Asphalt Pro - October 2015 by Asphalt Pro LLC

Control Quality with Technology

Maintain Control

What can IC, tech do for you?

Stay Safe: Do Not Pass Go

Mix in an SDS HFST Rocks Out Why Add Fracking Measure Augers for Mat Matching october 2015

COIL

U NMATC HED COIL PROT E CT ION Our UE differential pressure switch is used to protect the heater coil in the event of inadequate flow of thermal fluid. Inadequate flow can cause overheating that quickly destroys the coil. Maintaining adequate flow is critical for the long life of the coil. Coils can last 20 years or more if they are not subjected to overheating. We now use the most advanced pressure switch available from UE. It is 100 % solid-state microprocessor based with a digital display. It is highly accurate and repeatable. It is also expensive. In years past we tried various pressure switches and none were equal to the switch we now use.

So we know from experience it is unmatched and worth the extra cost! Please call today for more information.

HEATEC H E AT E C , I N C .

an Astec Industries Company

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

contents

Departments Editor’s Note 5 We’ve Got the Alternative to Coke Around the Globe 6

Safety Spotlight 8 Serve Time for Safety By Sandy Lender Mix it Up 10 Rock on Your High Friction Surface Treatment By AsphaltPro Staff Project Management 16 Manage Your Bridge Resurface Project By Del Williams Keep it Up 20 How to Use Water Absorbers By Scott Grossbauer That’s a Good Idea 48 Measure Auger Height for Matching By John Ball Product Gallery 50 Asphalt Production And Liquids Essentials Safety Data Required By AsphaltPro Staff

Articles 22 How to Maintain Control By Sandy Lender

26 Here’s Why WMA Works Check out multiple process options for warm-mix from dynamic foaming, chemical addition to onsite liquid mixing, blending By Rick Rees 28 Make U.S. Mats Better Here’s how intelligent compaction can and cannot do the job for you By Sandy Lender 36 Choose the training venue for your crew By AsphaltPro Staff

Here’s How It Works 61 CEI and Fireye’s Nexus 4000 System Here’s How It Works 62 Maxam’s CB Sampler Digital Details 66 Apps That Make You More Productive

38 Check Out Fracking Opportunities Integrating frac sand processing introduces another revenue stream in the asphalt producer’s business By Holly Bellmund 42 Meet the State Exec: Mel Monk By AsphaltPro Staff

Control Quality with Technology

Maintain Control

What can IC, tech do for you?

Stay Safe: Do Not Pass Go

Mix in an SDS HFST Rocks Out Why Add Fracking Measure Augers for Mat Matching OCTOBER 2015

On the Cover Paving automation, asphalt mix blending controls, weighing technology, intelligent compaction and other technologies are designed with quality operations in mind. See related articles throughout this edition of AsphaltPro. Photo courtesy Systems Equipment.

Rely on CEI

Equipment.

Parts.

CEI equipment has a proven legacy of quality & innovation since 1969.

We stock one of the largest parts inventories in the industry, for CEI and other brands.

Rely on CEI

Service. For troubleshooting, repair, maintenance or training, CEI’s service reach is global.

Whatever you need to keep your plant running,

Rely on CEI.

ceienterprises.com • 800.545.4034

CEI ENTERPRISES,INC.

an Astec Industries Company

245 WOODWARD RD, SE • ALBUQUERQUE, NM 87102 USA • 800.545.4034 • FAX 505.243.1422 • ceienterprises.com

editor's note October 2015 • Vol. 9 No. 1

We Have the Alternative to Coke

Here’s a fairy tale for you. Once upon a time, Alter Your Sealer Mix How to Pave Under the Deck everybody at County Fairgrounds A ordered and drank Coca Cola® because they didn’t know the last booth on the property offered Superior’s a hops-based beverage called Hatfield’s Tasty Communication Best. The local mom-n-pop brewery that made Hatfield’s Tasty Best didn’t display a sign about their beverage because they feared that their long-time competition, McCoy’s Better Beverages would come by to see what they had, Specialty Project taste it and guess their secret ingredient. So all Tennis Court the people of the county drank Coca Cola, nevHow to Place Petromat er realizing they could have had a tall, frosty Carlson Adds to mug of Hatfield’s Tasty Best instead. Commercial Pulls In the asphalt paving and production industry, owners tend to hold company secrets close to the vest. They fear the competition learning how many tons they produced last month, how many square feet they sealed last year or how many lineal feet of cracks they filled last season. A wise website developer once told me not to work from a place of fear. She reminded me that Yoda taught us fear leads to the dark side. By fearing to market our asphalt product, we leave our product in the dark. By fearing to share our good news and successes, we leave our best selling tool—our good name— in the dark. Consider the fairy tale above: We all know that the makers of Coca Cola don’t hide their name, and they don’t lose in the beverage game. When was the last time someone called the editor of the local newspaper and bragged about failing at a goal? That sort of thing doesn’t happen too often. Instead, businesses clamor for coverage of the corporate golf outing or an award someone gave them. It’s not very often that news outlets will pick up press releases about something so mundane. When a member of the media wants to cover your big-project winning bid or the successful completion of a job that required green practices, you have to jump on that. It’s Marketing 101. Why would anyone in his right mind hide good news under a bushel barrel when sharing that good news could garner another job for profit next month or next week? If telling a government letting agency that you completed a bonus-worthy project in your county could assist you in getting on its list of go-to bidders for the future, then you should jump at the chance to tell your story. Late this summer, the AsphaltPro family launched a sister publication named PavingPro that gives residential, commercial and pavement maintenance contractors an outlet for sharing their success stories. I’d like to introduce its editor, Sarah Redohl to you. During her time as editor at previous publications, Redohl has led production teams to win more than a dozen awards in design, photography, storytelling and writing. Previously, she has worked on projects for the Travel Channel, NPR and the U.S. Department of State, among others, and has been recognized as one of Folio: Magazine’s 15 Under 30 young professionals driving media’s next-gen innovation. You can reach her at editor@ mypavingpro.com to share your good paving news. Now that producers and highway contractors have AsphaltPro, and the rest of the paving industry has PavingPro, there’s no excuse to hide your good news and the good name of asphalt. We have the alternative to Coke. Let’s use it to get good, positive marketing out there for you and the entire asphalt industry. Commercial

602 W. Morrison, Box 6a Fayette, MO 65248 (573) 823-6297 www.theasphaltpro.com Group publisher Chris Harrison chris@ theasphaltpro.com publisher Sally Shoemaker sally@theasphaltpro.com (573) 823-6297 editor Sandy Lender sandy@theasphaltpro.com (239) 272-8613 Art Director Kristin Branscom business manager Susan Campbell (660) 728-5007

AsphaltPro is published 10 times per year: January, February, March, April/May, June/July, August, September, October, November and December by Asphalt Pro, LLC, 602 W. Morrison, Box 6a, Fayette, MO 65248. Writers expressing views in AsphaltPro Magazine or on the AsphaltPro website are professionals with sound, professional advice. Views expressed herein are not necessarily the same as the views of AsphaltPro, thus producers/contractors are still encouraged to use best practices when implementing new advice. Subscription Policy: Individual subscriptions are available without charge in the United Sates, Canada and Mexico to qualified individuals. One year subscription to non-qualifying Individuals: United States $90, Canada and Mexico $125.00. For the international digital edition, visit theasphaltpro.com/subscribe-2. Single copies available $17 each.

•

Residential

•

Maintenance

WWW.MYPAVINGPRO.COM 1

Mypavingpro.com

Stay Safe,

Sandy Lender www.theasphaltpro.com 5

around the globe

Industry News and Happenings from Around the World Canada

The next pavement recycling conference is a shorter flight than the last one! Pack a bag for PPRA 2015 this Oct. 13 through 15 in Niagara Falls, Canada. Get all the details at ppralliance.org.

China

According to a number of Bitumart’s Petrosil News reports in August, China had been buying up bitumen from a variety of sources in the first half of this year. For example, in June 2015, “Japan exported most of its bitumen to China and Taiwan.” Thailand did the same: “Thailand exported most of its bitumen to different countries like China, Indonesia and Vietnam in June 2015.” That same month, Singapore exported 261,607 megatonnes of bitumen to the same three. Even with all that bitumen going into China, “China bitumen imports dipped down by 9% in June 2015 compared to previous months imports.”

India

The Asian Bitumen Conference does something new this year on its tenth anniversary (AsB 2015). The conference will be held in New Delhi, India, for the first time with the Minister of Petroleum & Natural Gas, Government of India, to deliver the inaugural address. Conference dates are Nov. 19 through 20, 2015. Get information at www.asian-bitumen.com.

Malaysia

ALL-Test Pro, LLC, of Old Saybrook, Connecticut, sponsors an electrical machinery diagnostics workshop in Kuala Lumpur, Malaysia, Oct. 19 through 23. Need something closer to home? The IACET-certified authorized provider offers the workshop again Nov. 16 through 20 at the Fairfield Inn & Suites Chicago River North. Visit www.alltestpro.com/ training for all the information.

United States

• Like us at https://www.facebook.com/AsphaltPro. Follow us on Twitter @AsphaltPro. • The International Slurry Surfacing Association (ISSA) and the AASHTO Materials Research Laboratory (AMRL) are set to launch a Lab Assessment Program (LAP) 6 October 2015

to begin initial lab assessments for slurry seal and micro surfacing design as the first step in a multi-faceted approach to improved credibility and validation of the two pavement preservation technologies.

California

If you’d like to comment on the 18-page Caltrans document “California Test T125” test method for the collection of highway materials samples for quality control, that comment period is open with Caltrans at this time. Visit the Division of Engineering Services page at www.dot.ca.gov.

Florida

Make plans to encourage the industry’s next generation at the 12th Annual NAPA Young Leaders Conference & Tour this Oct. 19 through 21 at the Waldorf Astoria in Orlando. Get information at the events tab at http://asphaltpavement.org.

Georgia

Takeuchi-US has announced it’s expanding the Pendergrass, Georgia, operations by building a new distribution facility on the existing campus. The new facility is scheduled for completion by the end of this year, and will bring new employment opportunities to the area. The new facility will increase the storage space by more than 40 percent.

Illinois

The 7th Shingle Recycling Forum takes place Oct. 29 through 30, 2015, at the Crowne Plaza Hotel just outside Chicago’s O’Hare airport.

Massachusetts

Brookfield Engineering of Middleboro, Massachusetts, offers its Practical Course on Viscosity Measurements to help viscometer users understand the functionality of the instrument and create repeatable viscosity test methods fur use in R&D and QC/QA environments. Visit www.brookfieldengineering.com/services/educational-programs for the schedule and registration.

Missouri

CPH Holdings, Fayette, Mo., has successfully launched Paving Pro magazine in the North American marketplace, a sister publication to Asphalt Pro. Contractors and agency planners active in commercial and residential asphalt paving, and pavement maintenance qualify for a free subscription at www.mypavingpro.com.

New Hampshire

Subsurface Contractors of St. Louis, Missouri, has selected the Maintain construction software from B2W Software of Portsmouth, New Hampshire, with future plans to adopt the company’s Dispatch, Estimate and Track solutions. Currently, B2W Maintain enables Subsurface Contractors to streamline its back-office processes for reporting, inventory tracking and field support, while gaining a competitive edge for bidding, according to the supplier.

Oregon

Register to attend the 2015 Asphalt Sustainability Conference West at the Marriott Portland Downtown Waterfront this Oct. 13 through 14. Find information at the events tab at http://asphaltpavement.org.

Virginia

The Asphalt Pavement Alliance, Williamsburg, Virginia, named Amy Miller, P.E., as its new national director. Miller is a professional engineer licensed in Florida and has an extensive background in pavement design and pavement type selection. As national director of the APA, she will be responsible for coordinating and leading education and field deployment efforts for the asphalt pavement industry.

Washington

Continuing its history of partnering with other technology providers, Dexter + Chaney of Seattle, Washington, reported Aug. 18 accelerated growth in the first half of 2015 following a significant equity investment in the company by Pamlico Capital, which was announced in January. The growth includes new product functionality, new technology partnerships and the launch of an upgraded company website at www.dexterchaney.com, according to the software solutions manufacturer.

INNOVATIVE SOLUTIONS & SUPPORT

BOOST YOUR SUCCESS

ROADTEC COLD PLANERS PROVIDE EASY OPERATION, VERSATILITY, AND INNOVATIVE FEATURES. ACE™ Grade and Slope Control system automates the elevation of your machine in the most precise and user friendly way possible. New graphic displays allow the crew to easily select, calibrate, and control sensors with minimal time and effort. Roadtec’s FXS® dust extraction system increases safety and operator comfort by pulling dust from the primary conveyor and ejecting the particles into a dump truck beside the secondary conveyor. Guardian™ Telematics allows owners and service technicians to remotely monitor machine activity and production in real time. Roadtec service technicians can make machine adjustments remotely, giving you quick and simple troubleshooting with immediate benefits.

