo dealership, Flagler Construction Equipment’s Southwest Florida branch, where Dean Bengford was ready to help.

Dan Maitland, Ajax equipment operations manager, says the “coffee cup challenge” will allow drivers to drive down neighborhood roads and not spill a drop of coffee.

preventive maintenance was crucial. “This thing cannot go down. We haven’t had any major issues, but even oil changes have to run smoothly — we rely on [Volvo dealer] Flagler to keep us up and running.” Our preventive maintenance technician does a full machine inspection and we report back to Ajax if we see anything that’s a point of concern. Between the preventive maintenance agreements and the extended warranty,

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

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PAVING INNOVATIONS

Staying on schedule is important to Ajax and residents in the area. The project is currently projected to finish two months ahead of schedule.

we can help Ajax get a better fix on operating costs and reduce downtime.” And Maitland says they’ve done just that. So much so, that they’ve added three more P7170s to the fleet that are hard at work on other sites throughout Florida.

Speed is crucial when drivers need a green light While the team members and machines have been keeping the job on track, it certainly hasn’t been without its challenges. As with any job moving through neighborhoods, you have your fair amount of challenges keeping the public patient and focused on the end result. Steve Ayers, Area Manager for Ajax said one of the biggest challenges has been keeping the job progressing while giving the public access points from their homes. The best way to keep them happy is to keep the job moving, and Clay Collins says the screed is helping them do just that. “This is one of the industry’s true 20-foot extendable screeds, meaning we can do this whole street in one pass instead of two — it’s saving us time and money.” Bengford echoes Ayers praise of the Ultimat 200.

“Ajax really likes the screed since it’s a full 10/20-foot screed,” he says. “A lot of folks advertise that promise, but they can’t really, truly pull 20 feet like the Ultimat 200.” And, keeping them moving in a way that can help alleviate that neighborhood impatience. The crew’s contract is scheduled for the end of December, but they’re currently forecasting a finish date at the end of October. Ajax is delivering ahead of its promise in part because it says partners like Bengford and Flagler do more than keep theirs.

Ajax used the Ultimat 200 extendable screed, which allows the street to be paved in one pass instead of two.

An early finish helped by a commitment to providing team members with the best tools to get the job done — when North Port morning commuters take a sip of coffee without a spill this year, Herb Jacobs will be nodding in approval.

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

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WEILER E2850

ENGINEERED INNOVATION

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

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

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

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

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PAVING INNOVATIONS Weiler P385A Asphalt Paver The 18,000-lb. P385 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 • Manual slope adjustment (powered slope optional) • Includes extension-height adjusters, multiple seating positions, replaceable wear plates and a 9-ton hopper Search: 10246380

Road Widener Skid-steer Attachment The Road Widener can be used for work on road shoulders, driveways, trails and paths. • Handles widths of 1 to 3.5 ft. and can disperse a 20-ton truckload of gravel in minutes at speeds of over 12 mph • Width, height and flow hydraulically controlled with precise control of material placement

• Features include adjustable slope control and a hydraulic-driven conveyor belt with heavy-duty 10-in. head and tail pulleys • 2,600-lb. empty weight and 10-ft. width allow easy transport via a standard-width trailer Search: 10080713

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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!

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

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Caterpillar CB54 XW Tandem Vibratory Roller The CB54 XW Tandem Vibratory Roller offers compaction performance, application versatility and operator comfort to maximize productivity while providing exceptional product quality. • Standard compaction width: 79-in. • Max travel speed: 8-mph • 137.0 hp Cat C4.4 engine with ACERT • Machines are capable of performing effectively on a variety of mix types, while keeping pace with the paver, helps customers maximize resources and lower their capital investment Search: 12176975

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BOMAG CedarRapids CR652RX Remix Paver The Cedarapids CR652RX is powered by a 260-hp Cummins Tier 4 Final turbocharged diesel engine, which provides the power to operate the Remix Anti-Segregation System augers, paver functions and electric screed, as well as lights for night paving. • 16.7-ton standard receiving hopper capacity can be expanded to 27 tons when equipped with the available hopper insert • Available with the Fastach 10 or Stretch 20 diesel or electric screeds for mainline paving widths reaching up to 30 ft. at depths up to 12 in. • Frame Raise System raises and lowers the rear of the paver to allow the operator to fine-tune the head of material at the spreading augers • Three-Point Suspension “floats” the paver over subbase irregularities to maintain consistent material feed height at the screed • High-visibility operator’s platform with swiveling seat and redesigned operator’s console that moves and pivots to line up with the operator’s seat Search: 10250906

