Kilian & Keeley Excel on Illinois Interstate Complete Closure

1-255 KILIAN & KEELEY EXCEL ON ILLINOIS INTERSTATE COMPLETE CLOSURE

BY SARAH REDOHL

Interstate 255 was among the first Rebuild Illinois projects. It was completed in October 2020.

IIn June 2019, Illinois Governor J.B. Pritzker signed into law the state’s first capital plan in nearly a decade - and the largest in state history. The historic, bipartisan bill, Rebuild Illinois, aims to make $45 billion worth of investments in roads, bridges, railroads, state facilities and more by 2025.

A $67 million project on Interstate 255 was among the first Rebuild Illinois projects. The Kilian Corporation, Mascoutah, Illinois, and its partner on the joint venture, Keeley & Sons, East St. Louis, Illinois, bid the job in November 2019 and completed it Oct. 28, 2020.

I-255 is a six-lane interstate that loops around the St. Louis Metro East area on the Illinois side of the Mississippi River. The concrete road had badly deteriorated over the years. “There were a tremendous amount of potholes everywhere,” said Steve Williams, operations manager at Kilian.

This particular section of I-255 has an average annual daily traffic of 50,000. “There’s a tremendous amount of truck traffic on this portion of the interstate, because there are quite a few quarries along the

Mississippi River,” Williams said, adding that there are four quarries within 10 miles of the project. There’s also a lot of north-south truck traffic that uses I-255 to avoid traveling through downtown St. Louis. “St. Louis isn’t very conducive to truck traffic, and this is a major route to sidestep that.”

Because the road experiences such heavy use, closing any lanes for construction was likely to create major problems. The complete closure enabled cheaper, faster and safer construction, reducing the completion time from 4 years to 10 months while saving $14 million and increasing safety both for workers and drivers.

Although Kilian wasn’t involved in the decision to close 255 during construction, Williams said it was a smart move. “If IDOT elected to do periodic lane closures, the traffic snarls would have been so bad that our trucks wouldn’t be able to get to us,” Williams said. And, he added, Kilian’s crews prefer the complete closure to what would have been the most likely alternative of completing the job at night. “So much work in the Metro-East area these days is happening at night, and it really begins to wear out families and affects the ability to retain employees.”

“Being able to work in the day and having 24 hours a day available to us took the handcuffs off and allowed us to be creative with scheduling and methods,” Williams said.

COMPLETE CLOSURE, COMPLETE CONTROL

The work zone extended from I-55/70 to Illinois 15, and was divided by I-64 into two construction phases, north of I-64 and south of I-64. In addition to paving the 7.7-mile section of interstate, the job also required new underdrainage, a large quantity of pavement patching, guardrail replacement, and 20 bridge decks requiring a wide range of rehabilitation work.

The north section was closed from Feb. 1 to June 13, 2020, and the south section, June 13 to Oct. 28, 2020. Despite the safety and efficiency benefits of completely closing the interstate, this also presented unique challenges.

“We had to establish our own rules for working on a closed interstate,” Williams said. They posted 30 mile-per-hour speed limit signs throughout the work zone. They also posted directional signs to ensure everyone drove in the correct lanes within the job site, just as if it were an open interstate.

Williams recalled one of the owners at Keeley & Sons questioned the need for such a low speed limit in a closed work zone. "But then he drove through the work zone at 15 miles per hour and felt like even that was too fast because there was so much activity going on."

The key to working at a tremendous speed was establishing specific areas for each crew and subcontractor, and everyone was expected to honor the designated areas and stick to their individual schedules. “We made a rule that no one from one group could go into another group’s area without their permission,” Williams said.

Another consideration they had to make was at the entrances to the work zones. “We used flashing arrow boards and large signs telling the public not to follow a truck into the work zones,” Williams said, adding that trucks could only enter near one of those signs. “Once they pulled in, they were required to come to a complete stop to ensure no one followed them in.” Thankfully, Williams said, it was very rare that anyone unauthorized entered the work zone. The few times it did happen, he said, “we’d run them off really fast. Everyone could tell when someone who did not belong there has entered the job site.”

Once these safety protocols were established, Kilian was able to get to work - and quickly. “With the interstate being closed, a lot of the obstacles we’d normally face weren’t there,” Williams said. “It allowed us to really accelerate our work.”

And pace was paramount for this particular job, with a $50,000 per day penalty for running over schedule. They could also earn a bonus of $50,000 per day for up to 20 days for a total bonus of $1 million for early completion.

Over the years, Kilian has built a niche for itself performing large, fast-paced projects, “the kinds of projects that intimidate others,” Williams said. “We’ve assembled an amazing team that can look at a large project and know that we’re prepared to take it on.” The type and pace of work was similar to previous Kilian jobs, except this one “went on and on for months instead of weeks,” Williams said. The company had to make sure its workforce didn’t get exhausted by the work and risk creating safety issues by rotating various employees out to other projects to get a break.