BOOST YOUR SUCCESS TODAY VISIT ROADTEC.COM

1.800.272.7100

+1.423.265.0600

safety spotlight

Serve Time for Safety

n Aug. 11, 2015, notice from the U.S. Department of Labor explained why three Illinois construction companies face $1,939,000 in fines from the Occupational Safety and Health Administration. Here we discuss what happened and how members of the road construction industry can avoid not just the fines, but the actions that brought about the OSHA investigation and resulting fines. While the companies at fault are not members of the asphalt industry and the information is available as part of the public record, the purpose of this department is not to pass judgment on their business(es). The purpose is to educate; therefore, the names of the companies will be withheld. According to the notice, OSHA performed an investigation that found the three related construction companies had violated a number of OSHA health standards related to the dangers of asbestos when they “willfully” exposed at least eight workers to asbestos. The notice stated, “OSHA inspectors determined that [company] and supervisors… told employees to remove asbestos-containing materials during renovation of the former Okawville school….Many of the workers came to the U.S. to work for [the company] under the There’s a provisions of the H-2B visa protrend in gram that allows companies to higher fines hire foreign workers temporarily. and harsher The investigation also found the penalties for [company] management threatened some workers with terminaexecutives tion if they spoke with OSHA inwho deal spectors.” recklessly The day prior to the notice, with worker OSHA cited two of the three companies for 16 egregious, nine willsafety. ful and six serious violations, according to USDOL. “OSHA inspectors also found that [the companies] failed to warn employees, some of whom spoke only Spanish, of the danger—even though they were aware of the asbestos hazard. They also failed to ensure that workers used appropriate work methods and respirators, and to train them about the hazards of working around asbestos.” The notice stated that OSHA also cited the third company for one serious and two willful violations. “The willful violations were for not training the workers or informing them about the presence of asbestos-containing material. The serious violation was for failing to conduct inspections as required by law.” In its citations, OSHA has specific allegations against the companies that any employer can learn from. Here they are. • Provide basic personal protective equipment such as hard hats, eyewear and protective clothing. • Create a decontamination area for employees to remove work clothing before leaving the worksite. 8 October 2015

By Sandy Lender

• Use appropriate work methods to minimize asbestos exposure, such as removing tiles intact and using wet methods to keep asbestos fibers from becoming airborne. The example herein is from a building site, but asphalt contractors could have opportunity to come into contact with asbestos fibers when working with very old asphalt shingles. Luckily, that opportunity is low and getting lower by the day. Keep in mind that the Environmental Protection Agency classified asbestos as a known carcinogen in the late 1970s thus its use was banned. The website at www.mesothelioma.com discusses asbestos exposure in roofing materials specifically and states: “Asbestos was used in roofing products from the 1920s through the early ’80s.” A spokesperson for the Center for Environmental Innovation in Roofing said the chance of running into roofing shingles containing asbestos is now minimal. “At this point, the percentage [of tear-offs containing asbestos] is very low,” he said. “There may be some re-covered roofs with asbestos in the first layer, but that’s less and less likely each year. And it’s also important to know that the concerns for ‘encapsulated’ asbestos are not that big of an issue these days. Air-borne asbestos is the concern.” For asphalt producers and contractors, we’re encapsulating a carbon footprint as well. “What is impressive to me, is that after decades of protecting homes and businesses, asphalt shingles can and are finding even more decades of service in the construction of roads,” Greg Malarkey of the ARMA board said. “Asphalt shingles provide an impressive carbon sequestration opportunity for consumers as well as model for many other industries to emulate.” Even with a positive level of environmental sustainability, it’s up to the employer to ensure employees remain informed and safe at all jobsites. The editors at ConstructionDive.com pointed to a growing trend in harsher penalties for executives who deal recklessly with worker safety. For example, the State of California Department of Industrial Relations released a statement Aug. 3 with the results of the Cal/OSHA criminal investigation into the January 2012 death of a day laborer who had been buried alive in concrete. Santa Clara County Superior Court Judge William J. Monahan sentenced a company owner and a project manager to two years in prison for involuntary manslaughter. They received a prison sentence for a number of reasons, including, “When preventable deaths occur on the job, employers must be held accountable,” Cal/OSHA Chief Juliann Sum said. “Cal/OSHA worked closely with the Santa Clara District Attorney to ensure that criminal behavior in the workplace is addressed.” Under the Occupational Safety and Health Act of 1970, employers are responsible for providing safe and healthful workplaces for their employees. OSHA’s role is to ensure these conditions for America’s working men and women by setting and enforcing standards, and providing training, education and assistance. For more information, visit http://www.osha.gov.

mix it up

Rock on Your High Friction Surface Treatment

n July of this year, Michael Heitzman, PhD, PE, with the assistance of Pamela Turner and Mary Greer of the National Center for Asphalt Technology at Auburn University, Auburn, Alabama, released NCAT Report 15-04 to share the findings of a high friction surface treatment (HFST) study of alternative aggregates to calcined bauxite. The point of the study was to determine if there are good alternatives to calcined bauxite, which is a product that must be imported to the United States, for HFST. The alternative aggregates offered for study were granite, flint, basalt, silica sand, steel slag, emery and taconite. Researchers at NCAT used three studies—two lab-based and one field-based—to determine the longterm friction loss trend—also called the terminal friction—of the seven aggregates suggested for HFST. In essence, the study found all eight aggregates, which includes the original bauxite, maintained good macro-texture, but the measured friction for alternative HFST aggregates was not equal to bauxite. Let’s take a look at how the researchers came to these conclusions and what other facts they learned about the potential aggregates for HFST. First, the Federal Highway Administration Roadway Departure Safety Program includes guidance and tools to address crashes on wet pavement. Pavement friction is one component of the program and one of the tools in the design of pavement friction is HFST. The authors of NCAT Report 15-04 point out, HFST is an important application for critical safety locations such as bridge decks, horizontal curves and high speed deceleration ramps, which asphalt contractors pave on a regular basis. FHWA worked with American Association of State Highway and Transportation Officials and American Traffic Safety Services Association to develop a guide spec PP 79-14 Standard Practice for High Friction Surface Treatment for Asphalt and Concrete Pavements. This guide recognizes calcined bauxite aggregate for use in the HFST. The authors outlined where bauxite comes from, and that’s mainly China. 10 October 2015

According to the report: “Bauxite is mined in many countries, but the USA produces less than 1 percent of the product. The large majority of bauxite ore is used for the production of aluminum. Smaller amounts are used in chemical processes, industrial abrasives, and in the refractory industry. The suppliers of calcined bauxite for the refractory industry are the primary source for the calcined bauxite used for HFST. The amount used for HFST is a small fraction of the calcined bauxite produced for the refractory industry in the USA. In the USA, the majority of calcined bauxite is imported from China. The calcination cost, crushing requirements, and transportation cost make bauxite a more expensive product compared to other aggregates.” The series of studies discussed in “High Friction Surface Treatment Alternative Aggregates Study” divided the sets of aggregates and tests thus: “The scope of LAB-1 evaluated HFST test slabs with the bauxite and seven alternative aggregates under accelerated laboratory polishing and testing procedures. The scope of FIELD evaluated friction performance of HFST pavement test sections with the same eight aggregates under heavy truck loading in the west end super-elevated curve at the NCAT Pavement Test Track. LAB-2 evaluated the influence of particle size on HFST friction performance and examined other laboratory aggregate tests as a simpler approach to qualifying friction aggregates in HFST specifications.” The results of the three studies-withinthe-study were thus: LAB-1 showed that none of the seven alternative HFST aggregates provided friction comparable to bauxite based on the DFT [dynamic friction tester] measurements. Bauxite maintained a terminal friction value—DFT(40)—above 0.80; four aggregates—taconite, basalt, emery and flint—maintained values above 0.60, and two aggregates—silica sand and slag—measured terminal values at or below 0.50. All of the surfaces,

By AsphaltPro Staff

except slag, maintained surface macro-texture mean profile depth (MPD) values at or above 1.4 mm. Even though bauxite measured the highest DFT friction values, the bauxite surface texture was lower than most of the aggregates. All of the test surfaces had surface texture values much higher than MPD in the range of 0.30 to 0.50 mm for conventional dense graded asphalt mixtures. The data showed no correlation between the terminal friction and terminal surface texture. The first step of the FIELD analysis examined the changes in HFST friction and texture to establish terminal values. All of the sections, except for basalt, showed a 0.20 to 0.30 mm drop in MPD texture values after approximately one month of traffic, and in most cases texture continued to gradually decrease an additional 0.10 to 0.20 mm MPD through six months of traffic conditioning. The terminal texture values ranged from 1.10 to 1.50 mm MPD for all sections, except steel slag, which dropped below 0.90 mm. After one month of traffic, the wheel path DFT friction values for all of the HFST test sections had a general surface friction reduction of 0.15. The most probable explanation for the friction reduction within the first month is the traffic abrasion wearing down the sharp edges of the crushed faces of the aggregate particles. Most of the HFST test sections maintained their relative ranking of surface friction throughout the six-month conditioning period. The three sections conditioned for an additional 18 months showed no change in the ranking of friction performance. Locked-wheel skid trailer data for the three longer sections was only reliable for the extended 18 months. The trend lines generated by the skid trailer SN40R data sets showed bauxite friction dropped from 70 to 63, flint dropped from 54 to 43, and granite dropped from 54 to 40. The results clearly show the bauxite HFST

Click, click, boom. Youâ&#x20AC;&#x2122;re the smartest guy in the room. SaveMyRoad.com is the premier information hub for roadway planning and preservation. Here, youâ&#x20AC;&#x2122;ll find helpful information ranging from treatment options to preservation strategies that will put your projects in the fast lane.

Visit

SaveMyRoad.com

mix it up test section maintained higher friction levels over the 24 months of accelerated NCAT Pavement Test Track truck traffic conditioning.

tioning. Friction reduced after the first period of TWPD conditioning and did not change after additional conditioning. The terminal DFT(40) friction values for all four aggregates reacted similarly to the differences in particle size. There was marginal change in measured friction surfaces with No.12 and No.8 particles. Friction reduced for surfaces with either No.16 or No.6 particles. The evaluation of macro-texture and friction combined showed friction increased as macro-texture increased up to a MPD of 2.0 mm. Friction decreased on the conditioned slabs with MPD above 2.0 mm. For the second objective, the aggregates showed differences in Micro-Deval mass loss, but none of the aggregates reached a terminal mass loss. Mass loss results ranked bauxite as the best performer and taconite as the lowest performer. The rank order of the mass loss results agreed with the DFT(40) friction results,

LAB-2 had two objectives: (1) evaluate the influence of particle size and (2) examine other laboratory aggregate tests. … The surface macro-texture response from the particle size evaluation was consistent with LAB-1. The CTM [circular texture meter] measured some texture reduction after the first period of TWPD [three wheel polishing device] conditioning but no change after the second period of conditioning. As expected, the HFST surface macro-texture decreased as the size of the aggregate particles decreased. Surfaces with No.6 sieve particles measured 2.2 mm MPD and surfaces with No.16 sieve particles measured 1.1 mm. The friction response showed a similar trend during condi-

Table 1. Summary of Tests Performed During Study Material

Field ID

Sample ID

DFT

CTM

SKID

AIMS

LAB-1 Study Granite

W8 A

✔

Bauxite-1

W8 B

✔

Flint-1

W9 A

✔

Basalt

W9 B

✔

Silica

W9 C

✔

Slag-1

W9 D

✔

Emery

W9 E

✔

Taconite-1

W9 F

✔

FIELD Study Granite

W8 A

✔

Bauxite

W8 B

✔

Flint

W9 A

✔

Basalt

W9 B

✔

Silica

W9 C

✔

Slag

W9 D

✔

Emery

W9 E

✔

Taconite

W9 F

✔

Bauxite-2

✔

no test

✔

Flint-2

✔

no test

✔

Slag-2

✔

no test

✔

Taconite-2

✔

no test

✔

LAB-2 Study

DFT = dynamic friction tester CTM = circular texture meter

SKID = locked-wheel skid trailer data BP = British pendulum

AIMS = aggregate image measurement system

Three studies of aggregate types—LAB-1, FIELD and LAB-2—were conducted to determine if there are aggregates from U.S. sources that provide adequate friction performance as part of a HFST. Source: NCAT Report 15-04 12 October 2015

except flint aggregate ranked second for mass loss and fourth (last) for friction. The AIMS [aggregate image measurement system] measurements quantified the shape of all four aggregates in a narrow range of 6 to 8 on a scale of 0 to 20 and there was very little change in particle shape after Micro-Deval conditioning. Particle shape did not correlate to friction, so shape was not given further consideration. The AIMS angularity test results showed bauxite and taconite are very similar. The flint sample had a higher mean angularity and the slag aggregate had the highest angularity. The anticipated trend would be higher angularity achieves higher friction, but actual LAB-2 results show no correlation between particle angularity and DFT friction. Overall, the use of Micro-Deval and AIMS to condition and measure aggregate characteristics did not correlate to the aggregates’ friction measurements. As mentioned initially, all eight surfaces maintained good macro-texture, which the authors defined as predominantly MPD>1.0 mm. The series of three studies offered these additional conclusions, according to the report authors: • The eight surfaces measured terminal DFT(40) values in the range of 0.84 to 0.49 in LAB-1 and 0.79 to 0.43 in FIELD. • Terminal surface characteristics were achieved after early conditioning (less than one month for FIELD friction) both in the laboratory and in the field. The terminal texture and friction characteristics decreased very slowly during additional conditioning. • For each aggregate tested in LAB-2, the surface with MPD of 1.50 to 2.00 mm measured the highest DFT(40) friction. • There was no correlation between HFST surface friction and AIMS particle shape and angularity. • There is no correlation between HFST surface macro-texture and friction. • A DFT measures higher friction values than a locked-wheel skid trailer. Future studies could look into whether common friction aggregates with good micro-texture used in the United States could be combined with HFST pavement surfaces with high macro-texture to reduce crash rates comparable to HFST with bauxite.

Upcycle:

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

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

Ultradrum A.R.E. 50%

UltraRAP 70%

I t seems any plant these days can recycle, but have you ever asked about the quality of the mix produced? With higher RAP percentages comes the problems of degradation of the mix.

That’s why Gencor developed the innovative UltraRAP and MegaRAP concepts, which can process 70% and 100% recycle without superheating and degrading the quality of the mix. The result is a noticeably superior and consistent mix. So if you want superior high RAP capability, don’t just recycle ... Upcycle. Call Gencor today and learn how you can “Upcycle”. 407.290.6000 or visit www. gencor.com

MegaRAP 100%

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.

At the end of the day, our plants speak for themselves. But we certainly appreciate that our customers have so many good things to say. They’re the ones we listen to, and we think you should, too.

BEVILACQUA ASPHALT EX SERIES PLANT Uxbridge, MA

Commissioned: 2013

Production: 300 TPH

“I had an ADM plant in my former business and had tremendous success with it. I really saw no reason to look elsewhere. That’s why we went with the new EX plant. We knew we could depend on ADM’s engineering expertise to help make our project a success.” - Steve Bevilacqua President/Owner Bevilacqua Asphalt

Scan to read more about Bevilacqua’s experience.

VISIT WWW.ADMASPHALTPLANTS.COM

project management

Manage Your Bridge Resurface Project

By Del Williams

Manage for best traffic control. When the project’s timeline requires a gap between the bridge deck’s sealing and asphalt paving, some spray applied waterproofing systems allow an aggregate top coat as a temporary driving surface for up to two weeks.

t’s a fact that many bridges in America have outlived their intended service life. When waterproofing coatings fail, it leads to a significant corrosion of structural elements, including corroded rebar and crumbling concrete. New waterproofing alternatives have appeared on the market to help civil and structural engineers protect and maintain critical infrastructure ranging from rail, highway, and pedestrian bridges to tunnels, parking decks, airport terminals, and DOT entrance/exit ramps. Let’s take a look at how to apply one such waterproofing technique on your next bridge resurfacing project. “Spray applied waterproofing now accounts for over 50 percent of the membranes applied to our bridges,” Alexander Bardow, P.E., said. He’s the state bridge

16 October 2015

engineer for Massachusetts Department of Transportation, a member of AASHTO’s subcommittee on bridges and structures representing Massachusetts, and past president of Boston society of civil engineering section of ASCE. He oversees and helps to prioritize work on 5,000 bridges that receive federal funds for MassDOT. “What drove us to spray applied waterproofing is its enhanced durability, bonding to concrete, and crack-bridging ability,” Bardow said. He explained: “If cracks form due to deck deterioration or traffic loading, then water gets into those cracks and the concrete matrix. The [underlying] membrane must be pliable enough to accommodate these cracks without failing. “We expect spray applied waterproofing membranes to last about 30 to 50

years,” he added. “We would still repave and resurface the asphalt overlay, but would not need to do anything to maintain the underlying waterproof membrane during that time.” “Instead of traditionally sealing bridge decks every five years or so, they could be spray applied waterproofed with materials like BDM (Bridge Deck Membrane by Bridge Preservation) that can last five decades or more,” Traci Micucci said. She’s the president of Eastern Bridge Works, a waterproofing contractor based in Poughkeepsie, N.Y. “That would eliminate repeatedly tearing up the asphalt overlay, resealing the deck and repaving it, plus all the required lane closures. It would stop rebar corrosion and concrete spalling in decks to keep infrastructure safely operating.”

project management

The high-traffic Brooklyn Bridge received a waterproofing treatment with Bridge Deck Membrane (BDM).

ber of cold joints for a more durable final wear course. The aggregate top coat also enhances the bond between the membrane and asphalt, adding further longterm performance to the finished system. “With new spray applied waterproofing technology designed to reliably last decades without ongoing maintenance, civil and structural engineers have a valuable new tool that can help them cost-effectively maintain critical infrastructure while minimizing downtime,” Eastern Bridge Works’ Micucci said. Del Williams is a technical writer based in Torrance, California. For more information, contact Bridge Preservation at (913) 9123305 or visit www.bridgepreservation.com.