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For more information, contact Libra Systems via email (sales@librasystems.com) or phone (215.256.1700) Search: 10073668

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

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PAVING INNOVATIONS Carlson LED Blade Light

Vögele MT 3000-2i Material Transfer Vehicle

Carlson's LED Blade Light has the ability to mount on a wide range of equipment including rollers, pavers, milling machines and more. • An all-in-one lighting platform able to be powered by 110/220v AC and 12/24v DC for a greater range of versatility • Produces equivalent light output of a 2,000watt halogen while offering a lifespan of 50,000 hours • Low profile and directional light creates safe working environments by eliminating dangerous glare while illuminating positions and mobile equipment • Cool-to-touch LED’s enable quick breakdown and storage in durable, hard-sided case

The MT 3000-2i material transfer vehicle from VÖgele offers optimal performance in a new-design MTV for asphalt paving. • Unit weighs 56,000 lbs. and has an 18-ton storage capacity • Low profile gives it a low center of gravity, and it can move 1,300 tph • Active remixing is achieved by two 16-in.-diameter conical augers in the receiving hopper • Auto feed function automatically slows or shuts down feeding when the hopper insert is filled • Primary and secondary conveyor belts are 43 in. wide, and are heated to keep material from sticking, and eliminate “warm-up” loads; secondary conveyor can swing 55° to left or right • Heated scrapers also keep belts constantly clean with a minimum of fuss • Propel system with auto distance control keeps the feeder at a preset distance from the paver. • 215-hp Deutz water-cooled, Tier 4i-compliant engine

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“Hot Mix Asphalt, Paving the Highway to the Future”

C.M.Consulting

NEW COUNTERFLOW AND PARALLEL FLOW ASPHALT PLANTS FOR SALE 1,000 gallon Portable Asphalt Oil Calibration Tank. Available now.

Bon Tool Asphalt Checking Straightedge Bon Tool's aluminum Asphalt Checking Straightedge can be used to detect particularly low areas which may create pooling or uneven paved surfaces. • Made of 1-in. by 4-in. aluminum • Available in 8-, 10- and 12-ft. lengths • Level vial for accurate reading of the alignment of surface • Fold down comfort grip handle Search: 10735910

ANNOUNCING

We are proud to announce a new Division of Cliff Mansfield Inc.: C D Road Equipment Sales & Service. Located in Swift Current Saskatchewan Canada. We operate from Manitoba west. As usual we will offer Plant Consulting, Operator training, Burner Solutions, Parts and plant trouble shooting. Please call with anything we can help you on. Our Canadian Division is in partnership with Mr. Doug Bleackley and will be offering the same knowledgeable "hands on" approach that we’ve been known for in the past. Mr. Doug Bleackley CD Road Equipment S & S 313 Cowie Crescent Swift Current, SK S9H 4W1 Canada Phone: 306 741 1333 dougbleackley@sasktel.net

Our staff of qualified Field Technicians service and support anything we sell. From Mix Design Compliance to air quality compliance, from mechanical to computer issues, we can help.

MANY NEW AND USED ASPHALT PLANTS FOR SALE NEW - 1,000 gallon portable Asphalt Calibration Tank. Self-Contained..........Call. 1990s ADM SPL-60 Portable Drum Plant. 65 ton Silo/Drag ........................Call. 2006 Cummins 275kW 480v Generator. 0 hours! Selling as USED...................Call. Wylie 3140 AC Plant, Baghouse, AC tank Generator. Down & ready to move...Call. 2- Stationary 80,000 ACFM Baghouses in good operating condition............Call. New, used and rebuilt Hauck & Genco burners. Burner Controls.....................Call. Cliff Mansfield Inc. P.O. Box 407 Odell, OR 97044

Office 541-352-7942 Fax 541-352-7943 www.hotplantconsulting.com

Trimble MX7 Mobile Imaging System The MX7 Mobile Mapping Imaging system is a fast and cost effective way to manage assets such as bridges, buildings, roads, highways and power stations, and document site conditions with geo-referenced images. • MX7 with VISION technology is a vehicle-mounted photogrammetric system equipped with six, 5-megapixel cameras, and Applanix GNSS and inertial geo-referencing modules • Can be deployed on vehicles of all sizes to capture 30-MP geo-referenced images at highway speeds with rapid 360° image documentation • Precision positioning is achieved using the GNSS and inertial referencing system Search: 12250736

