2009 Spring Newsletter by Guntert & Zimmerman

Guntert & Zimmerman

Construction Profiles

Spring 2009

Acme Paving at McCarran Airport

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Concrete Paving in The Wettest Place on Earth p. 5

Equipment Delivery to the East Coast p. 9

No Gambling at the Las Vegas Airport

Runway 25L/7R, the busiest runway at McCarran Airport in Las Vegas, has recently underwent a $75 million reconstruction. The 25L/7R reconstruction was one of the largest airport paving projects under construction in the USA. The project required extensive planning efforts due to a hefty liquidating damage clause in the contract of $500,000 per day. This liquidating damage clause is purported to be the largest in the history of paving. Asphalt milling of the existing runway began on November 3, 2008 and was completed just 16 days later, producing more than 300,000 tons of recyclable AC millings. Las Vegas Paving, the prime contractor on the project, subcontracted the paving operation to ACME Concrete Paving, Inc (Spokane, WA). Upon milling completion ACME rapidly mobilized 2 RexCon Dual Drum 12 cubic yard (9.17 cubic meter) concrete plants, 2 G&Z pavers (S850 and S1500), 2 G&Z belt placers (PS1200 and ISF150), and a G&Z texture/cure machine (TC1500). Concrete paving began on November 19, 2008 with production rates sometimes exceeding 7,000 cubic yards (5,351 cubic meters) per day. Paving dimensions on the 18” thick runway were 10,525’ x 150’ wide and 11,000’ x 100’ wide on the parallel taxiway. A unique setup at the plant-site allowed stockpiling to occur at night during minimal traffic hours. A single drive over grizzly with large receiving hopper permitted tandem and triple belly dump trailer delivery, dumping onto a simple reversible belt that allowed feeding to either batch plant. The sand and two coarse aggregates were stockpiled using radial stackers. Individual stockpiles were kept small to minimize stockpile loss with timely deliveries by aggregate producer and prime contractor, Las Vegas Paving. Also unique to this job was ACME’s utilization of Kawasaki loaders, water trucks, and light plants supplied by Las Vegas Paving all of which greatly reduced mobilization costs for Acme Paving coming all the way from Spokane, WA. This job was well underway during the 2009 World of Concrete and allowed frequent visits by interested World of Concrete attendees. Even though the project limits were directly adjacent to the east west runway, security was handled by erecting a fence encircling the entire project site which made for easy access to this high profile job. The pours on the runway were paved at 37.5’ (11.43 m) lanes with the G&Z S1500 fed by the new PS1200 Placer/Spreader from the right side and the older G&Z ISF-150 feeder from the left side. The taxiway pours were paved at 33’-4” (10.15) wide with Acme’s new G&Z S850. The PS1200 which was purchased specifically for this project was delivered to ACME in 2009. The PS1200 was designed with the ability to leave the tractor at 37’-6” (11.43 m) while rapidly changing strike-off widths to 33’-4” (10.15 m) using a specifically designed set of strike off support arms.

The ability of the G&Z equipment to rotate tracks 90 degrees enabled quick moves to the next pour and minimized hand pours on cross taxiways where ACME utilized a pair of MultiQuip roller screeds. Acme also cited the effectiveness of the S850 to pave “stringless” on the closure passes. Elevation was sensed by “locking to grade” where the elevation sensors took their grade reference off the crawler track yokes. Alignment was accurately sensed for both the front and rear crawler tracks in the “front steer only” mode requiring only the front steering sensor referencing off the inside of the previously poured concrete. Acme also made good use of the S850’s Computerized Crown Control feature which allows automatic transitions in and out of crown. The runways were paved at a consistent 1.25% crown, but the taxiways were paved with a 1.25% variable crown. The pavers ability to automatically adjust to the specification saved a lot of time.