Sprays Get Tested This new category of spray-applied waterproofing is designed to provide a seamless crack-filling membrane that’s impervious to water, and it can be applied to highway surfaces as seen here.

For the project manager with a large job, the spray applied membrane can be sprayed by hand or machine. “By robot, we can consistently spray apply waterproof over 10,000 square feet of deck per day with BDM at 80 to 85 mils on any surface,” Ted Predki said. He’s the chief estimator and project manager at Pine Waterproofing and Sealant. “[The waterproofing] can set in 10 seconds so you can walk on it,” he said. In Orland Park, Illinois, Pine Waterproofing and Sealant installed nearly 7,000 square feet of spray applied waterproofing on the Metra Bridge over US45 (Structure No. 0166201), which was originally constructed in 1940 for the Wabash Railway Company. Pine Waterproofing recently completed a CDOT project in downtown Chicago 18 October 2015

that involved applying 65,000 square feet of spray applied waterproofing and then returning the road to service as soon as possible. The contractor installed more than 30,000 square feet of 80 mils BDM and 40 mils of top coat with aggregate within seven days, and completed the job within four weeks. Some spray applied waterproofing products can accept temporary traffic or asphalt overlays one hour after application. For highway bridge projects that involve complicated staging and traffic management, some spray applied waterproofing systems with an aggregate top coat can be used as a temporary driving surface for up to two weeks. This allows large areas of waterproofing to be applied prior to paving, and reduces the num-

Because crack-bridging is critical in ensuring long-term waterproofing protection, many owners require the ASTM C-1305 crack-bridging test for liquid-applied membranes. The test consists of applying the membrane system across two concrete blocks with matching faces. The test sample is then brought down to -15oF for 24 hours to stabilize it at this temperature. The testing requires the two blocks be pulled apart at a rate of 1/8-inch per hour to a maximum opening of 1/8 inch, and then closed to a zero gap at the same speed. The test fixture must maintain the sample at the -15oF temperature through the 10 cycles of testing required. (Some spray applied elastomer waterproofing systems have coefficients of linear thermal expansion similar to concrete and steel, the most common bridge building materials. This physical property is an important prerequisite to ensuring success when membranes are used as a composite with layers of asphalt.)

ASTEC

速

Knowledge to the

power

advanced customer schools J a n . 04-07, 2016 J a n . 11 -14, 2016 F e b . 01-04, 2016 F e b . 08-11, 2016 F e b . 15 -18, 2016 F e b . 22 -25, 2016

astecinc.com Registration Opens on October 1, 2015 Ph 423.867.3754 | Fax 423.867.9761 or email, sbradshaw@astecinc.com

keep it up

How to Use Water Absorbers

By Scott Grossbauer

When installing a combination of particulate and absorbent filters, the particulate filter goes first in the series. This allows the particulate filter to grab and hold dirt, giving the water absorber longer life and a better chance to do its job.

ree water is probably the single biggest cause of fuel system failure. Original equipment suppliers require that zero free water reach the high pressure common rail (HPCR) fuel system. Water absorbers are the only sure way to prevent free water from being dispensed into your equipment. Eliminating water will reduce rust, corrosion, wear, fuel degradation and other damage. It will also help prevent denied warranty claims. Regular/particulate filters and water absorbers do two distinct jobs; the first removes hard particulate from fluids while the second removes free water. The medias are different, each designed to optimize the specific job at hand. For example, a particulate filter made of synthetic fiber should have fibers of consistent size and shape to allow for specific pore size control and the maximum amount of contaminant-catching surface are. The result maximizes both filter efficiency and dirtholding capacity. Water absorbers use polymer technology with a high affinity for water absorption. This media is designed to remove free water from petroleum-based fluids. Unlike coalescing media, absorbent media isnâ&#x20AC;&#x2122;t disabled by the surfactant in ultra-low-sulfur diesel (ULSD). 20 October 2015

The DBB0248 water absorber may be installed in combination with particulate filter(s). It fits all Clean Solutions heads and manifolds. It is also included in the X011449 Clean & Dry filter kit. When plumbing the absorbers together with particulate filters, you connect them in series. The fluid should flow first through the particulate filter to clean it, and through the water absorber second to remove free water. The absorber is installed in the secondary position because the particulate filter is much better at catching and holding dirt. Dirt will not reach the absorber; therefore, it will last much longer. In addition, this enables the differential pressure gauge on the absorber to work as a diagnostic tool alerting when there is a water problem in the tank so you can take appropriate measures. If the absorber were plumbed first, it would load with dirt and water, plugging faster and losing its diagnostic capability. Scott Grossbauer is the global director for Donaldson Company, Inc., of Minneapolis, Minnesota, clean fuel & lubricant solutions division.

Medias at 100x under SEM

Particulate Media

Absorbent Media

速

Maintain Control By AsphaltPro Staff

22 October 2015

The entire plant team must work together with the proper tools; that will make all the difference in producing quality mix. Photo courtesy of Systems Equipment.

earning to use blending and loadout controls at the asphalt plant is only one portion of today’s plant operator’s job. AsphaltPro asked a number of controls and plant OEMs to share specifically how the plant operator or ground personnel can participate in the routine maintenance of controls to keep unplanned downtime at bay. Here are some suggestions for your operation, in alphabetical order by responding company. Dennis Hunt Gencor Industries How an operator troubleshoots controls varies greatly depending on the company he works for, their safety policies. In some cases he can’t even open the cabinet to look at the controls; the work must be done by an electrician. If he suspects it is an electrical problem, an electrician is called in. If he suspects a mechanical problem, several other types of specialist could be called in until the problem is identified and enough people are on site to solve all aspects of the problem. Some controls systems…will detect a component failure for the operator and pop up a help screen with troubleshooting instructions to guide the operator to the problem resolution step by step. Other systems may simply post an error message and the operator must determine the cause and resolve it on his own. And finally, some systems only sound an alarm and maybe blink a light to indicate the area of concern. A good maintenance program can prevent many issues from occurring. Electrically, each wire termination point should be tightened at least once a year. Loose wiring is a frequent cause of intermittent failures which can be difficult to identify. Safety systems should be checked on a regular basis. Lubrication and cleaning of the equipment is also critical. A good operator will learn the sound of a properly operating plant and is attune to any changes to that sound or noises that are not typical. These can be early indications of a maintenance need before a shutdown occurs and save thousands of dollars in repair cost and lost production.

Caretaking of the controls themselves, like any other computer based system, requires typical IT skills to make sure the system stays virus free, that hard drives are working properly and not getting cluttered, that the computer is staying cool and that the computer itself is free of accumulated dust on its components. Windows security updates and proper firewall management is important to combat the ever increasing threat of malware attacks. If a system does not need to be connected to the internet 24/7, disconnect it for absolute guarantee that a virus will not penetrate through that connection; only reconnect it when needed. Hard drive utilities are built into the operating system for maintaining the hard drive. Check the temperature of the computer cabinet and clean air filters like you would for your home AC system. Canned air can be purchased for blowing dust off of the motherboard and other electronic components. Dust on a circuit board traps heat in the electronics and can also short out sensitive circuits causing premature failure.

“Each wire termination point should be tightened at least once a year. Loose wiring is a frequent cause of intermittent failures which can be difficult to identify.”—Dennis Hunt Ken Cardy Libra Systems, Inc. Plant control automation is the heartbeat of an asphalt plant and is interfaced to the various plant devices, including solenoids, motors, limit switches, valves, tachometers, load cells and thermocouples. When these devices fail, or are prevented from performing their intended function, the symptoms of the problem are typically first noticed at the automation. A modern automation system will include input/output (I/O) diagnostic screens help to pinpoint the problem area, or assistance can be provided from the automation manufacturer. Plant automation is only as accurate as the sensors that

www.theasphaltpro.com 23

are sending the required information, so it is very important that all of these devices and the interconnecting wire are maintained in good working order. When troubleshooting electrical problems, it is very helpful for the operator to have access to a multi-meter, which measures current, voltage and resistance. Current clamps also allow electric current to be measured without having to make physical contact or disconnect the conductor.

“Electrical wiring should be clean, orderly and easily traceable. All wires should be labeled. Wiring diagrams should be current and maintained in a secure location.”—Ken Cardy It is important to control the environment by keeping dust around the computers and electronics at a minimum. Temperature and air quality can prolong the life of most automation components. With this in mind, it is a good idea to blow out the PC and printer once or twice a year to prevent dust from blocking sensors and or burning out fans. Electrical wiring should be clean, orderly and easily traceable. All wires should be labeled. Wiring diagrams should be current and maintained in a secure location. The power source supplying power to parts of the automation should be protected from power fluctuations such as brown outs or surges. This is best accomplished in many applications by connecting the proper equipment to an online uninterruptible power supply (UPS). This not only protects from voltage interruptions but also isolates this equipment, making it less vulnerable to damage when power interruptions or surges occur. It is important that solenoid valves are maintained and function properly for the accuracy of the plant automation when weighing materials during batch plant and silo loadout operations. Weighbridges on a continuous mix asphalt plant must be checked regularly for accuracy. This includes string lining the belt, weighing idler checks for correct positioning of the idlers and visual checks for any materials that may be stuck in the weigh bridge, which can affect accurate weighing of the material being measured by the automation. 24 October 2015

Keeping controls and the wiring for them clean and organized is the first step toward maintaining control. Photo courtesy of Stansteel.

Thermocouples that measure temperature should be calibrated and checked for accuracy periodically. David L. Enyart SYSTEMS Equipment Corp. Every year I work with many customers to update their controls to the latest PC/Windows/touch screen equipment now available. The goal of this automation in addition to making a quality product, is to give the plant team a greatly enhanced view of the complete process, such as annunciating possible problems before they become serious, comparing expected results with actual results with settable ranges of acceptable tolerances, reminding the operator when a production change is made of any additional settings that could possibly affect the product quality….This being said, we often find that once it’s installed, the plant team who ran the plant with the old controls does not embrace the enhanced features now available to them. If no new approach to plant troubleshooting or plant maintenance is implemented the overall effect will be no improvement in results. New automation will not repair failed equipment, correct a bad mix design, or remove the plant team’s responsibility to maintain the plant effectively. New automation will provide the plant team with top

notch tools to assist in maintaining a quality plant, a quality process and a quality product when utilized to their fullest. The plant team needs to understand their controls, trust their controls and act on the information provided by their controls…. As a team, a continuous improvement approach to plant quality will result in less down time, lower costs and higher quality.

“The plant team needs to understand their controls, trust their controls and act on the information provided by their controls….As a team, a continuous improvement approach to plant quality will result in less down time, lower costs and higher quality.”—David L. Enyart As the equipment manufacturer, it is our ongoing responsibility to assist the plant team. Supporting them with a continuous improvement approach to their job with ongoing product support and training when it is needed most. Working through the issues with the team and empowering them with the knowledge required to face future issues on their own. We know that the plant operator and the entire plant team, when working together, with the proper tools, will always make the difference.

YOUR PARTNER CWMF IS AN EXTREMELY SUPPORTIVE SUPPLIER THAT HAS NO PROBLEM STANDING BEHIND THE PRODUCTS THEY SELL. REITH-RILEY HAS EXPERIENCED RAPID RESPONSE TIME, CONSTANT COMMUNICATION AND CONTINUOUS PRODUCT SUPPORT AND THAT HAS MADE CWMF ONE OF OUR KEY PARTNERS. AL CAGGIANO Equipment Manager Reith-Riley Construction Co.

CWMFasphalt.com | 877.457.3938

YOUR PARTNER IN TOTAL PLANT PERFORMANCE

Testing foam ratios, the sample can is filled and allowed to set. The steam gas dissipates through a process called half life. Full life measurement and foaming ratio is then established. The samples here have a foaming ratio of 5.5:1 and a half life of 2 minutes. Photos courtesy of Stansteel.

Here’s Why WMA Works Check out multiple process options for warm-mix from dynamic foaming, chemical addition to onsite liquid mixing, blending By Rick Rees

here are many ways to reduce the temperatures in asphalt these days. Chemicals can be added to the liquid asphalt at the terminal that will require a dedicated storage tank or blend inline at the asphalt plant. Water foaming is another way that uses devices that can be added to liquid asphalt piping prior to the plant’s mixing zone. Water foaming has an initial start-up cost considered relatively inexpensive to operate and maintain when compared to the chemical-process cost. In this case, water is metered into a liquid asphalt line and introduced into a metered flow of liquid asphalt that is stored at the recommended storage and operating temperature. When water comes into contact with the liquid asphalt, it immediately expands as it becomes steam gas. The expanding steam gas and liquid asphalt are then processed through some type of device to agitate the two materials. The agitating process produces steam gas micro-bubbles and the liquid asphalt is expanded and car26 October 2015

ried into the plant’s mixing zone. Accurately produced foam should last throughout most of the mixing cycle. Liquid asphalts each have their own chemical footprints. When foaming there will be differences in the reaction of each grade. For example a PG64-22 will foam differently than a PG70-22 or PG76-22 or ground tire rubber asphalt designs. Each of the PG grades uses different amounts of polymer and have different viscosities that affect how they react to water percentage and the process used to manufacture the foam. The foaming ratio and half life can be negatively affected if not produced with adequate mixing equipment. To produce warm-mix asphalt, the temperature of the aggregate needs to be reduced to establish desired asphalt mix temperatures. The reduced aggregate temperatures do not mix well with the liquid asphalt in its natural state. The foaming process expands the liquid asphalt causing a temporary viscosity change in

the liquid asphalt. As the foamed liquid asphalt is introduced into the reduced temperature aggregates the viscosity change allows the liquid to coat the aggregate and dust more efficiently. The better the foam, the better the mix. The foaming ratio as explained above demonstrates the viscosity change while the half life determines if your expanded liquid asphalt is entering the mixing zone at its optimum expanded state. Once the foamed liquid asphalt is mixed with the aggregate, the steam gas is flashed off in the gas stream and the liquid asphalt returns to its natural state. Foamed asphalt, if produced correctly, has many benefits for the asphalt contractor. Reducing asphalt mix temperatures below 290oF—and sometimes much lower—helps minimize blue smoke emissions from the plant, silo loadout, trucks transporting mix to the job, and laydown and compaction operations. Silo system drag slat amperage is typically reduced and silo storage time is increased by minimizing the downward migration of liquid asphalt in the asphalt stored in silo systems. Reduction in burner output reduces fuel consumption (and cost), stack emissions and temperature impact throughout the plant. Asphalt mix transportation time is extended and asphalt mix is able to be used many hours after hot mix would need to be rejected from paving operations. Roller patterns are typically reduced as densities are easily achieved. Most contractors that have adapted to

the foaming process use foamed liquid asphalt in both warm-mix and hot-mix applications coating aggregates more efficiently and securing return on investment throughout their asphalt operations. Rick Rees is the technical director of technology and applications at Stansteel.