Search: 10072464

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

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Sakai SW654-Series Rollers Designed to meet the rigors of daily use in medium-sized to highway-class paving jobs, the single eccentric shaft SW654 and SW654B and twin-eccentric shaft SW654ND rollers are for small to large tonnage jobs requiring oscillation. • “B” model features a split drum suited best for operating in tight corners without pushing or shoving material • 73-hp Kubota diesel engine achieves Tier 4 Final emissions compliance • ECO Compaction Mode (ECM) reduces fuel consumption up to 37% • 58-in.-wide, 42-in.-diameter drums achieve 3,000 vpm in low frequency or 4,000 vpm in high frequency • Cross-mounted drive and vibration motors evenly apply force to the mat and prevent material shoving or pushing during compaction Search: 12192099

Solar Technology Arrow Boards with Cellular Communication Solar Technology's flashing arrow boards will now include a built-in modem, GPS and free cellular service – for the life of the board. • Remote communications included as standard equipment • Allows customers to create intelligent traffic solutions easily • Cellular connection will enable customers to locate their boards via GPS, check battery voltage from their desks, and change arrow patterns remotely • Data also includes a recorded history of what was displayed and when

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

Live Bottom Trailers

Heavy Duty Trailers

Crude Oil Transports

ChipSpreaders

Search: 12226870

Search: 12237057

Atlas Copco Dynapac F800W Paver The Dynapac F800W wheeled paver offers a paving capacity of up to 1,000 tph and 8- to 19-ft. paving widths. • Carlson EZIV08-15 vibratory front extension screed • 34-kW, hydraulically driven, oversized generator heats the full width of the screed at all times • Smart controls automatically lock screed, halting leveling, feed and vibration when the paver comes to a stop • Dual, swing-out operator platforms • 173-hp Cummins QSB 6.7 Tier 4 Final engine Search: 12214773

Asphalt Distributors

E. D. Etnyre & Co.

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

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

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PAVEMENT PRESERVATION

CIR Around the U.S. A look at some case studies where cold in-place recycling was successfully used to rehab pavements Project data Recycling width 12.5 ft. Recycling depth 4 in. Percentage cement 1.0% Percentage foamed bitumen 2.2% Production rate > 400 tph

old in-place recycling (CIR) is a fast, economical asphalt pavement rehabilitation technique that reuses existing pavement materials. CIR involves the processing and treatment with bituminous and/or chemical additives of an exiting asphalt pavement without heat to produce a restored pavement layer. All work is completed while on the pavement being recycled and is therefore less disruptive than other rehab techniques. It is also environmentally preferable because transportation of material, except the recycling additive being used, is not normally required. Below are some case studies were CIR was successfully used to rehab asphalt pavements.

Redmond Ave., San Jose, CA Redmond Avenue in San Jose, CA, is a highly trafficked road used by cars, buses, vans and delivery trucks. The existing pavement was in need of repair and the CIR process was selected as the preferred method, mainly to accommodate high-traffic levels. The contractor used a Wirtgen 3800 CR with integrated VÖgele screed and a recycling width of 12.5 ft. Before recycling the pavement, 1% cement was prespread in front of the 3800 CR. Recycling pass 1: The 3800 CR recycled the pavement in-place to a depth of 4 in., simultaneously adding 2.2% foamed bitumen. The recycled material was paved directly behind the recycler using the

Redmond Ave., San Jose, CA integrated screed, and finish compaction was achieved using Hamm rollers. Recycling pass 2: This pass required a total width of 13.5 ft. As the 3800 CR was fitted with a 12.5 ft. cutter, a Wirtgen W 150 pre-milled a section of pavement ahead of the CR and windrowed the milled material between its front tracks. This material was introduced into the mixing chamber along with the material cut by the 3800 CR, providing sufficient material to pave to a width of 13.5 ft. The on-board mixing computer was adjusted to compensate for this additional material to maintain the mix design requirements.