PS1200 Equipment Choice G&Z engineers and service personnel learned a great deal about the capacity of the PS1200 while it was being pushed to its outside limits on this project. With important lessons learned and much knowledge gained through the experience, the PS1200 placer/spreader proved to be an ideal machine in this application for the following reasons: 1. S preading Capability up to 40 ft.: Heavy duty tractor frame capable of spreading widths from 18 to 40 ft. 2. T ransportable in a Single Load without a Crane (patented): The PS1200 is self loading in a matter of a few hours. 3. R apid Belt Relocation (patented): The tractor is universal with only the relocation of the strike-off / spreader plow required which can be accomplished in under 1.5 hours without a crane. 4. P owerful 60” Roll-In / Roll-Out Concrete Belt: • The belt skip is hinged support by hydraulic cylinder to allow for haul road elevation variations. • Belt doesn’t require stopping to allow trucks to pass and rolls in / out under 7 seconds. • The belt also strikes off and spreads the top of the concrete pile as it rolls in. 5. Heavy Duty Strike-Off: Module is strong enough to push concrete back to the paver and tall enough to contain concrete pile. 6. P owerful Spreader Plow System: After pre-spreading by the concrete belt, material spreading is accomplished by a powerful hydrostatic wire rope winch driven spreader plow. • Almost zero maintenance. • Cost to operate is a fraction of the cost to operate an auger. • Spreading action is not impeded by a center auger bearing or outer gearboxes like an auger system.

The G&Z PS1200 Placer/Spreader has been working in the North American Concrete Paving Market in a number of different paving applications for over 5 years. Never has it been utilized in a tougher application than on this project. For this particular application, the design limits of the G&Z PS1200 were tested by the 18” thick 37.5’ wide pavement, concrete with an average slump of 1”. This low slump airport mix was made partially with manufactured sand which added to the “stiffness” of the mix. One challenge was the concrete being pre-placed in front of the PS1200 by another G&Z Placer. This created large piles of concrete that had to be pushed by the PS1200 while still receiving and placing concrete. Acme was impressed with the PS1200’s mobility which saved them a lot of time maneuvering around the job site as well as on/off the site. Due to the time sensitive nature of the job, it was necessary that all pieces of equipment used were highly productive. The PS1200 was designed to operate at a level of high productivity. Though the conditions were challenging, the PS1200 met them time and time again. With this large scale project completed, Acme Paving is quite satisfied with its purchase of G&Z equipment. Not only did the G&Z equipment perform well on the job site despite the challenges allowing Acme to finish two weeks ahead of schedule. Furthermore, the professionalism and knowledge displayed by the G&Z service techs during the project added to the value

of the equipment. Even under a rigorous timeline and tough airport paving conditions, the team at Acme along with the G&Z equipment and personnel rose to the challenge. There were a large number of participants on the team that made this project successful; however, we want to recognize a few key companies and individuals instrumental in the project’s success:

ACME

Vice President Robert Seghetti Vice President Steve Clark Paving Superintendent Brian White Equipment Manager Steve White

Concrete Removal and Diamond Grooving

Project Manager and Estimator Ryan Mendenhall (grandson of Las

Vegas Paving’s founder Bob Mendenhall)

2009 Paving School Recap

This was my second year helping coordinate and also attending, the G&Z annual paving school. Nothing is more worthwhile then the quality time spent with our existing and potential customers during the paving school week. Paving School offers a full three days of time to spend with concrete contractors from all over the country. It provides an excellent forum to listen and learn through the stories and experiences of the professionals that are out on job sites everyday building our roads and airport pavements. One behalf of Guntert & Zimmerman, I would like to say thank you to everyone who participated in this year’s concrete paving school. The turnout this year was great. We had 68 attendees representing 15 different contractors from around the nation. I would like to extend a formal thank you to Paul Okamoto and Paul Jaworski for their brilliant addition to our in house experts. The mix design and vibration class received many accolades from our attendees. G&Z hopes to continue to bring experts from our industry to paving school to add to the wealth of knowledge transferred during the week. Paving School is an excellent value to the attendees. In addition to the knowledge gained through the classes offered, they have several opportunities through the school to network with their peers to gain helpful insights and “tricks of the trade”. There is much excitement around G&Z these days. We are about to launch our new S600 half width slipform paver which will incorporate several of the same productivity features combined with the ability to achieve smooth ride as provided by the S600’s big brothers - the G&Z S850 and S1500. With the S600 market introduction, we are planning on introducing several new modules and classes about the S600 in G&Z’s paving school next year. With next year in mind, I hope you will choose to return to paving school again or attend for the first time. As paving school grows, so does the program. In 2010, we hope to offer a robust and redesigned paving school that continues to transfer vital knowledge from different aspects of our industry. Stay tuned for details as the event gets closer. If you would like to be kept apprised on paving school developments for next year, please e-mail David Lipari at dlipari@guntert.com. Good luck in this years’ paving season. With the infusion of stimulus money towards road projects, it will no doubt be a busy season. Thanks again for your attendance and participation. We look forward to seeing more of your team next year! - Ron Meskis, National Sales Manager