Foamed Properties

Define What it Does Expansion Ratio: the measurement of the viscosity of the foam; determines how the liquid asphalt will disperse into the mix; it is calculated as the ratio of maximum expansion volume compared to the asphalt’s original volume. Half Life: a measurement of the foam’s stability; provides an indication of the rate of collapse of the foam; it is calculated in the time it takes in seconds for the foam to collapse to half of its maximum expanded volume (Note: the higher percent of water used the higher the expansion ratio, but half life is reduced)

Graphic courtesy of Stansteel.

Asphalt Shingle Grinding Service, LLC

It’s More Than Fine...

Recycled Asphalt Shingles (RAS/RAP) Production Sales

It’s Just Right!

Manufacturers Waste Tear-Offs Nationwide Mobile Grinding Asphalt & Concrete Crushing

877-679-5708 ShingleGrinding.com

AN ASTEC INDUSTRIES COMPANY

Regional Sales Manager-Construction

(Southwest/Midwest Territory) (Kentucky, Tennessee, Arkansas, Missouri, Louisiana, Texas and Oklahoma) Heatec is looking for that special someone who is driven and determined to be successful in the area of sales. This individual must be technically savvy and commercially inclined with strong interpersonal skills and able to communicate well with customers’ decision makers. Position Summary: Responsible for implementing and supporting sales strategies to gain market share in defined and new accounts within a geographic sales territory while meeting or exceeding annual revenue targets. Contact new and existing customers on a regular basis.

Essential Duties and Responsibilities • Identifies and assesses sales opportunities with specific accounts and territories. • Prospects for and develops new accounts. Preferred Education/Experience • Must have college degree or equivalent marketing experience. • Understanding of heat transfer and the asphalt industry desirable. • Computer knowledge of Microsoft suite of products such as, Word, Excel, Power Point and Outlook required. • Three year experience in sales of capital equipment and services a plus.

To view and apply for positions currently available go to:

WWW.HEATEC.COM

Company in business since 1977 HEATEC, Inc. is a Drug Free Workplace and An Equal Opportunity Employer.

www.theasphaltpro.com 27

Make U.S. Mats Better Hereâ&#x20AC;&#x2122;s how intelligent compaction can and cannot do the job for you By Sandy Lender

28 October 2015

From paving automation to intelligent compation, the technologies developed to assist with quality control only work when the members of the crew have the desire and knowledge to use them. Incentivize your crew members to learn and grow in their careers. Photo courtesy of Roadtec, Chattanooga.

Author’s Note: Many articles discussing intelligent compaction systems have taken up page-space in trade publications during the past few years. This article will delve into exactly how the systems can help your roller operator achieve desired density.

et me begin this discussion of intelligent compaction (IC) by reminding contractors we have an article about training in this edition of AsphaltPro because a quality mat comes down to the capabilities of the crew. If the members of the crew are complacent in the use of technology designed to assist in achieving compaction and in the upkeep of the equipment, then the project is probably doomed. But if the members of the crew are invested in the company’s positive future, the end product for the end user has a greater chance for long-lasting success. First, remember that not all IC systems communicate with the roller operator in the same manner. Obviously, there will be a learning curve no matter which system your crew uses. The first thing you have to teach the roller operator is what the IC system will do and what it won’t do toward achieving compaction of the asphalt mat. Chris Connolly is the director, national accounts and dealer development for Roadtec, Inc., of Chattanooga. While the company doesn’t manufacture rollers, Connolly began working in earnest with the Federal Highway Administration on the IC concept in 1998 when in the employ of a compaction equipment company. His considerable experience with asphalt rolling patterns and practices brought some truths to light for this discussion.

www.theasphaltpro.com 29

The accelerometer measures the stroke of the drum, counting each time the eccentric shaft within the drum turns. It then provides that information to a processor, which does the math.

“The optimum time for compaction is when you have the optimum temperature,” Connolly reminded readers. “With asphalt compaction, you’re looking for particle re-arrangement. Gravity then pulls it all into place.” That re-arrangement takes place when the material is at its best temperature and viscosity.

Target Density

Optimally, the mat immediately behind the screed would have 88 percent of the density a project requires, Connolly shared. This goes back to our original thought; aptitude and attitude are vital to success. The paver operator and his use of automation play a role in achieving a high percentage of density prior to the breakdown roller’s first pass. If the contract for a project requires 94 percent density, then the compaction train needs only to achieve that last 6 percent. “If you get 88 percent off the screed, you need to get 6 percent air voids out,” Connolly said. “The biggest bite of that 6 percent is coming out during breakdown rolling.” Before we show how to get that last 6 percent, let’s talk about the first 88. It might be a lofty goal to hit with the vibratory screeds of North American paving. When the mantra is “more 30 October 2015

tons” and foremen race the paver to keep up with a line of haul trucks out of the plant, the heavy or tamping bar screeds of Europe won’t work out on a large scale here. The United States encompasses a large geographic area; our contractors don’t have oodles of time for meticulous paving along a 2-mile stretch of road when another 22-mile stretch is waiting. Brodie Hutchins, vice president of dealer development of Wirtgen America, Antioch, Tennessee, shared that we could do better than 88 percent if we used the right equipment. “It is very common to get 90 percent plus density behind the screed with the tamping/ pressure bar screed designs,” Hutchins said. “North America is one of the few places in the world that uses the rollers for the breakdown process, primarily because we use vibratory-only screeds.” Tim Kowalski, Hamm applications support manager at Wirtgen America, agreed that in the United States, equipment choices are based on more tons. “The tamping bar, pressure bar screeds that we have can get over 96 percent density,” Kowalski said. “The reason we have a hard time selling them in the U.S. is because you cannot pave as fast with them as the regular vibratory screeds and achieve that kind of density. Here in the U.S. it is about production. How many tons can we get out in a day?”

The Endless Summer

Low paving temperatures mean hot savings. Evotherm warm mix asphalt technology allows paving at temperatures up to 90Â°F lower than traditional hot mix, turning your paving season into the endless summer. No other warm mix lets you start paving sooner or keeps your season going longer. Evotherm achieves excellent compaction all summer and lets you keep paving when things cool down. Drop in on the proven technology of Evothermâ&#x20AC;&#x201D;and catch the wave to an awesome bottom line. Dude.

www.evotherm.com

IC can help prevent the roller operator’s over-compaction of the mat by sending a message to him. What happens is this: An accelerometer sends information to a processor, which sends information to the operator station. The operator then needs to respond and work according to what he or she sees.

The accelerometer of the Intelligent Compaction with Density Direct™ from Volvo provides feedback on the amount of compaction energy that is absorbed or repelled by the asphalt mat. The processor uses that information to develop a readout for the operator, showing him or her when to roll additional passes or when to stop rolling an area.

Kowalski shared what we can do with the status quo. “Most of the time, the compaction behind the screed is more in the upper 70 to low 80 percent compaction range. That being said, if we can be more consistent with our roller passes and stay within a certain temperature range, we would have much more consistent densities across the mat. With more consistent densities comes smoother rides, longer lasting roads, fewer roller passes, which saves in fuel, and more bonus money for the contractor.”

Break it Down

Behind the screed, the breakdown roller of the North American market is the workhorse for getting density. It’s the machine that gets the IC system. Mark Eckert, the compaction product manager for Volvo Construction Equipment, shared: “Using an IC roller for breakdown makes the most sense. The breakdown roller will achieve more significant air void content reduction because of lower mix viscosity and higher material temperatures.” While the discussion so far has focused on getting full compaction—achieving a set percent density—Bert Erdmann, product manager of heavy compaction for BOMAG Americas, Inc., reminded contractors that roller operators don’t want to go too far. “IC is a tool to help contractors deliver more accurate results for their customer. It helps to prevent under-compaction and over-compaction. However, the vast majority of asphalt contractors in North America do not require the level of documentation, vectoring drums, GPS, expense and increased level of operator training required by advanced IC systems.” Erdmann suggested that “entry level” IC systems can help newer operators or those with less training to obtain density and move on to another section of the mat. “This can save companies money and fuel by preventing unnecessary passes, and it saves money by preventing over compaction.” 32 October 2015

This is a common denominator in IC systems. Systems also tend to include a temperature sensor—or two—that points at the mat to read and send the mat surface temperature to the processor as well. For those systems, the temperature may be factored into the information sent on to the operator station, even though the reading does not indicate the interior mat temperature where air void reduction takes place. Everyone knows how a temperature sensor works. In simple terms, it’s a thermometer with range. Let’s look at the accelerometer. This device is typically the size of a box of kitchen matches and is typically placed on the interior frame of the roller’s drum. Connolly explained its function. “The accelerometer measures the stroke of the drum, counting each time the eccentric shaft within the drum turns. It then provides that information to a processor, which does the math.” The BOMAG Economizer has the accelerometer located in the drum frame area, according to Erdmann. He said it measures the asphalt stiffness. “As the roller makes its series of passes, the material stiffness increases, and a higher number of LED indicator lights illuminate on the operator control panel display. When the number of lights stops increasing, the optimum level of compaction has been achieved. If the 10 yellow LED indicator lights and the red LED light illuminates, this indicates over-compaction, and provides the operator with immediate feedback to stop compacting this area to prevent over compaction.” The Economizer offers a mat thermometer that is located in the center articulating joint area of the machine.

“North America used tamping screeds many years ago but moved away from them during the 1950s when it became more important to increase the quantity of the material being paved. Contractors could build more roads faster by increasing paving speeds from 20 to 30 feet per minute to more than 100 feet per minute. Now that most of the infrastructure is in place and most of the paving is overlay of surface, the tonnage is decreasing and rideability is becoming more important than tonnage. Paving incentives also indicate this.”—Brodie Hutchins, Wirtgen America For the Cat® Compaction Control with Compaction Meter Value (CMV), the accelerometer is mounted to the front drum. Bryan Downing, global sales and support consultant for Caterpillar Paving Products, Peoria, Illinois, provided written commentary of how the system works. “A simple way to explain what is happening is that the accelerator [sic] measures the ground response to being struck by the vibrating drum. This response is weighed against the degree to which the drum is rebounding from the resistance of the surface material and given a ‘dimensionless’ value, which can be regarded as an indication

The BW138-AD with Economizer from BOMAG Americas lights up from 1 to 10 when the roller operator is working on density.

of the level of stiffness of the material. The reason we say that it is dimensionless is that the value is a result of the variables and factors present at the time of measurement and cannot be correlated to any other set of measurements or scales. In other

words, the value is relevant to the particular place and factors it measured, and is not relevant elsewhere. “It is important to understand that this measurement is a composite measurement; an ‘average’ of the entire volume of material extending to the depth of compaction influence of the compactor, perhaps as deep as a meter and a half. This will include not only the asphalt layers, but potentially much of the base as well—all represented as a single value. It is not simply measuring the asphalt layer.” Cat Compaction Control with temperature measurement includes two, infrared, air-purged sensors—front and rear. “Depending on the direction of travel,” Downing provided, “the lead sensor measures the surface layer temperature.” The accelerometer for the Hamm Compaction Quality (HCQ) system from Hamm/Wirtgen America is mounted on the left of the roller’s front drum, in the center of the drive motor and inside the rubber buffers. “This is to not get a false reading of stiffness if it gets dampened by the buffers,” Kowalski said. “The accelerometer measures the reaction of the drum to the material it is compacting. A softer material will mean a slower reaction. A stiffer material with mean a faster reaction and a higher number. This does not mean density.” Hamm offers a temperature sensor for the front and rear of its asphalt rollers. “This is to give you the hottest reading of the asphalt in the direction you are creating compaction,” Kowalski said.

Eckert shared the Intelligent Compaction with Density DirectTM from Volvo has the accelerometer mounted on the rear drum of the double-drum vibratory compactor. His colleague, Fares Beainy, research engineer in emerging technologies for Volvo, explained how it works for their system: “The accelerometer is providing the vertical acceleration of the roller drum from which the magnitude of the frequency spectrum at a periodic interval is calculated. In simpler text, the accelerometer is providing feedback on the amount of compaction energy that is absorbed or repelled by the asphalt mat.”

“The value is relevant to the particular place and factors it measured, and is not relevant elsewhere.”—Bryan Downing, Caterpillar Paving Products The Density Direct has two temperature sensors—front and rear. Eckert explained: “Mat surface temperature is monitored based on the travel direction of the machine.” With IC systems providing a reading based on mat stiffness to the operator, what happens when the mat cools to the point no more density can be achieved? Connolly explained that the accelerometer will still read the stiffness, giving the operator the idea that adequate compaction has been met, whether it has been met or not. “The accelerometer will stop giving reliable information when the particles can no longer move. It all comes back to tem-

perature and getting on the mat when the mix is malleable and viscous, when you can move the particles.”

Teach Them Well

That brings us full circle: train your personnel. A well-trained roller operator who understands the concepts behind time and temperature is the first step toward successful use of the IC systems available to contractors. Then the tools of technology become a true force to be reckoned with. They provide real-time feedback that the savvy operator puts into play. Cat’s Downing agreed that IC systems can function well “as a process control tool. These systems provide information to the operator in real time that they would not ordinarily have. This information allows them visualize and react to data in process, resulting in efficiency and uniform work. Operators are able to execute complete coverage and limit over-compaction while performing the work at the proper temperature range.” Hamm’s Kowalski shared that the systems also provide backup. “Another thing is now you have a permanent record of what was done on the road that you can always go back to if there are any problems.” With proper training and care, the roller operator can put the IC technology available today into practice for outstanding results. Preventing over-compaction while building up target density numbers gets a helping hand from the system on the breakdown roller, where North American compaction has time and temperature on its side.

Dillman builds tough equipment. Equipment that performs reliably for years. Equipment you can count on to produce high quality asphalt mix. Full plants. Single components. Individual parts.