Highway 15, Mason County, IL In accordance with the Mason County bid documents, CIR was the designated rehabilitation method for Highway 15. The existing pavement was highly distressed, being

over 40 years old, with extensive alligator cracking and areas of cold-mix patching. In addition, this section of the highway suffered high levels of transverse cracking with affected driving conditions. The contractor for this project selected the Wirtgen 3800 CR with a working width of 12.5 ft. and integrated VÖgele screed. This unit features the ability to hydraulically open both the right and left end gates to discharge material to the sides in case of excessive material build up at the screed head. The mix design and pavement investigation were carried out by the emulsion supplier. The design called for the project to be divided into two sections, with a recycling depth of 3 in. for the first 2 miles and a depth of 4 in. for the remaining 6 miles. The emulsion content was calculated on a range of coarse to medium gradation at 2.25% to 3.75%. The 3800 CR pushed the bitumen tanker. Simultaneously, the 3800 CR milled the existing pavement to the required thickness,

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

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A WIRTGEN GROUP COMPANY

Brand New Highway Class Paver SUPER 2000-3i.

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

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

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

www.wirtgen-group.com/america

Search: 10075240

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

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PAVEMENT PRESERVATION

Project Data Recycling width 12.5 ft. Recycling depth 0-6 in. Percentage emulsion 2.25-3.75% Total area 93.646 square meters Production rate 410 tph

Highway 15, Mason County, IL added the design percentage of emulsion proportional to the working speed and added metered amounts of compaction moisture to suit varying in-situ conditions. The 3800 CR paved the recycled material immediately with the integrated VÖgele AB425T screed. No windrowing or pick-up machine or additional paver was required. Compaction was carried out right behind the screed using a Hamm HD 120 roller.

First, a milling machine pre-milled the exiting asphalt pavement to a depth of 2 in. Then the compact recycling train reported for duty. Preceding tanker trucks deliver hot bitumen and water to the 3800 CR Rear Load via hose connections. The cold recycler milled off and granulated the damaged asphalt layer down to a depth of 5 in. in a single pass while the milling and mixing

Route 17, Hampton, VA Route 17, Hampton, VA Route 17 in Hampton, VA, runs with two lanes in each direction. As a result of continuously increasing traffic volumes (approximately 15,000 vehicles per day, 3% trucks), the pavement surface was covered with extensive areas of patching and transverse and longitudinal cracks extending throughout the pavement structure. The rehabilitation method chosen for Route 17 was CIR using foamed bitumen as the binding agent. A Wirtgen WLB 10 S foam lab delivered the mix design and pavement investigation.

Project Data Recycling width 12.5 ft. Recycling depth 5 in. Percentage cement 1.0% Percentage foamed bitumen 2.2% Average working speed 28 ft./min. Production rate 520 tph

rotor mixed in foamed bitumen and water at the same time. The 3800 CR Rear Load forwarded the recycled material directly to the VÖgele Super 2100-2 paver. Rollers compacted the new pavement right behind the paver. Down-cutting recycling thus produced a bituminous base layer of superior quality – no crushing or screening plant was required.

Baileysville Road, Freeport, IL Baileyville Road in Freeport, IL, is a highly trafficked business road. The distressed pavement showed extensive alligator and transverse/longitudinal cracking, with irregular and unstable shoulder widths. CIR was selected to renew the road, mainly to accommodate high-traffic levels. The contractor used a Wirtgen 3800 CR cold recycler with a recycling width of 12.5 ft. and foamed bitumen as the binding agent. The 3800 CR stabilized the pavement to a depth of 4 in. in a single pass and across the full width of the traffic lane, adding 2.5% foamed bitumen and 1.5% water. The 3800 CR then loaded the recycled material into the paver’s receiving hopper. A paver worked behind the 3800 CR, paving the recycled material to the required grade. Traffic was guided past the construction site on the adjacent lane.

Project Data Recycling width 12.5 ft. Recycling depth 4 in. Percent foamed bitumen 2.5% Percentage added water 1.5% Average working speed 22 ft./min.

Baileysville Road, Freeport, IL

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

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HOT POUR CRACK FILLING SOLUTIONS. • CrackPro® Melter / Applicators • CrackMaster® Materials

H E AT ED H OS E M ACHINES

G RAV ITY FLOW M ELTERS

HOT POUR MAT E RI AL S

Your One-Stop Source for Hot Pour Crack Filling Equipment and Materials. Rental Programs Available.