Concrete Paving in The Wettest Place On Earth

As we all know it takes a coordinated effort of man, materials, and equipment to construct a concrete roadway under a tight smoothness specification. Now, toss in the element of weather but not just any weather, the wettest conditions found anywhere on earth.

the slab) across these joints. The typical spacing of the dowels is 300 mm (11.8 in.) with exceptions of 200 mm (7.8 in) and 150 mm (5.9 in) on centers at the median and shoulder respectively. The longitudinal joint is tied with a 16 mm x 640 mm (.6 in x 25 in) tie bar spaced on 600 mm (23.6 in) spacing.

The Assam region of India is known for an average rainfall of approximately 1270 cm (500 in). The world’s highest recorded rainfall which occurred in Cherrapunji (Assam) was 2290 cm (75 ft) of rain which fell in one 6 month period (Cherrapunji is about 180 km [112 mi] from the jobsite). These annual monsoons typically begin in March and continue through the end of September. It is so wet in this region of the world that “Google” claims this to be the “wettest place on earth!” This doesn’t leave a very big window to construct a quality concrete pavement.

There was a significant amount of planning on the concrete batching operation that occurred prior to the first slab being placed. It was decided to erect two batch plants (Ajex Feori & Penta 3000 TS), both of which could produce 120 cubic meters of concrete per hour (157 cubic yards per hour) with the use of a twin shaft mixer.

It is under these extreme conditions that Patel KNR (JV) is paving concrete on a straightening and widening project of the National Highway (NH37) in the Assam region of India. The project is located between Guwahati, the state capital and Dharamtul, thereby connecting the upper and lower parts of Assam.

Once the batch plants were erected a series of batch trials were carried out to check the accuracy and uniformity of the batching & mixing process. Additionally, slump tests were performed at 20, 30, 45, and 60 second mix times to verify what mixing time achieved a specified slump of 20-25 mm (.78-.86 in) at the paver.

Average annual rainfall of over 1,270 cm (500 in.)

The project consists of a four lane reconstruction of the roadway for a total concrete paving length of 41 km (25.5 mi). The project also includes a 16 km (10 mi) stretch of new construction known as the Nagaon Bypass. The concrete paving work is scheduled to be completed by March 2009 with the total cost of the project at approximately Rs 238,72,47,500 (USD 46,050,004.75). The project is being constructed using a Guntert & Zimmerman S850 with Compact Dowel Bar Inserter (CDBI) at a paving width of 8.75 m (28.7 ft) and at a thickness of 310 mm (12 in.). Transverse joints are sawn every 4.5 m (14.7 ft) with load transfer dowels (32 mm x 500 mm [1.25 in x 19.6 in] located mid-depth in

The target paving speed was 1.0 meter per minute (3.2 feet per minute), while ignoring any concrete waste translating to an average of 162 cubic meters per hour (211.8 cubic yards per hour) delivered to the paver. This concrete production amounts to approximately 70% of the combined rated output from both plants. The batch size on each plant is 3 cubic meters ( 3.9 cubic yards) with a plan for discharging 3 batches per truck to achieve the target truck load of 9 cubic meters. Both batch plants were located at Patel KNR (JV)’s site offices which are 3 km (1.8 mi) beyond the Eastern limit of the contract. The first section of pavement constructed was at the opposite (Western) end of the contract on a 7.7 km (4.7 mi) portion of the NH-37 that is being re-constructed. The average haul to this section was 22.8 km (14 mi) and the route is through the town of Nagaon.

A trial paving section was completed prior to full scale production, with two objectives in mind. The first was to verify that all the needed resources (tools and labor) were deployed to the job site prior to full production. Secondly, the test was conducted to demonstrate to the engineer Patel KNR (JV)’s abilities to construct an 8.75 m ( 28.7 ft) wide pavement with the G&Z S850 and CDBI while achieving all the required specifications relating to strength, smoothness, straightness of edges, texturing, curing, saw cutting, etc.

personnel were critical components to the success of this project. They were helpful from every aspect of concrete paving from pre-planning, mix design analysis, equipment set-up, operation, and trouble shooting. In my opinion, I would pave with no other machine with such confidence.”