Dillman gets the job done

Choose the training venue for your crew A By asphaltpro Staff

sphalt Producers make significant investments every year in the most durable and efficient equipment to run their operations. However, owning the equipment is only part of running your plant and paving operation safely and profitably. Having a properly trained crew to operate and maintain this equipment is just as important. Training is an investment in the one asset that can have the most impact on your success— your employees. There are many training options and venues and, as an owner or manager, choosing the most effective and efficient method can lead to the best outcome for your employee, and ultimately your operation’s success.

Trade Shows – Collaborate with Industry Experts and Colleagues One of the most popular and well-attended training venues is trade shows such as the World of Asphalt. The 2016 World of Asphalt will be held on March 22 through 24 in Nashville, Tennessee. Attendees to the show can purchase training from some of the industry’s leading experts in a wide range of topic areas.

The World of Asphalt, and other industry trade shows also offer a chance to collaborate with industry colleagues in between sessions and see the newest equipment by spending some time walking through the exhibit hall. www.worldofasphalt.com/Education/

one-on-one interaction with Astec field service technicians, engineers who design the plants, sales, parts and manufacturing. During the schools, attendees have the opportunity to tour the manufacturing facility and see first-hand how the equipment is made.

Manufacturers - Straight to the Source

Associations

What better way to learn than to send your key people to the source? Most plant manufacturers are happy to lend their expertise to help you use their equipment more efficiently. Companies like Astec, Inc. offer annual training schools to keep equipment operators up-to-speed on the latest technology. Astec, Inc. offers annual Advanced Customer Schools that give attendees direct,

Notable state meetings where you might see The AsphaltPro magazine staff: Indiana Asphalt Pavement Association—www.asphaltindiana.org Rocky Mountain Asphalt Conference and Equipment Show—www.co-asphalt.com

36 October 2015

One of the best ways to invest in training and stay in touch with what is happening in your state, or nationally, is to get involved with an association. These associations offer a vital connection to your industry by offering online training, white papers, and best practices protocols. Typically these associations collaborate at annual meetings that include training programs from industry experts. Some some states offer equipment exhibits that provide your crew a chance to kick the tires. State association meetings are a great way to send your crew to valuable training without blowing your entire training budget.

Check Out Fracking Opportunities Integrating frac sand processing introduces another revenue stream in the asphalt producerâ&#x20AC;&#x2122;s business By Holly Bellmund

38 October 2015

or hydraulic fracturing, fluids and proppants are forced under pressure down a hole to stimulate the source rock to release oil and gas. This has been a widely adopted commercial practice since the 1980s with explosive growth beginning in 2010 when horizontal drilling was combined with hydraulic fracturing to produce oil and gas from the U.S. shale plays. The rise in hydraulic fracturing has driven the demand for frac sand, a natural proppant, from 41 million tons in 2013 to about 54 million tons in 2014. The top five producers in the United States—Unimin, U.S. Silica, Fairmount Santrol, Hi-Crush Proppants and Preferred Sands—produced 55 percent of the frac sand for the industry in 2014. Asphalt producers can give themselves another revenue source by entering the frac sand supply chain, serving as a processing plant to wash, dry, screen and then blend the sand before providing it to the horizontal drilling www.theasphaltpro.com 39

Figure 1. Frac Sand Mining and Production

Frac sand is sourced from sandstone or loose sand grains. Material is mined and transported to a processing plant where sandstone may be crushed to further break down the sandstone into individual grains. The sand grains are washed and screened to remove clays and silts. Moisture is reduced by allowing stockpiled sand to drain or is removed mechanically by compression, vacuuming or blowing air on the sand. The sand grains are dried using either fluid bed or rotary drum dryers. Fluid bed dryers use forced air to move the grains across a heated plate; rotary drum dryers tumble the grains while the grains pass through heated air. Whichever dryer type is used, dried sand grains are less than 1 percent water by weight. Dried sand grains are separated into sizes using rotating or shaking mesh screens. The sized sand is then blended to conform to product specs and is then stored in final product silos for shipping. ÂŠ2015 Proppant Today, LLC

company/hydraulic fracturing company. There are aspects of preparing frac sand and supplying it that will be familiar to asphalt producers. Frac sand is subject to quality test protocols recognized by the American Petroleum Institute and the International Organization for Standardization. Particle distribution, grain roundness and sphericity, turbidity, specific gravity, acid solubility, and crush resistance are tested for suitability to withstand temperature and pressure downhole. Frac sand is sold in graded sizes, much like aggregates. The sand grains are sieved on woven wire mesh screens and blended to meet specs. Products are named by their size relative to the top and bottom mesh numbers, which relates to maximum and minimum grain diameter. Standard product sizes, from coarsest to finest, include 20/40, 30/50, 40/70 and 50/140 also known as â&#x20AC;&#x153;100 mesh.â&#x20AC;? One of the differences producers will notice between frac sand and asphalt is that the application for frac sand is in the oil field, most often a distance of 500 miles 40 October 2015

Heyl & Patterson, Carnegie, Pennsylvania, manufactures rotary dryers to provide versatility in processing a range of bulk materials. Rotary dryers are forgiving regarding feed material properties such as moisture content and particle size. Photo courtesy Heyl & Patterson.

This fluid bed dryer manufactured by Heyl & Patterson processes sand for the mining industry. The dryer has no moving parts, and the fluidizing action provides a high rate of heat transfer while handling the sand gently. Photo courtesy Heyl & Patterson.

or more from the production site. As a distribution strategy, leading frac sand producers develop a network of frac sand storage terminals. For example, Fairmount Santrolâ&#x20AC;&#x2122;s distribution network includes approximately 50 terminals, a fleet of more than 8,500 railcars with the ability to deliver to each of the major basins. Just as it is in asphalt, plants that are closest to the job site have an advantage. Most frac sand originates from the upper Midwest states and is delivered to Texas, Pennsylvania, North Dakota, and Colorado mainly by rail, but also by truck or barge. In July 2015, Unimin set a record for shipping frac sand by loading and sending a 140-car train to Elmendorf, Texas, according to a July 6 Unimin Energy press release.

Market Moves

Frac sand comprises 92 percent of proppant used with a total market size of about 54 million tons of frac sand sold in 2014. As of the oil pricing environment at press time, frac sand sales volumes were expected to decline by about 15 percent in 2015. Beginning in 2016 and through 2020, market growth is expected to resume as the amount of oil and gas to supply domestic energy increases. Despite the slump in oil prices at press time, each of the top five frac sand producers had indicated plans to grow in 2015. Given expected demand for proppant, opportunities exist for new entrants. Frac sand requires drying material and moving material, which are core strengths for asphalt producers. On the sales side, asphalt and frac sand customers have little in common. Asphalt producers may want to investigate the potential of partnering with sand miners to dry sand as a way of new market entry. Holly Bellmund is the president of Proppant Today, LLC, a research, media and consulting firm. For more information, contact her at hbellmund@proppanttoday.com or visit www. ProppantToday.com. www.theasphaltpro.com 41

Meet the State Exec:

Mel A. Monk

• Personal recruitment of prospective members and detailing the benefits of association membership; stressing that there is strength in numbers in speaking with one voice on technical issues and funding issues Do you have a degree related to the industry? Yes, Bachelor of Civil Engineering from Auburn University. I got an early introduction to the asphalt industry during college. I was able to work two summers for an asphalt contractor— Couch, Inc.—in their lab, and one summer at NCAT working in their lab. This practical work experience helped in my classes at Auburn and served as good knowledge base for future jobs.

Sherry and Mel Monk

We continue the introduction to state asphalt pavement association (SAPA) executive directors with Alabama’s Mel A. Monk. Working with the Alabama Department of Transportation (ALDOT), the National Center for Asphalt Technology (NCAT), various universities, and 90 percent of the asphalt industry in his state, Monk is waving the asphalt banner to keep skilled workers flowing in and to bring our positive story of sustainability and economic prosperity to the elected budget-setters who need to hear it. State Association: Alabama Asphalt Pavement Association (AAPA), Montgomery, Ala. How long have you been in the asphalt industry? 23 years 42 October 2015

How long have you been the executive director of your state association? 13 years In what year was your state association formed? 1959 How many producer and/or contractor members are in your state association? 16 (about 90%) What are the top two or three ways you have increased membership in the association? • Contractor members recruiting their subcontractors, vendors and suppliers to join the association • Member discounts for training, seminars, etc.

What is your favorite method for recruiting new asphalt professionals to the industry in general? I am invited to speak several times a year to engineering students at Auburn University, University of Alabama—Birmingham, and University of South Alabama. I discuss the basics of asphalt technology and asphalt industry in general. I have later met several of these students in industry-related jobs who remembered me speaking to their class several years earlier. Several contractors hire students for summer jobs and several contractors host plant tours for local college engineering students. This is all positive exposure for young people to our industry. In what month do you hold your annual meeting? We hold our annual convention in May, our annual technical conference in March and our annual paving awards luncheon in December. Do you have a staff that assists in preparing the annual meeting? Yes; the office manager and myself.

THE FACES OF ASTEC PARTS

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

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

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

Any part, any brand. We can help.

ALDOT engineers are fully qualified to select and design pavement types without legislative directives or mandates. We believe pavement type selection should always be an engineering decision and not a political decision. On a scale of 1 to 5 (1 being none at all; 5 being very much), how much difficulty are your members having in finding qualified workers for their asphalt paving or production crews? 4

During the September 2014 NAPA Fly-In, delegates from AAPA met with Alabama United States Congressional Representative Martha Roby. From left: Brett Armstrong of Wiregrass Construction Company, Mel Monk, Rep. Martha Roby, David Church of Midsouth Paving.

Does your staff hold educational seminars or webinars for members separate from the annual meeting/ convention(s) throughout the year? Yes. We conduct upper level training for our asphalt personnel every March and April. The training is part of an ALDOT technician certification program. The training is two classes of about a week each. One is “Asphalt Mix Design Training and Certification” for our industry personnel involved in designing asphalt mixes. The other is “Asphalt Plant Operations” for our industry personnel involved in the operation of an asphalt plant to produce quality asphalt mixes within agency specification parameters. About how many member asphalt projects do you visit per year/paving season? 35—This includes taking our paving awards team to perform their project evaluations. About how many member asphalt plant tours do you assist/are you a part of per year? 3 About how many member asphalt open house events do you attend per year? 1 About how many state agency or DOT meetings do you attend per year? 3—ALDOT normally has an annual conference for pre-construction personnel, maintenance personnel and 44 October 2015

construction/materials personnel. We also have several yearly liaison committee meetings between AAPA personnel and our industry partners at ALDOT. On a scale of 1 to 5 (1 being none at all; 5 being very much), how much of a threat to your members’ marketshare/livelihood is the concrete industry in your state? 4

We have fought off several attempts by the concrete/cement industry to pass legislation to dictate how ALDOT chooses pavement types. ALDOT engineers are fully qualified to select and design pavement types without legislative directives or mandates. Could you share an example/anecdote of a time when the concrete industry encroached on the asphalt marketplace in your state? About 6 to 7 years ago, we lost two interstate maintenance projects to concrete. We won the engineering and LCCA battle, but lost the political battle. We have fought off several attempts by the concrete/cement industry to pass legislation to dictate how ALDOT chooses pavement types.

On a scale of 1 to 5 (1 being none at all; 5 being very much), how involved are your state elected officials in transportation issues such as funding and infrastructure improvements? 4—Our state elected officials are becoming more aware every day of our pressing funding needs. A few years ago our current Gov. Robert Bentley authorized a program named ATRIP to use Garvee bonds to fund approximately $1 billion of infrastructure improvements on our county and city road and bridge network. Discussions are now focused on how to address needs on our state-maintained (ALDOT) infrastructure network. On a scale of 1 to 5 (1 being none at all; 5 being very much), how involved are your asphalt members in transportation issues such as funding and infrastructure improvements? 5— Increased funding is a top priority for all of our members. The funding for ALDOT, counties and cities is totally insufficient to maintain the current and future needs of our infrastructure system. ALDOT has approximately a $3 billion backlog of needed construction projects that can’t be funded. Education of elected officials and the general public on the need for increased transportation funding is an ongoing process. It is impossible to overstate the importance of this continuing effort. Could you share an example of a time when your state APA hosted elected officials to educate them? Over the years, we have hosted elected officials to several of our contractor asphalt plants, and on one occasion to NCAT. Each time our elected officials are amazed and impressed by the economic impact our industry has on their district, including

is never a boring day or a lack of goals to accomplish. I am honored to be able to tell the story of the asphalt pavement industry to all who will listen. I am truly very blessed to have a job that I love. What has been the most rewarding experience for you during your time as the executive director? Seeing the results of the hard work by the AAPA and its members. Working with our partners at ALDOT to develop and revise

specifications and procedures to maintain and improve the quality of HMA. Then going out to actual projects and seeing quality work that has made roadways smoother and safer for the traveling public. Knowing that our industry positively affects the daily lives of all Alabamians. I am impressed every day by the honesty, integrity, hard work and commitment to quality by our contractors and other industry partners.

AAPA Executive Director Mel Monk addressed the membership at the December 2014 AAPA Paving Awards Luncheon.

the value of our equipment, the tax dollars paid and the number of employees. Officials are also very impressed with our commitment to sustainability through the use of RAP and RAS. Our industry has a great story to tell and hopefully we are getting better at telling it.

Get to Know Mel A. Monk

Why (or how) did you join the asphalt industry? I worked for more than 10 years with ALDOT in the Mobile area in various construction and materials position. I was approached by the local asphalt contractor to see if I was interested in interviewing for the open AAPA executive director position. I interviewed and was hired and am now blessed to work for the best group of folks in the greatest industry around.

What do you see as the most important part of your job as an executive director of a SAPA? Relationships with people. Developing positive and productive relationships with contractors, subcontractors, vendors, suppliers, ALDOT, counties, cities, consulting engineers, elected officials, etc. Building a partnership and a trust with all of these groups and individuals to provide quality asphalt pavement to the taxpayers of Alabama. What do you find most enjoyable about your job as an executive director of a SAPA? Having a job that is a pleasure to come to work every day. Each day is different and you never know what a call or contact is going to bring. There www.theasphaltpro.com 45

ASTEC

PAT E N T E D S TA C K T E M Run dense graded mix, warm mix, high RAP and OGFC all with no flight changes and no loss of production rate or fuel efficiency.

M P E R AT U R E C O N T R O L S Y S T E M â&#x20AC;&#x153;The V-Pack stack temperature control system is the most important improvement to asphalt production since long-term storage.â&#x20AC;?

Dr. J. Don Brock

Founder, Astec Industries, Inc.

that’s a good idea

Measure the augers to ensure the auger assembly is in the correct position, but also pay attention to auger condition, wear and cleanliness. This area needs to be cleaned well to keep old material from disturbing the quality of your new mat. Smaller photos: Measure augers from the head of the curve to the pre-strikeoff to determine whether or not they are worn, and to ensure they are in proper position. You will want to see a distance of 5 to 6 inches from the head of the curve to the pre-strikeoff. Measure augers from the head of the curve/base to the ground to determine if the bar is set at the correct height. If the mat you wish to match is 2 inches in depth, then you will want the bottom of the augers to be 4 inches off the ground.