AVAILABLE AT SEALMASTER LOCATIONS NATIONWIDE To learn more contact your SealMaster Representative at 1-800-395-7325 or visit sealmaster.net Search: 10074572

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FEB. 1-4, 2017 | MUSIC CITY CENTER | NASHVILLE ALL-NEW LEADERSHIP BOOT CAMP — JANUARY 31 Maximize your skills and enhance your career at the largest event specifically designed for paving and pavement maintenance professionals.

» Exhibit Hall featuring Weiler, Bobcat, BOMAG, KM International, Gradall, CASE Construction, and many more! » 50+ conference sessions » Equipment giveaways on the show floor » FREE Industry Roundtables

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Crack Maintenance Trailer Package

10-Gallon Melter/Applicator

FRI., FEB. 3 AT 4:00 P.M. IN THE KM BOOTH

FRI., FEB. 3 AT 2:00 P.M. IN THE NEYRA BOOTH

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EQUIPMENT DESIGNED

with the paving professional in mind. Worldwide dealer network and industry-leading parts availability. All major components from trusted suppliers to support reliability in the field. Over 50 years of industry experience and US market leader for four decades. LeeBoy equipment built in the USA.

Search: 10075155

www.leeboy.com

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PAVEMENT PRESERVATION Rayner RoadSaver IIIG Micro Surfacing Machine

Dynapac PL350TD Compact Planer

The next generation, the RoadSaver IIIG micro surfacing machine, features an eco-friendly design with no side engine - an industry first - that is designed to reduce emissions, maintenance and administrative costs. • PACCAR truck engine runs quieter and reduces the air quality concerns inherent in older equipment, preparing your organization for ever-tightening environmental regulations around the world • Electric over hydraulic throttle controls • Hot water jacketed emulsion pump & valve provides timely valve & pump performance even on cold start days • Convenience Package: includes walk around lubrication, aggregate inspection window, camlock fittings, DOT dome covers & ladders both front & rear • 100% hydraulic drivers, no chains or sprockets • Security covers for the operator control center & joysticks • A protected compartment is built under the pugmill to provide secure mounting of valuable hydraulic components, sealed from weather & work contamination • Pavement water/fog spray system

The PL350TD mills 13.8 in. wide to a depth of 3.9 in. with a cutting diameter of 20.5 in. • Left and right steering angle of 75° and a 3.9-in. milling radius • Powered by a 60-hp Cummins B 3.3 engine

Search: 10450589

• Easy Level system controls slope regulators, ultrasonic sensors and height sensors for accurate leveling during daily milling • An automatic mode for the conveyor belt and water spray bar is activated during milling and turns off when milling stops Search: 10834347

PHCo Patch King Asphalt Patchers

Search: 10072313

Process Heating Co. offers a line of asphalt patchers for patching with either hot, warm or cold mix asphalt. • Designed to keep mix warm all night ready for use the next day with minimum waste • Available in three models: the slip in PK-30H to PK-80H; the rotary auger models PK-35HSD and PK-40HSD; and the trailer version model PK-30T • Uses electric power • Exclusive "Lo-Density" heat translates into even heat distribution preventing damage to the mix • Tac-King emulsion storage tank is also available Search: 10089587

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

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RLS

Parts and Equipment

“Manufacturer of Asphalt Plants & Components” 33595 Bainbridge Rd. Suite #204 • Solon, OH 44139 PHONE: 440-498-1843 • FAX: 440-498-1921 EMAIL: rlspartsandequipment@gmail.com • www.rlspartsandequipment.com

PLANTS * ACS * Astec * Barber Greene * CMI-Simplicity * Cedar Rapids * Cummer * Custom Built * Estee * FAB Spec * H&B * Kenco * Littleford * Madsen * McCarter * Stan Steel

Tips

Shafts

Shanks

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Request a catalog for your plant(s). Email rlspartsandequipment@gmail.com

Dryer

Flights

•J

• Basket

• Converta

• 120 degree

• Combustion

• Saw Tooth

Elevators Bearings Spacers

Buckets Motors Gears

Trunnions Trunnion Assembly on Angular Frame

Chain Reducers Plate Washers

Sprockets Dodge Parts Hardware

Order with confidence, high quality, low prices, customer satisfaction

We look out for YOU! Search: 10218626

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PAVEMENT PRESERVATION Wirtgen WR 240i Recycler/Stabilizer