The philosophy at G&Z is to design and manufacture paving equipment that best addresses the needs of the contractor and results in higher productivity and better quality pavements. Though the up-front costs will be higher, it is an easy case to prove that any extra initial investment will be quickly recaptured in what the contractor gains in productivity due to:

Dramatically reduced time to load, set-up, tear down, and change widths versus the competitors

2. 3. 4. A critical element to successful slipform paving in India is good technical field support for the contractor. Allen Buildwell (G&Z’s representative in India) and G&Z supplied many technicians over a period of months. The duties of these technicians included assisting with operation of the Penta batch plant and the assembly of the G&Z equipment as well as its operation during the course of the project. Prior to the first installation of concrete, Allen Buildwell and G&Z provided training to the Patel KNR (JV) personnel in the safe operation of the S850 Paver, CDBI, and texture cure machine.

Patented 90 degree and counter-rotation steering. This allows for easy maneuverability around the site and for loading onto a transport vehicle. Narrow profile design so the paver can work as close as possible to obstacles. Reduced hand pours at headers because of the machines capability to back onto previous days pour and begin right at the header.

The project to date has been an astounding success. The engineer on the project representing the state is pleased with the overall quality and smoothness that is being produced by the Patel KNR (JV) team with the help of the G&Z equipment. According to Mr. Panindra Reddy of Patel KNR (JV), “We are overjoyed at the performance of the G&Z equipment. For as big as this equipment is, it was relatively ready-to-go after being unloaded.” Additionally, “The Allen Buildwell and G&Z

G&Z S850 quickly paving away from the previous days concrete slab.

S1500

SCP-6 TC1500

PS1200

PAVING AUSTRALIA’S EAST COAST PACIFIC HIGHWAY G&Z RECENTLY COMMISSIONED A S1500 PAVER, ONE PS1200 PLACER SPREADER AND TWO TC1500 TEXTURE CURE MACHINES ALONG WITH TWO CONCRETE PLANTS IN COLLABORATION WITH THEIR CUSTOMER THEISS PTY LTD IN AUSTRALIA. THEY HAVE JUST BEGUN TO USE THE EQUIPMENT AND HAVE BEEN THRILLED WITH THEIR GOOD FUNCTION AND END PRODUCT RESULTS. MORE NEWS TO COME IN G&Z’S WINTER 2009 CONSTRUCTION PROFILES MAGAZINE AS THESE MACHINES CONTINUE TO BE PUT TO THE TEST.

Bringing G&Z Excellence to the East Coast Increased productivity and opportunity for contractors to earn smoothness bonuses have long been the key criteria driving the design philosophy at Guntert & Zimmerman (G&Z). Quite often, the significant cost saving details get overlooked because contractors donâ&#x20AC;&#x2122;t always have the time to delineate these savings when analyzing equipment value. More often than not, the primary consideration in making an equipment purchase is initial price and not the total cost of ownership over the equipmentâ&#x20AC;&#x2122;s life. G&Z is usually not the lowest initial cost machine being considered in a buying decision. However, the G&Z machine generally contains features the competition just doesnâ&#x20AC;&#x2122;t offer.

A G&Z machine is extremely well constructed and engineered for precision and versatility. These machines are high value equipment with a rapid return on initial investment as well as retaining value for a longer length of time. Enhanced mobility and other features make G&Z more efficient which allows for increased productivity due to less downtime between pours and between job sites. For a contractor to successfully construct high quality concrete pavements attention to the details is a necessity. This requires attention to the concrete materials, the equipment, and people executing in the field. Therefore, it is not uncommon for contractors to share that same focus for quality and detail as G&Z.

It was these same set of values that brought G&Z and Golden Triangle together as a team in the Pennsylvania concrete paving market. Chuck Niederriter, C.O.O. for Golden Triangle, and Ron Guntert had been speaking for years prior to Golden Triangle’s first purchase of a new S850 slipform paver in 2008.