Measure Auger Height for Matching

o get the head of material right, the paver operator will set the paver speed and auger rotation so that mix reaches the center of the augers as it feeds under the tractor. You won’t want the material to run low, starving the augers, or run too high, filling the auger box while you’re trying to pave a smooth mat. For the center of the augers to be in the right place, you need to measure before you even begin the pull. First, set the screed down and pull ahead of the mat you’re going to match. Then measure the augers with a tape measure. Is 48 October 2015

the bottom of the auger sitting 6 or 7 inches off the ground? That’s too high and you’ll find yourself fighting with too much mix as you pave. Instead, you want to go with the rule of thumb that augers should be 2 inches above the existing mat. If you have a 2-inch mat that you need to match, you want the bottom of the auger to be 4 inches off the ground. Measure and set your bar appropriately. Also measure from the head of the auger curl to the pre-strikeoff. You want it to be 5 to 6 inches. If your augers have worn too much, you’re going to see a larger space in

By John Ball

there—6 to 7 inches—which will create the over-feeding problem as well. That’s one of the reasons it’s important to check the condition of the augers for thickness and wear. Also clean the box, giving equipment a proper wash-down so the area isn’t dropping chunks of old, cold material into your hot, tested mix. Make top quality paving your goal throughout the process. John Ball is the proprietor of Top Quality Paving, Manchester, New Hampshire. For more information, contact him at (603) 4931458 or tqpaving@yahoo.com. Visit his site at www.tqpaving.com.

One of the top state asphalt trade shows in the USA for the money with an unbelievable Return on Investment! Put your company’s product or service in front of our buyers at a very low cost in the Hoosier Heartland of America. We’ve grown from 15 booths to 50 in five years – come see why! Last year’s record attendance was 550. We comp our contractors’ public agency customers so that means YOUR customers turn out in big numbers to rub elbows with THEIR customers! The Winter Conference features specialized educational programming and committee meetings for plant production and QC managers, laydown crew supervisors, safety and environmental managers, owners, partners and senior management executives, project managers and estimators, controllers, etc.

www.asphaltindiana.org Dates: December 10-11, 2015 Location: Indianapolis Marriott East Indianapolis, IN Seven hours of exhibit time with no conflicting sessions or meetings…Exhibit Hall Attendance Prizes and Drawings. Limited Exhibit Booth & Sponsorship opportunities are available. For more information, visit www.asphaltindiana.org For more details and booth pricing, please email : Laura Jackson at LauraJ@cmcglobal.com or Bill Knopf at Wknopf@asphaltindiana.org

product gallery

Asphalt Production and Liquids Essentials

sphaltPro brings you a new way to examine the equipment, products and services available to you in the marketplace. Of course we still focus on the items relevant to an asphalt business, but we have a different approach to make the focus more useful to you. Notice this month that all equipment listed in the product gallery relates to production. The information contained herein pertains to the AC, aggregate, design and production portion of our industry. Let’s start by taking a look at the globally harmonized system (GHS) and safety data sheet (SDS) requirements specifically.

SAFETY DATA REQUIRED As of June 1 this year, all asphalt producers have been required to provide GHS-compliant SDS information to customers. That means when a customer comes to your plant to purchase a few tons of mix, you must provide the haul truck driver with a label that includes warning language about the ingredients of the mix. Let’s have a quick review. The International Agency for Research on Cancer (IARC) proved asphalt fume is not a carcinogen, but components associated with mixes can be deemed hazardous. The National Asphalt Pavement Association (NAPA), in its Environment, Health & Safety Alert “Complying with GHS HazCom Requirements for Safety Data Sheets,” reminded us that ingredients in asphalt pavement mix can range from aggregate to asphalt binder to antistripping agents, etc. “Some of these raw materials carry various classification labels, e.g., identifying the hazard of crystalline silica exposure from aggregate dust. However, because of the unique characteristics of asphalt pavement mix, many of the potentially classifiable hazards from individual raw material ingredients may be minimized once the material is combined into its final product, asphalt pavement mix.” Even so, asphalt mixes must have an SDS that identifies the product’s hazard “as sold or used,” so that each batch of mix meets the GHS requirements. Chemical or product suppliers are required to include a safety label on the initial shipment of a product so that each employee or worker who will have contact with the product has clear and full information about its potential hazards. That means an asphalt producer needs a safety label on more than the haul trucks in his in-house fleet. Customers who haul mix away need the label, too. You must provide it along with the mix. Controls systems manufacturers such as B&S Light Industries and Libra Systems can help there. “Our system allows an administrator to configure any safety message to print on the tickets,” Ken Cardy of Libra said. Notice in this month’s product gallery listing that Fairbanks Scales has a new printer with advanced abilities. Many controls OEMs offer ticketing kiosks that can be programmed to include your company’s SDS for the mixes you’re 50 October 2015

By AsphaltPro Staff

providing. Be sure you ask about this capability or how the OEM can help you get it set up. Printing the SDS label on the back of loadout tickets is the method Oldcastle Materials found most expedient to be in compliance, as shared in the March edition of AsphaltPro. Now each and every load of asphalt pavement mix that leaves an Oldcastle facility can meet regulations and direct customers to a page on the company’s website with additional information. Your company may think of a different way to get the SDS to accompany initial deliveries of product, but it’s good to know there’s a working model in action. Your company may also wish to look into the service providers who can help prepare the SDS from the get-go.

Printing the SDS label on the back of loadout tickets is the method Oldcastle Materials found most expedient to be in compliance. NAPA worked with an SDS authoring consultant earlier this year, and decided producers would have a more legitimate labeling item if they contacted an SDS authoring vendor individually as well. NAPA worked with Experien Health Sciences, headquartered in Kingwood, Texas, which you can reach at (281) 812-6667 or visit at www.experienhealthsciences.com. Are you feeling creative? Check out www.chemdox.com/en/materialsafetydatasheet for SDS software, admin documents, and templates to create your sheets. Be aware that items are spelled with the Queen’s English, so you’ll want to proofread carefully. Do you only need a consultant? Try www.ehsi.com out of Flemington, New Jersey, or call them at (908) 237-9348. The point is you don’t have to face the construction of a safety data document alone.

CEI GIVES TEMPERATURE A BOOST The vertical asphalt booster heater from CEI Enterprises, Albuquerque, New Mexico, is used to boost the heat of liquid asphalt from storage temperatures to usage temperatures. The heater is typically used at asphalt terminals to boost the heat of liquid asphalt as it is pumped to a tanker truck. This application allows terminals to store bulk quantities of liquid asphalt at lower temps, reducing the energy demand and heating expense associated with storage. The booster heater raises the temperature of the liquid asphalt up to approximately 360oF before it is loaded into the tanker. The booster heater contains a helical coil inside its shell. A burner fires a flame upward through the center of the helical coil, transferring heat to the coil via radiation and convection. Hot burner gases turn at the end of the coil and pass along the coil’s outer surface, transferring heat to the coil only be convection. Exhaust

800-826-0223

www.stansteel.com

STANSTEEL Asphalt Plant Products

GTB-5122 - Gencor® Portable CF Drum Mix Plant

Nominal 400 TPH

Gencor®, Portable Model UDP®-400 Counter-Flow Dryer/Drum with Quad trunnion drives, heavy duty beam frame, rap collar, breechings & Burner. Gencor®, Model 182-CFP Portable, Reverse Air Baghouse equipped with 1,050 Oval Bags. Also included is a Gencor®, Exhaust Fan with inlet vane damper, twin 125 HP Motors and an Air Compressor. Gencor®, portable Knock-Out Box type Primary Collector. Gencor®, Single Deck. 5’ x 14’ Skid mounted Virgin Scalping Screen. Gencor®, Five (5), 9’ x 14’ portable Coldfeed Bins equipped with Belt Feed Conveyors. In addition to the bins, an integrally mounted collecting conveyor and scale conveyor are included. Gencor®, portable coiled AC Tank, with a Hot Oil Heater mounted on the gooseneck. Included with the AC Tank is a mounted Mass-Flo AC Metering System, AC unloading pump skid and a 1,000 Gallon AC Calibration Tank. Gencor®, portable, Triple Bin RAP System with feed conveyors and collecting conveyor mounted on a common frame. A RAP Scale Conveyor with a mounted belt scale and a Single Deck Scalping Screen are also included. Gencor®, nominal 70 Ton capacity, Self-Erect Silo System with a nominally rated 500 TPH Slat Conveyor, mounted on a tandem axle chassis with hydraulic installation package. Gencor®, Portable Control House with Gencor®, Model BC-250 Controls, JWS Load-out switchgear, breakers and etc. are included.

GTB-5083 - Gencor®, Model 300, ULTRA®-Drum plant

Nominal 300 TPH

Gencor®, Portable 300 TPH Counter-Flow Dryer/Drum with four trunnion drives, heavy duty beam frame, rap collar and Gencor® Combination Burner set up for Natural Gas. Gencor®, Six (6) Bin, skidded Cold feed system with 5 HP AC Feeders. Completing the coldfeed system is a Kolberg, Double Deck, Virgin Scalping Screen and a Kolberg, Virgin Aggregate Scale Conveyor. Gencor®, Pulsejet Baghouse with Exhaust Fan, exhaust type damper and damper control. Also included is a Gencor® Knock out box, Dust Return Augers, Dust Run-Around metering Pod, a 50 HP Air Compressor and ductwork. Gencor®, skidded RAP Bin, equipped inclined feed conveyor, Grizzly, rear mounted Air Cannon and leg extensions to grade. Also included in the RAP System is a Kolberg Double Deck Scalping Screen and a Belt Scale Conveyor. A Gencor® Portable, Split-Level Control House with Motor Starters, Breakers, & Gencor® Plant Operating Controls are also included. Burke, skid mounted hot oil heater equipped with an expansion tank, a control panel and hot oil circulation pump. In addition there are Three (3), Skid Mounted Horizontal AC storage tanks and a Gencor®/Bituma® AC Metering System and Unloading Pump Skid. The Asphalt storage system consists of Two (2), Dillman 200 ton silos, with 7 Ton weigh batchers, factory cone liners, top mounted batchers, a bintop transfer conveyor and Main Drag Slat Conveyor. All platforms, walkways, ladders, and safety guards as exist are included.

GTB-5113 - Astec Model SEB-10036 Self-Erect Silo system. • • • •

Single piece system includes a 60 Ton nominal capacity silo and a drag slat Factory rated at up to 400 TPH. Heavy Duty system includes the complete self-erect package and a Quad axle portability assembly. Self Weighing capability via. (4) Load Cell/Strain Gauges, suspended in each corner of the bin support frame. Conveyor mounted anti-segregation batcher.

GTB-5121 - CMI Drum Mix plant

• Single CMI Cold Feed Bin • Five (5) Bin CMI Cold Feed System w/collecting conveyor • Virgin Feed Conveyor w/supports and walkways • CMI SMD732 Parallel Flow Drum Assembly w/warm mix system • CMI AP450 Baghouse w/air compressor • Portable CMI 30k Gallon Direct Fired AC Tank • 17k Gallon vertical AC Tank • Maxam RAP Bin 8’x14’ • Deister 3x6 Screen Deck • Recycle Feed Conveyor • CMI Silo System which includes CMI Main Drag, Two (2) CMI 100T Silos w/batchers, Astec Bin Top Transfer Conveyor, and Truck Scale • Control House w/ controls • Two (2) horizontal 10k gallon fuel tanks w/preheater

GTB-4804 - STANSTEEL Batch Plant Size - 10,000 # COLD FEED: (6) six 14’ long x 10’ wide bin stationary cold feed. Cold feed system is equipped with belt feeders, bin extensions, and a Dodge reducer. DRYER: Stansteel 9’ dia. x 36’ long Counterflow aggregate dryer, gravity feed chute, and cradle chain drive. Also equipped with a Hauck burner and blower. BATCH TOWER: Totally enclosed Stansteel vertical hot aggregate bucket elevator feeding a 10,000 lb. capacity batch tower. Tower includes a horizontal screen, four (4) compartment hot bin section, and a 10,000 lb. pugmill with a 200HP motor. WARM MIX SYSTEM: Maxam Aqua Black warmix system BAGHOUSE: Stationary Herman Grant Pulse jet baghouse with exhaust damper. Twin City Fan with (2) motors 125HP each. SILO SYSTEM: (3) 200 ton Gencor® silos with bintop slat and 32” wide x 83’ long, 400TPH main drag slat. Gencor ® Bintop Conveyor slat type, 15” long x 32” wide. Equipped with a Thurman 10’ wide x 70’ long x 12’ tall above ground steel truck scale. A.C. SYSTEM: (1) Vertical Meeker, late model, nominal 30,000 Gallon, coiled only AC Tank. (1) Vertical Hy-way® nominal 25,000 Gallon, coiled only AC Tank. (1) Horizontal Hy-Way® 30,000 Gallon coiled only AC Tank. (1) Hy-Way® Model HyCGO200, 2M-B.T.U, and has a combo fuel type natural gas and #2.

GTB-5103DNI - Barber Greene Plant

Size - 6,000#

DRYER: Barber Greene Dryer that measures a nominal 7’-0” Dia. x 30’ long, counter-flow aggregate dryer, mounted on a stationary style frame. The dryer is driven by a Cradle Chain Sprocket powered by a heavy duty reducer and motor. The Burner is a Hauck Starjet, Model SJ-360 combination fuel type and is capable of operating on Heavy Oil. BATCH TOWER: Barber Greene Batch Tower and bucket elevator with a 6,000# capacity pugmill. DUST COLLECTION: H&B® Pulse Jet Baghouse. This Baghouse is equipped with (540), 6” Diameter x 10’ long Single Bags for a nominal total of 8,482 Sq. Ft. of cloth. Also included is a 20 HP Piston type Air compressor, exhaust fan with drive, stack, damper and leg extensions to grade.

Scan this code with your smart phone for thousands of used equipment listings Gencor®, H&B®, Hy-Way®, Ultra®, and Bituma® are trademarks of Gencor® Industries, Inc. and Stansteel® is not related to or licensed by Gencor®.

Interested in used equipment? Go online to find hundreds of listings with photos at:

www.stansteelused.com

product gallery Step 5 Heated asphalt exits the booster heater and is piped to the loading rack for loading into a tanker truck.

Burner gasses exit the exhaust stack.

Step 4 Hot burner gasses turn at the end of the coil and pass along its outer surface, transferring convective heat.

Step 3 Asphalt travels upward through the coil, gaining heat.

Step 2

Step 1

The burner fires a flame up the center of the helical coil, transferring radiant and convective heat to the coil and asphalt flowing inside it.