Etnyre FWD and QUAD ChipSpreaders Etnyre's FWD and QUAD chipSpreaders are designed to spread aggregate in the chip seal process. • Computer-controlled application rates • Front-wheel or four-wheel drive • Fixed spread hoppers from 10 to 15 feet • 148- to 230-hp engines Search: 10078188

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

with sound reducing muffler and added sound control from an optional engine cover Search: 12226854

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

The WR 240i stabilizes large areas of incohesive soils utilizing any stabilizing medium, and recycles 100% of existing asphalt pavements in situ. • Working width of 7 ft. 10 in. and maximum working depth of 20 in. • 600-hp Cummins six-cylinder Tier 4i engine • Nine rotor speeds aided by computer-controlled metering technology with automatic monitoring • All-wheel steering and a separate steering angle on the rear axle for a tight turning radius • All main functions controlled via the multifunctional joystick in the right-hand armrest • Automatic lowering and raising of the milling and mixing rotor Search: 10942294

Caterpillar RM500B Rotary Mixer The all-wheel-drive RM500B is available with a choice of universal, soil or combination rotors that provide cutting widths of 96 in. and maximum cutting and mixing depths of 16, 18 and 20 in.

• 546-hp C15 ACERT turbocharged, six-cylinder, Tier 4 Final diesel engine • Automatic rotor load control enhances machine productivity • Travel, manual and automatic modes for rotor depth control • Large, variable-volume mixing chamber mounted mid-point between the front and rear tires • Hydraulic sliding, fully pressurized cab repositions from side-to-side and can be positioned at any point in between Search: 12055195

Road Science ColdGrip IQ Road Science's ColdGrip IQ cold patch mix for pothole repair is designed to chemically transform cutback asphalt to be highly compatible with cool, damp and dusty aggregates for easier production and longer patch life. • Easy handling features in cold temperatures and low odor • Improves coating and adhesion of the cutback to cool, damp and dusty aggregates during production, eliminating aggregate coating challenges and enabling use of less pricey aggregates for reduced costs and improved production efficiency • Extends patch life by strengthening adhesion of the cold patch to the pothole by displacing and repelling water from the pothole and forming a stronger bond to the existing Search: 12247937

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

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

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BOMAG BM1200/35 Cold Mill

Lake Erie Pitbull 2300 Propane Screener The 13,500-lb. Pitbull 2300 Propane screener for topsoil, mulch, gravel, stone, asphalt and other materials features a 48-hp Zenith 1.6-liter propane engine that can be easily converted to natural gas. • Upper and lower screening decks provide 41+ sq. ft. of screening area each • Loading apron accepts up to 3 yds. of material at a time depending on the feed rate • Dump height of 8 ft. 4.5 in. allows the hopper to be filled using standard construction equipment • The 20-ft.-long stacking conveyor adjusts hydraulically from 7 ft. 6 in. up to 13 ft. to feed material directly into a dump truck or tri-axle trailer • The hydraulically driven transfer conveyor achieves production rates up to 100 yds. per hour Search: 12207712

The BM1200/35 cold milling machine offers a 47.2-in. cutting width and 13-in. maximum cutting depth and features a rear rotor design that optimizes milling performance. • Cutter design with the BMS 15 interchangeable holder system incorporates a single bolt for holder retention and requires a low tightening torque of 75 ft.-lbs. • 349-hp MTU Tier 4 Final diesel engine offers power to efficiently mill asphalt at speeds reaching 105 fpm • 85-, 95- and 107-rpm milling drum speeds • 25.6-in.-wide inside and 23.6-in.-wide outside conveyors with capacities reaching 6,357 ft. per hour • 224.4-in. maximum conveyor discharge height • Pressurized water injection system offers a variable flow rate of 0 to 1.6 gpm to the cutter housing Search: 12095029

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

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PLANT MATTERS Walsh & Kelley recently opened a portable ashalt plant on a 20-acre location in LaPorte, IN, to serve a growing market.