“This is the first time our mechanics and equipment technicians haven’t been all over the paver making adjustments before and after the first load of concrete arrived. Not only did the machine start-up go smoothly, but we were able to achieve the needed IRI numbers from that first pour forward.” -Chuck Niederriter, C.O.O. for Golden Triangle

Prior to Golden Triangle purchasing the G&Z S850, Chuck Niederriter was concerned because the pavers they owned were not able to achieve profileograph results to meet Pennsylvania’s tight International Road Index (IRI) smoothness specifications. Additionally, when evaluating equipment, Niederriter recognized the value in the S850’s solid structure, transportability, and other productivity features.

we were able to achieve the needed IRI numbers from that first pour forward.” The first project the S850 was used on by Golden Triangle was near New Alexandria, PA, which consisted of a $35 million reconstruction of SR22 having 4 lanes of concrete pavement plus a turning lane. The 12 inch thick concrete was poured at 24 feet wide with the G&Z S850. After this project is completed early this summer, Golden Triangle will transition to another project located on the east end of this project which is valued at $20 million and consists of a 2 mile reconstruct with the same pavement section as the 4 mile section they are presently constructing. Golden Triangle experienced first hand on this project the ease of transport of the S850. They expect to be moving the S850 back and forth between the SR22 project as well as a couple of other PA Turnpike projects near Brownsville, also known as the New Mon-Fayette Corridor, in order to meet the tight schedules on these projects. One of the reasons they chose the G&Z S850 was for its ability to make transport quick and easy. In addition to the ease of transport and other cost saving features of the S850 paver, Golden Triangle was very impressed with the level of service they received from G&Z’s Service Department. “The G&Z serviceman, Scott Mallory, did a great job teaching everyone from the finisher to the project manager on how to get the best results out of the paver. He was knowledgeable about not only the paver, but ALL aspects of the paving process,” praised Niederriter.

Chuck Niederriter had been a regular attendee at the ConExpo show held in Las Vegas every three years. He, along with several other team members from Golden Triangle, spent a number of hours “kicking the tires” of an S850 on display at the 2008 ConExpo. With a healthy paving backlog going into the 2008 season and impressed by what they saw, Golden Triangle ordered a new G&Z S850 and took delivery of it in October 2008. Taking possession of a new piece of “iron” is always exciting to a concrete contractor, and this delivery was especially so. After unloading their new S850 with the help of G&Z service technicians, Golden Triangle did some minor assembly of the machine, set the elevation and grade control, and began paving. Niederitter was amazed at how quickly the paver was ready for paving after being delivered. “This is the first time our mechanics and equipment technicians haven’t been all over the paver making adjustments before and after the first load of concrete arrived. Not only did the machine start-up go smoothly, but

NARROW PROFILE

PAVING KIT G&Z Delivers New Technology to Keep Our Customers Competitive

Narrow profile paving gives contractors the ability to pave close to barrier wall, lane additions, and reconstructions without the need to shut down an additional lane of traffic. This configuration is often used in tight confines as in city, county, and industrial applications. Zero or minumum clearance paving has been done from time to time over the past 20 years. However, limitations exist including inability to achieve smooth ride and pave with a dowel bar inserter. G&Zâ&#x20AC;&#x2122;s current slipform pavers with DBI can achieve zero band smoothness specification while paving with a minimum clearance of 32 inches. G&Z recognizes the need for narrow profile paving without sacrificing smoothness. G&Z offers a Narrow Profile Paving Kit which is now available on the G&Z S850 Slipform Paver with Dowel Bar Inserter to accommodate paving with less than 25 inches of clearance. This allows the S850 to pave next to an active lane of traffic. The Narrow Profile Paving Kit is available as a retrofit or at time of order.

Guntert & Zimmerman Const. Div., Inc.

222 E. Fourth St. Ripon, CA 95366 U.S.A. Phone 209-599-0066 Fax 209-599-2021 Toll Free 800-733-2912 Email gz@guntert.com Web www.guntert.com

Construction Profiles is published by Guntert & Zimmerman to inform readers of applied construction technology utilizing Guntert & Zimmerman equipment. All rights reserved. The contents of this publication may not be reproduced either in whole or in part without the consent of Guntert & Zimmerman. Printed in U.S.A.

Manufactured under one or more of the following U.S. or Foreign Patents: 4,433,936; 4,483,584; 0051885; 6,390,727; 6,390,726; 6,176,643B1; 5,135.333 and 117323 and Patents Pending. Some items shown may be optional. Guntert & Zimmerman Const. Div., Inc. will custom build any machine or accessory to suit your particular job requirement. G&Z reserves the right to make improvements in design, material, and/or changes in specifications at any time without notice and without incurring any obligation related to such changes. Brochure No. 400P099