Liquid asphalt enters the heater’s helical coil.

The vertical booster heater from CEI raises the temperature of liquid asphalt from cost-efficient storage levels to flow-efficient transport levels.

gases then exit the heater through the exhaust stack. Liquid asphalt enters the coil and gains heat as it flows upward through the heater. Heated liquid asphalt then exits the heater at the pre-set temperature. Digital controls allow the user to precisely control the outlet temperature of the liquid asphalt. • Use this at the terminal. • For more information, contact Mike Bremmer at (505) 842-5556 or visit www.ceienterprises.com.

CLARENCE RICHARD INDICATES LEVELS Does your loader operator ever allow one cold feed bin to run almost empty while filling another to overflowing? Clarence Richard Company, of Minnetonka, Minnesota, offers two choices to help. The Ez-Bin Wizard addresses the need as described above while Ez-Weigh Loss scale control does that and more. First, the Ez-Bin Wizard, is designed to provide the loader operator an indication of the level of material in each bin. The 24inch vertical bar has eight horizontal rows of green LEDs to indicate the level, and also one horizontal row of red LEDs on top to indicate when the bin is running. The light bar is made of polycarbonate to resist scratching and fading. The mechanic mounts the Bin Wizard above the bin on the opposite side from the loader with Sorbothane, which is a vibration-isolating medium. The acoustic sonar sensor has waveform signature analysis that makes it virtually impervious to external noise, according to its manufacturer. The “empty” and “full” trimpots will allow the Bin Wizard to fit bins anywhere from 5 to 15 feet deep. As the level of material in the bin goes down, the horizontal rows of green LEDs extinguish. As the loader operator fills the bin and the level of material rises, the horizontal rows of green LEDs light up. The plant operator usually can see the light bars from the control room. This helps the plant and loader operator determine how much to fill the bins when getting close to shutdown at the end of the day. Next, the Ez-Weigh Loss scale control has the same features of the EZ-Bin Wizard plus bin calibration ability. The scale-control portion controls the feeder belt speed based upon the rate of material depletion. The Ez-Weigh Loss scale control is designed 52 October 2015

The Ez-Bin Wizard “reads” the level of material in the bin and gives the loader operator a visual indication of how much more room the bin has for material to be added.

to work with any existing blend control without requiring any changes to the customer’s equipment. Clarence Richard Co also offers the new Ez-Flo scale with low, 4-inch profile; web-based training; the tank gauge to prevent running low or running over on liquid material. • Use this at the plant. • For more information, contact Clarence Richard at (952) 939-6000 or Clarence@clarencerichard.com.

D&H BLENDS, STORES The high production asphalt rubber blender from D&H Equipment, Ltd., has new controls to include new reporting capabilities. The automated valving on the blender and reaction tank has the ability to manage all aspects of the plant from precise metering of ingredients to the reaction time and temperature, according to the manufacturer. The plant uses low NOx burners and redesigned finned condensers. A second hopper has been included with the system so the customer can add two different dry material modifiers, or hold SBS or other polymer material. A new, 30,000-gallon, two-compartment reaction tank accompanies the rubber blending unit and a new premier automation package replaces the manual valves to allow the PLC to automatically record reaction tank data. Both compartments are heated by smooth hot oil serpentine coils and feature D&H’s unique topmounted agitation system. For storage, D&H builds tanks ranging from 10,000 to 32,000 gallons for a variety of asphalt needs. They feature agitation using top-mounted drive screw augers or top-mounted mixers, heating coils or direct fire systems to regulate temperature, and highdensity fiberglass insulation and embossed aluminum skin. • Use this to make asphalt mix. • For more information, contact Jason Cox at (830) 833-5366 x227 or Jason@dhequip.com.

The asphalt rubber blending plant from D&H Equipment is designed to produce AR at up to 50 TPH.

End users of the Libra web services can receive alerts on their smart phones, and can dictate what information is included in the alerts.

LIBRA PINGS INFO

The tanks available from D&H Equipment come in horizontal skid-mounted, trailermounted, container-framed or vertical configurations.

Web Services from Libra Systems Corporation of Harleysville, Pennsylvania, is a new platform that provides real-time information to customers. Its Web Alerts function allows authorized users to configure alerts that they will then receive via text or email on their portable devices. Its Web Reports function provides authorized users mobile access to company-wide or filtered reports. Administrators of the Web Services may grant “end-user customers” the right to subscribe to alerts or access reports as well. Web Services is designed to automatically and securely limit the end user’s information access to only that information that pertains to his/her particular job(s). Libra also offers self-service kiosks and remote printer terminals for use at the plant, as well as the Libra Silo Safety System. Libra offers the Generation3, PlantWise and Enterprise control systems. • Use this at the plant. • For more information, contact Ken Cardy at (215) 256-1700 or kcardy@librasystems.com.

MAXAM GETS SAMPLES

The larger SE magnets feature Eriez’ external oil expansion tank, which keeps the coils fully immersed in cooling oil while the BAM uses a short-belt conveyor built around the magnet to automatically remove tramp iron from the magnet face.

ERIEZ GETS METAL OUT If your large recycling or mining operation needs to keep oversized pieces of tramp metal from messing up the crusher or grinder downstream, Eriez of Erie, Pennsylvania, offers the SE 7000 model line of large suspended electromagnets for heavy-duty applications. These BAMs are designed to accommodate belt widths up to 144 inches and magnet sizes starting at 90 inches. They are offered with a five-year warranty on the coil assembly. • Use this in recycling. • For more information, visit http://ow.ly/PXAYT or contact John Blicha at jblicha@eriez.com.

Automating material sampling at the silo loadout area offers safety and quality assurance for producers. To that end, Maxam Equipment, Kansas City, Missouri, offers the California bulk sampler. It has a trailer-mounted, conical hopper designed to receive a 1,000-pound sample directly from a hot mix silo. Once loaded, the CB sampler is towed by pickup truck to the plant lab or other testing location. The hopper of the CB sampler sits directly atop a CalTransapproved Gilson Quartermaster asphalt sample divider for splitting samples into four 4-gallon buckets. Hopper gate control for discharging into the splitter is by air-actuated cylinders powered by a self-contained air tank. After the samples have been taken, the hopper can be laid on its side for ease of cleaning. Simply pull on the lock bar handle and reverse the 12-volt winch to recline the hopper to a horizontal position. With the CB sampler laid on its side and secured with deck-mounted toggle clamps, the unit can be towed back to the silo area or to another plant site. See the Here’s How it Works feature on page 62 for details. • Use this at the plant. • For more information, contact Mike Hawkins at (800) 292-6070. www.theasphaltpro.com 53

product gallery

The EX series plants from ADM are available in portable or stationary versions and are designed to meet federal and state specs.

ADM OFFERS EX SERIES Asphalt Drum Mixers, Inc., of Huntertown, Indiana, offers a single-drum counterflow plant in its EX series of asphalt plants. The series is designed to offer high efficiency in a compact design for producers with low to medium production needs—the range begins at 100 TPH—while processing high percentages of RAP. Using counterflow technology, the EX series has separate drying and mixing zones. The system is designed to introduce residual gases back to the drum’s combustion zone. • Use this to make asphalt mix. • For more information, contact Mike Devine at (260) 637-5729 or mgdevine@admasphaltplants.com.

the requirement of the new CalTrans sampling spec, according to the manufacturer. It obtains a 50-pound sample from the haul truck and drops it into a sample separation device. It is designed to sit on a

MEEKER COMMUNICATES The Patriot hot oil heater from Meeker Equipment includes a way to access its status remotely. It features PLC touchscreen technology and “SABER” technology, which is designed to reduce stack temperatures. • Use this at the plant. • For more information, contact Meeker Equipment at (888) 3330323 or visit www.meekerequipment.com.

HMA LAB GETS SAMPLES The T-REX hydraulic truck sampler distributed by HMA Lab Supply of Richmond, Virginia, is designed to address safety concerns while obtaining quality HMA samples at the loadout site. T-REX meets 54 October 2015

The T-REX hydraulic truck sampler is available exclusively from HMA Lab Supply and InstroTek, Inc., and comes ready for sampling HMA mixes with trailer mount or on a pedestal.

pedestal, mounted at the end of a sampling rack, or it can be mounted on a trailer for mobile and portable operations. • Use this at the plant. • For more information, contact HMA Lab Supply or InstroTek, Inc.

FAIRBANKS PRINTS CODES With the safety data sheet requirements for asphalt products, producers must now provide information beyond the weight of loads ordered from their plants. Fairbanks Scales, Inc., of Kansas City, Missouri, announced this summer the release of the PM43 direct thermal label printer, which allows for the printing of additional information. The PM43 is an industrial, mid-range, direct thermal and thermal transfer label, ticket and tag printer, and was designed for applications in distribution centers, warehouses, manufacturing and transportation environments, according to the manufacturer. It features a large, color, multi-lingual, tamper-proof touch screen user interface, and a built-in web interface for device monitoring. The new printer’s precision print feature allows for printing of small bar codes and images. It is the only CCX certified fixed printer with standard IPv6 implementation, according to the manufacturer. • Use this at the plant. • For more information, contact Ingrid Adel at (816) 471-0231 ext.288 or iadel@fairbanks.com.

The PM43 direct thermal label printer is a USB printer capable of printing small bar codes and images on the tickets you print for haul trucks leaving your loadout area.

SAVE TIME. SAVE MONEY. It’s automatic with HOMESTEAD

Valve Types ■ ■

Homestead’s unique, innovative design lets your upgrades to automated systems go seamlessly…so you can spend your time on REAL problems. Cast iron and ductile iron material options offer a complete source of valves for any liquid asphalt. Our full line of hot-jacketed 3-way and 2-way manual, pneumatic, and electric actuated valves cover all operation requirements.

■

■ ■ ■

Valve Materials ■

Only Homestead’s cutting-edge actuation design allows you to easily add or replace actuators in line—without modiﬁcation.

Full Port – Standard Port 2-Way Shutoff and 3-Way Diverter Patterns 1"-8" Flanged and 1/2"- 4" Threaded Steam/Hot Oil Jacketed Transﬂo Plug Proportioning Plug

■ ■

Cast Iron – to 450° F Ductile Iron – Over 450° F High Temperature Seals

Field-mountable actuation kits are available for your existing Homestead valves.

Actuator Types

Flexibility, quality, value…it’s automatic with Homestead.

■ ■ ■

THE ASPHALT VALVE EXPERTS

■

Pneumatic Electric Open-Close Modulating

610-770-1100 asphaltvalves.com Fax: 610-770-1108 sales@homesteadvalve.com

www.theasphaltpro.com 55

product gallery

The Charles Blalock and Sons plant features multiple Heatec components.

HEATEC INSTALLS BLALOCK COMPONENTS

RAP TECH GOES ALL RAP

Heatec of Chattanooga, Tennessee, provided a number of products for the Charles Blalock and Sons, Inc., facility in Sevierville, Tennessee. Those products include: unloading pump; horizontal additive tank; vertical 15,000-gallon emulsion tank; two 35,000-gallon vertical asphalt tanks with vent condensers; two 20,000-gallon vertical fuel tanks; one 1,000-gallon calibration tank; one 2-million BTU/hour hot oil heater; and a twin pump metering system. • Use this at the plant. • For more information, contact Heatec at (423) 821-5200.

RAP Technologies offers a portable plant designed for small paving contractors interested in producing their own mixes. The plant uses a 75kW generator. It comprises a dryer, two cold feeds, a baghouse and control room on two trailers. With this setup, it creates up to 100 percent RAP mixes at 50 to 150 TPH, according to the manufacturer. • Use this to make asphalt mix. • For more information, contact Bob Frank at bobfrank@raptech.us.

IROCK RETURNS PRODUCTION IROCK Crushers of Valley View, Ohio, introduced its RDS-15 horizontal impact crushing plant with four-bar impactor design this summer for those contractors who need to crush on the go. The manufacturer states the compact crushing and screening system is ideal for processing smaller materials such as RAP. It’s powered by a Caterpillar® C-9 ACERT Tier 3 engine with 350 horsepower. The plant is self-contained with on-board power supply and three outlets to power optional auxiliary conveyors. The mobile crusher can be hooked up to a truck and hauled as one unit. • Use this in recycling. • For more information, contact Robert Nelson at (866) 240-0201 or rnelson@irockcrushers.com. 56 October 2015

The portable VR 102 plant from RAP Technologies is designed to produce up to 100 percent RAP mixes

Boost your production with the return conveyor when you move the RDS-15 horizontal impact crusher from site to site to crush RAP.

Astec Relocatable 300TPH Double Barrel Plant ®

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

423.867.4210 ext.1245

VIEW ONLINE # 820

astecused.com ASTEC, INC.

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

www.theasphaltpro.com 57

ALL PLANT PARTS. ALL ADM QUALITY.

ADM customers have long known about our excellent parts quality and availability. Now, users of non-ADM equipment can get that same level of confidence in replacement parts. At ADM, we stock a huge inventory of industry-standard parts and components for all major manufacturers’ systems and can have them most anywhere for next-day delivery and installation. You’re up and running and we’ve made another satisfied customer. It’s what we do best.

ADM - More Than Metal For more information call

(260) 637-5729 MasterCard and Visa accepted

Asphalt Drum Mixers, Inc. 1 ADM Parkway • Huntertown, IN 46748

parts@admasphalt.com service@admasphalt.com VISIT ADMASPHALTPLANTS.COM

58 October 2015

On the Powerscreen Trakpactor 260SR horizontal shaft impact crusher, the 8-foot by 4-foot single deck post-screen can be used for fine-sizing and recirculation of uncrushed materials.

POWERSCREEN COMPRESSES IMPACT CRUSHING Powerscreen®, a Terex brand, has added the new Powerscreen® Trakpactor 260 and Trakpactor 260SR horizontal shaft impactor tracked crushers for the recycling and demolition markets. The 260 is designed to yield up to 175 TPH of product, is compact and mobile, and includes a Tier 4 Final Scania® DC9 engine. The impact crusher chamber has a feed opening of 34 inches by 24 inches and can be configured with a variety of blow bars. • Use this in recycling. • For more information, visit www.powerscreen.com or contact Dearbhaile. mulholland@powerscreen.com.

PROCESS HEATS TANKS Process Heating Company’s Lo-Density® unitized storage tank heaters are designed to be installed into any above-ground tank or vat, and then dissipate controlled heat as low as three watts per square inch on the heater’s sheath to prevent coking or damaging of temperature-sensitive material. Unitized heaters feature the company’s unique drywell-style elements that reside inside the sheath, making them accessible from outside of the tank and eliminating the need to drain the

tank to service the elements. UL-listed controls offer easy-to-use complete automation of temperature regulation. The main indicating temperature control regulates the product temperature and includes a high-limit control for safety. There is a main disconnect, and the individually fused heat circuits provide overcurrent protection. All components are mounted and prewired in a NEMA Type 4 enclosure. Custom control panels are also available. • Use this at the tank farm. • For more information, contact Process Heating at (866) 682-1582 or visit www.processheating.com.