Walsh & Kelly

Creating Its Own Opportunities Indiana-based asphalt company expands its asphalt plant operations to a new location in order to meet potential market demand By Jessica Stoikes, Associate Editor

ransportation of asphalt mix can be one of the most costly parts of your business. Not only does it cost money to physically haul the mix to the jobsite, but as the mix cools you’re also potentially letting money fly out the window (or in this case the truck bed) with every passing mile. Walsh & Kelly, one of the largest civil contractors in Northern Indiana, recognized the value in having plant proximity to developing areas and has expanded its plant operations to meet demand. Recently, Walsh & Kelly opened a new production facility on a more-than-20-acre site on County Road 450 North just west of Indiana 39. The company has four other asphalt plants in Griffith, Valparaiso, Lowell and South Bend. The company’s plan was to grow the amount of work it does in the LaPorte area by reducing

the cost of transporting the product and maintaining quality by shortening the distance asphalt travels once leaving the plant, according to John Wall, project manager with the company. ''We can service that market from afar, but this new location will allow us to be more competitive and a little more aggressive in the marketplace for the municipal work and the state jobs and some of the private commercial work that we do,'' Wall says.

Guaranteed growth Any decision to buy and build a new asphalt plant is not taken lightly or without the potential for a return on investment. One of the reasons Walsh & Kelly chose this location for its new plant was based around city planning. Wall said among the new job prospects in the area is the city of LaPorte, which is laying

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

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plans to adopt a wheel tax for fixing a greater percentage of its streets than in previous years. The Wheel Tax Ordinance is a response to the Indiana Department of Transportation Community Crossing program in which the city will have the ability to receive $1 million for road and street repair if a matching $1 million can be raised by the city. To enter into the program and to earn the money, the city must adopt the wheel tax which declares a $25 rate on all passenger vehicles, motorcycles, trucks with a declared gross weight that does not exceed 11,000 pounds and motor driven cycles per year with the registration. It also taxes $40 to buses, recreational vehicles, semitrailers, tractors, trailers and trucks. The uses of the funds, as stated in the ordinance, will go to the construction, reconstruction, repair and maintenance of the streets and roads under the city’s jurisdiction. The taxes will go toward the city’s contribution to obtain a grant from the local road and bridge matching grant fund. “We made an analysis of the future work volume in our markets and the appropriate

The City of LaPorte plans to adopt a wheel tax to help fund street and road repairs in the area. Walsh & Kelly opened the new production facility to help meet this potential demand.

The new Astec Double Barrel plant features a Phoenix Talon burner that delivers low emissions and, when combined with a siliencing package, allows this portable plant the ability of operating anywhere, even residential areas if needed.

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

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PLANT MATTERS plant configuration to meet the projected work and determined that a new plant in the LaPorte area would best serve the needs of our customers and our continued growth,” says John Peisker, Walsh & Kelly vice president of asphalt operations. “As we mapped out our other asphalt plants, our analysis indicated that locating a plant in the LaPorte area would allow us to more efficiently serve our customers in that area, especially with the new wheel tax initiative." ''Logistics are what keep the economy moving," Wall adds. "You need to get goods transported from one place to the other and that's really what we're talking about being able to do that better and more efficiently with this location.''

Portable production The company chose a portable Astec Double Barrel portable plant with a Phoenix Talon burner, paired with two long-term storage silos. “We wanted the flexibility to serve a larger geographic area made possible by a portable plant,” Peisker says.

“We wanted the flexibility to serve a larger geographic area made possible by a portable plant,” John Peisker, Walsh & Kelly. While this is the only portable plant the company owns, Peisker says the potential is greater for the market and a plant with the option of portability. "We are looking at other sites in other counties that will add to our ability to serve them," he adds. The company started receiving parts midJanuary and the plant was ready two months later with production beginning in June. The company chose the Phoenix Talon burner as it uses the latest burner technology to deliver very low emissions combined with energy efficiency. With the optional silencing package, it’s even possible to have a phone conversation on the burner platform while it’s firing. “The burner and drum combination we selected provide a significant noise reduction

benefit,” Peisker says. "In this location, it's not a big deal, but this gives us the option of being a good neighbor in any environment we choose down the road where we would have homes or businesses located close by." Each of the two silos can store 200 tons of hot mix for as long as 48 hours depending on conditions. The company outfitted the drum with the Astec V-Pack Stack Temperature Control System and tretrofitted the plant with a warm mix system they already had on hand. The new plant produces about 400-tph in a full range of mixes for its customers that include the Indiana Tollroad, Indiana DOT, counties, municipalities, airports and private developers, as well as custom mixes for specific use.

Need a replacement part or additional supplies at a job site? Need it now? Search the updated online

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