STURTEVANT MOVES AIR CLASSIFYING Aggregate and sand producers with multiple quarries now have an option for a portable air classifier. Sturtevant, Inc., Hanover, Massachusetts, has introduced what it purports is the world’s only self-contained, 100 percent mobile air classifying plant with integral collapsible conveyors. The Whirlwind air classifier and conveyors hydraulically unfold for setup and fold away for breakdown and transport, with no cranes, no boom trucks, no front-end loaders or special crew needed for any part of the operation, according to the manufacturer. Dual hydraulic cylinders provide the steady raising and lowering of the Whirlwind air classifier and the integral, collapsible feed and dual discharge conveyors. www.theasphaltpro.com 59

product gallery

TOP: Sturtevant’s mobile air classifying unit unfolds to operational mode with the push of a button. BOTTOM: The Whirlwind portable air classifier plant is designed to go from transport to production without the cost and delay of special lifting equipment, according to Joe Muscolino, senior project engineer for Sturtevant, Inc.

60 October 2015

The plant is mounted on a chassis frame with tri-axle suspension for travel on highways and back roads. The compact design features a transport height of 13 feet 5 inches, trailer transport length of 61 feet 9 inches, and transport width of 12 feet 7 inches. The feed capacity is 30 to 90 TPH with a 50-horsepower variable frequency motor. Other features aggregate and asphalt producers requested include the long, high discharge conveyor for greater stockpile heights of de-dusted manufactured sand, and a feed conveyor intake hopper that is low to the ground and can be fed by a frontend loader. Also, the feed hopper is located behind the trailer rear wheels to prevent feed material spilling onto the chassis. The smaller side conveyor is for byproduct fines. An internal fan lifts minus #200 mesh fines out of the feed, and removable selector blades within the housing control the amount of fines to be removed. For safety and nuisance dust control, all three belt conveyors are covered and can be vented. In addition, the gravity feed inlet at the top of the classifier is under a slight vacuum to prevent airborne nuisance dust during material transfer. The conveyor covers also help reduce moisture. The air classifier is designed for dry operation and to eliminate the need for screening, cyclones, bag houses or wet washing where water is not readily available or where waste water disposal is a problem. • Use this in the quarry. • For more information, contact Sturtevant at (800) 992-0209 or visit www.sturtevantinc.com.

here's how it works

Step 1 Step 3

The O2 sensor measures emissions and air temperature going through the stack, and then analyzes the data.

The PPC4000 processes the information.

Step 2 The O2 sensor feeds the data to the PPC4000 fuel-to-air ratio controller in the control panel.

Step 4 The PPC4000 adjusts the servo motors on the burner’s fuel and air intakes.

CEI and Fireye’s Nexus 4000 System

o offset the effects of air temperature shifts on burner emissions and cool-weather burner performance, the engineers at Fireye™ developed the Nexus 4000 system, which is available through CEI Enterprises, Albuquerque, N.M. Here’s how it works. Combustion efficiency is affected by changes in air temperature, even if the burner is properly tuned. As air temperature increases and air becomes less dense, the burner’s fuel-to-air ratio increases, which causes the burner to run rich. This results in wasted fuel and higher emissions. Conversely, a drastic

decrease in air temperature can cause the air to become dense enough that it starves the burner of adequate fuel, causing unwanted burner shutoffs. First, the Nexus 4000 management system’s O2 sensor, which is installed directly in the heater’s stack, measures emissions and temperature data. The sensor analyzes the exhaust going through the stack and feeds that data to the PPC4000 fuel-to-air ratio controller, mounted in the heater’s control panel. The PPC4000 processes that information in real-time and automatical-

ly adjusts the burner’s fuel-to-air ratio by continually adjusting servo motors mounted on the burner’s fuel and air intakes. As less fuel, or more air, is needed for proper combustion efficiency, these adjustments are performed continually by the servo motors. User interface is provided by the NXD410 keypad display, and flame safeguard control is provided by the YB110. Both of these are mounted in the heater’s control panel. For more information, contact CEI’s Parts & Service Dept at (800) 545-4034 www.theasphaltpro.com 61

here's how it works

Step 1 The driver brings the hopper to the loadout area via trailer.

Step 4 When the sequence is complete, the driver lowers the hopper back into place.

Step 2 The hopper rises into position via electric winch and locks into place beneath the silo.

Step 5 The driver locks the hopper into place with cam-lock latches for transport to the lab site.

Step 3 As the silo dumps mix into the hopper, air-operated clam gates allow the mix to fall into the sample splitter below.

Maxamâ&#x20AC;&#x2122;s California Bulk Sampler

utomating sampling at the loadout area can offer safety and quality enhancements for producers. To that end, the engineers at Maxam Equipment, Kansas City, Mo., designed and now offer the California bulk sampler. Hereâ&#x20AC;&#x2122;s how it works. The trailer mounted, conical hopper that is the heart of the sampler sits in a horizontal resting position while transported to the loadout area. After moving to the general loading area, the driver exits his truck and manually releases the cam-lock latches that hold the sampler safely in place for transport. He then 62 October 2015

raises the hopper to the upright loading position via a battery operated electric winch, which powers the hopper upright in less than 10 seconds, where it automatically locks into place. Next, the driver drives the trailer beneath the designated silo gate, where the plant operator loads the hopper with the requested amount in the same manner he would load a truck. Total water level capacity is 3,000 pounds, but most test samples would be less than 1,000 pounds. After the hopper is filled, the driver transports the hopper nearby the plant

lab where he places a Caltrans-approved sample splitter beneath the hopper. Airoperated clam gates on the hopper, supplied by an onboard air tank, can be chattered to fill the sample splitter, which splits the sample into four equal parts. Based on the fill level of the hopper, several samples can be taken. Once the sampling is complete, the driver releases the automatic lock and powers the empty hopper back to the horizontal position for cleaning and transport to the next test. For more information, contact Mike Hawkins at mhawkins@maxamequipment.com.

2 0 1 6 N A PA A N N UA L M E E T I N G

February 7–10, 2016

La Quinta Resort & Club • La Quinta, California www.AsphaltPavement.org/AnnualMeeting

Training: Why Bother? New!!! Now have access to review this Training: ContraCtor’s Web Based Training 25 foroperators as long as said: you wish. Why Bother?

• 92% was at the least as to what they expected. • Over half felt the content was excellent or perfect. • 80% agreed the contents met their expectations. ContraCtor’s 25 operators said: • 96% agree that at least somewhat that expectations • 92% werewas met.at the least as to what they expected. ••Over half feltagree the content excellent or Two thirds their jobwas performance willperfect. improve. ••80% the contents met theirwill expectations. 96%agreed agree their job performance somewhat improve. ••96% that at somewhat that expectations Over agree two thirds feltleast Web-Based Training is more effective than were met. Classroom Training. ••Two thirds job performance will improve. 100% will agree refer ittheir to others. • 96% agree their job performance will somewhat improve. test results: • Over two thirds felt Web-Based Training is more effective than •Classroom The Operators improved 44%. Training. Two thirds had over 10 years experience and they improved 40%. ••100% will refer it to others. • ROI:2/3 gave it a payback within 6 months. test results: • Nearly 1/4 of them felt the payback was going to • The Operators improved 44%. every week. ••Two over giving 10 years they improved 40%. Twothirds thirdshad of those thisexperience one week and payback • ROI:2/3 a payback within 6 months. were 10gave yearitveterans. • Nearly 1/4 of them felt the payback was going to every week. • Two thirds of those giving this one week payback were 10 year veterans.

HAVING TROUBLE WEIGHING!!! REPLACE YOUR WEIGH POD THESE PEOPLE HAVE... www.ez-flo.us • 952-939-6000

clarence@clarencerichard.com 952-939-6000 www.clarencerichard.com clarence@clarencerichard.com Consider e-Electro-Mechanical Workshop 952-939-6000 Private Workshops available on request

www.clarencerichard.com Consider e-Electro-Mechanical Workshop Private Workshops available on request

WEIGH RAS Easily and Accurately...

load cells installed by your scale company....

CONTROL RAS Easily...

2 wires and no plant computer hard/software changes... Controller started up by you...

...plus low bin indicator and alarm ...plus bridge alarm w Auto Blast

clarence@clarencerichard.com • 952-939-6000

resource directory Asphalt Drum Mixers........ 14, 58 Contact: Steve Shawd or Jeff Dunne Tel: 260-637-5729 sales@admasphaltplants.com www.admasphaltplants.com Astec, Inc.......... … 19, 43, 46, 57 Contact: Tom Baugh Tel: 423-867-4210 tbaugh@astecinc.com www.astecinc.com B & S Light Industries...............17 Contact: Mike Young Tel:918-342-1181 Sales@bslight.com www.bslight.com

CWMF Corporation................. 25 Tel: 877-457-3938 www.CWMFasphalt.com Dillman Equipment…............. .34 Tel: 608-326-4820 www.dillmanequipment.com E.D. Etnyre............................... 59 Contact: sales@etnyre.com Tel: 800-995-2116 www.etnyre.com Ergon Inc....................................11 Savemyroad.com Fast-Measure…....................... 65 Tel: 888-876-6050 www.Fast-measure.com

CEI.............................................. 4 Tel: 800-545-4034 info@ceienterprises.com www.ceienterprises.com

Gencor Industries…................. 13 Contact: Dennis Hunt Dhunt@gencor.com www.gencor.com

Clarence Richard Co................ 64 Contact: Clarence Richard Tel: 952-939-6000 Carrie@clarencerichard.com www.clarencerichard.com

Heatec, Inc. ....Inside Front Cover Contact: Sharlene Burney Tel: 800-235-5200 sburney@heatec.com www.heatec.com

Homestead Valve…................. 55 Tel: 610-770-1100 Sales@homesteadvalve.com www.homesteadvalve.com Libra Systems…….................. .45 Contact: Ken Cardy Tel: 215-256-1700 Sales@librasystems.com www.librasystems.com Meadwestvaco…...................... 31 Tel: 800-456-4034 www.evotherm.com www.mwv.com Meeker Equipment...............….37 Contact: Jeff Meeker Tel: 215-361-2900 Cel: 215-828-2651 Jeff@meekerequipment.com www.meekerequipment.com Recycling & Processing Equipment……………............…..27 Contact: Jerry Lambert Tel: 765-472-5500 Jerry@recyclingandprocessing.com www.recyclingandprocessing.com

Reliable Asphalt Products,................... Back Cover Contact: Charles Grote Tel: 502-647-1782 cgrote@reliableasphalt.com www.reliableasphalt.com

Systems Equipment............... .33 Contact: Dave Enyart, Sr. Tel: 563-568-6387 Dlenyart@systemsequipment.com www.systemsequipment.com

Roadtec……........................... .7, 9 Contact: Sales Tel: 423-265-0600 Sales@roadtec.com www.roadtec.com

Tarmac International, Inc........ 39 Contact: Ron Heap Tel 816-220-0700 info@tarmacinc.com www.tarmacinc.com

Rotochopper, Inc................... Inside Back Cover Tel: 320-548-3586 Info@rotochopper.com www.rotochopper.com

Top Quality Paving…............... 60 Contact: John Ball Tel 603-624-8300 Tqpaving@yahoo.com www.tqpaving

Stansteel AsphaltPlant Products…......... 51 Contact: Dave Payne Tel: 800-826-0223 dpayne@stansteel.com www.stansteel.com

Transtech Systems Inc............41 Tel: 800-724-6306 Sales@transtechsys.com www.transtechsys.com

Stansteel.................................. 21 Tel: 800-826-0223 dkochert@hotmixparts.com www.hotmixparts.com

Willow Designs........................ 28 Contact: Jerod Willow Tel: 717-919-9828 Eoawillow@aol.com www.willowdesignsllc.com

AsphaltPro’s Resource Directory is designed for you to have quick access to the manufacturers that can get you the information you need to run your business efficiently. Please support the advertisers that support this magazine and tell them you saw them in AsphaltPro magazine.

www.theasphaltpro.com 65

get online for your bottom line

Digital Details

Asphalt Pro magazine’s guide to managing your company’s online presence Use the rule of thirds: • of your social content should promote your business, convert readers, and generate profit. • of your social content should surface and share ideas and stories from thought leaders in your industry or like-minded businesses. • of your social content should be based on personal interactions and build your personal brand. Source: Hootsuite

Engage by sharing

3 of the most important Facebook metrics to track

If your company has a Facebook, Google+ or other social media presence, your main goal should be to engage your customers and potential customers. Sharing information on these outlets positions your company as an authority in your market. Photos of recent jobs, video, links to interesting articles, industry news, Twitter are all great content. Your goal is also to project the image of your company. Post photos of your employees volunteering at a local food pantry, or a picture of your newest piece of equipment and how it will allow your company to provide a better finished product.

Find the right frequency

Trial, Review and Rework

Manage your Style

Social media marketing trends for asphalt producers evolve more slowly than in other markets. With a little investment in time and a good plan, you’ll be able to manage your social media outlets in an efficient and effective manner. And if you review your efforts regularly, you’ll begin to see potential customers being converted to customers.

• Reaching Fans/Non Fans • Engagement Rate

• Optimal Posting Times Source: www.adweek.com

When and how often should you post? Each social media outlet will determine how often and how much you need to post. Twitter limits you to 140 characters, Instagram is photo based and offers very limited text, while Facebook readers will typically be looking for longer content.

Asphalt producers are busy trying to keep up with the day-today operations - not to mention keeping up with social media publishing. Creating a style guide allows multiple employees the ability to post to your social media outlets in a way that follows the image your company is trying to create.

Watch the Numbers

source:www.adweek.com

What would one good lead be worth to your company? How many potential customers have been converted by your social media efforts? Wouldn't it be nice to track the value of this ROI? You can track ROI manually or by using tracking software such as Google Analytics (it's free) or a number of other software packages you'd have to pay for.

You can connect with Asphalt Pro magazine on: Facebook, Twitter, through our Monday Toolbox tips e-newsletter and on our website www.theasphaltpro.com

Commercial • Residential • Maintenance

If your company does commercial or residential paving or maintenance, be sure to subscribe to our sister magazine Paving Pro by visiting www.mypavingpro.com

B-66 MultiPurpose Shingle Grinder

Up-Time vs Up-Keep Each Rotochopper shingle grinder is designed with one simple goal—maximizing the value of your shingle waste by minimizing wear costs and maintenance downtime. • No weekly hardfacing • Less spillage • Most uptime • Best horsepower efﬁciency RG-1 Purpose-Built Shingle Grinder

Follow Rotochopper on

320-548-3586 www.rotochopper.com

• Fast tooth & screen changes

• No augers, sprockets, or chains operating in abrasive ﬁnes • 350-765 HP, electric or diesel

Which Rotochopper grinder is right for your volume of shingle waste? Contact us today to learn more.