LEFT: This particular section of I-255 has an average annual daily traffic of 50,000, with heavy truck traffic due to area quarries and north-south truck traffic that uses I-255 to avoid traveling through downtown St. Louis. RIGHT: The complete closure of I-255 enabled cheaper, faster and safer construction, reducing the completion time from 4 years to 10 months.

Choosing subcontractors who could also work at that pace and scale was key, as was working with a partner they could trust. Kilian and Keeley & Sons have worked together on several joint ventures over the years. “Working that fast and at that large of scale, we needed a lot of trust in each other,” Williams said.

NEED FOR SPEED

Kilian and Keeley & Sons bid the job in November 2019 and started at the end of December with prep work in advance of the shutdown on I-255. This included 23,000 square yards of patching, performed by Keeley & Sons, along detour routes as well as on the second phase section of I-255, “to make sure it didn’t fall apart in the meantime,” Williams said. They also widened small intersections along the detour routes in advance of increased traffic.

On Feb. 1, they closed the northern section of I-255 and began work on the underdrainage. “Our rule was we couldn’t take any bridge out of action until the underdrains came across,” Williams said. “But as soon as they did, we shut that bridge down.” The bridge work was shared by Kilian and Keeley & Sons.

After the bridge work was complete, milling and paving could begin. The milling subcontractor, Kaskaskia Engineering Group (KEG), Belleville, Illinois, milled off 1 inch of concrete in the driving lanes with their Wirtgen milling machines. The job originally called for milling half an inch off the shoulders and driving lanes, but Kilian

suggested milling the shoulders might not be necessary. “The shoulders were almost new,” he said. Meanwhile, the driving lanes had a lot of surface cracking. Killian suggested milling 1 inch off the driving lanes for increased longevity and smoothness and leaving the shoulders as is. This change would save the DOT $500,000.

The IDOT liked the idea of leaving the shoulders as is. They spent the $500,000 they'd be saving, plus an additional $500,000, to pave thicker lifts on the mainline portions of the job. The original bid was two 2-inch lifts of SMA asphalt, but this was changed to one 2.5-inch lift followed by a 2-inch lift.

The interstate is three lanes in each direction, plus 10-foot shoulders, for a total of 56 feet wide on each bound along with 22 interchange on/off ramps. At 7.7 miles long, Kilian paved roughly 55 lane miles plus ramps over the course of 45 days of paving with its Caterpillar AP1000 pavers and Weiler material transfer device.

In total, the job required 150,000 tons of asphalt, 81,500 of which was SMA, made at two asphalt plants belonging to Kilian’s sister company Asphalt Sales and Products. They had two plants equidistant from the project, and equipped both with cellulose blowers to add cellulose fibers into the SMA mix, as well as dust run-a-round systems. “We wanted to make sure both plants were prepared to make SMA at all times,” Williams said. “SMA doesn’t have a lot of fines, so it likes to drain down if you don’t have the cellulose fibers in it.”

The company predominantly relied on its plant north of the job, in Roxana, Illinois, because its staff had more experience with SMA. “We were confident they’d be able to run that mix at high efficiency and quality,” Williams said. The plant south of the project, in O’Fallon, Illinois, also produced mix when needed, though it tends to be the busier of the two.

CONFIDENCE TO OVERCOME CHALLENGES

In addition to the unique challenges of a complete closure, the I-255 job had other quirks. For example, mainline bridges required 28,000 square yards of waterproof membrane system. IDOT usually uses coal tar emulsion and fiberglass sheets, Williams said, “but it’s an extremely labor-intensive process.” Plus, coal tar was not in production during the time of year they were performing the bridge work. “Usually you can’t get it until mid-April at the earliest.”

Kilian got creative about how they could overcome those twin challenges, proposing an alternative waterproof membrane system: full lane sealant. They could apply the same longitudinal joint sealant material on the bridge decks, but applied in full-width passes versus in 18-inch wide passes and then overlay it.

“We did a project in 2018 using this material as a waterproof membrane and it took a lot of unpredictability out of the job.”

They conversed with IDOT, conveying how using FLS would bypass labor and material availability issues to ultimately speed up the project, while saving quite a bit of money. “IDOT thought it was a good idea,” Williams said. “Without that change, we could have easily finished 15 days late because the other process is so laborious and unpredictable. Now, IDOT has a new process they feel comfortable doing that they can use on future projects.”

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“If IDOT elected to do periodic lane closures, the traffic snarls would have been so bad that our trucks wouldn’t be able to get to us.” — Steve Williams

In addition to a large quantity of pavement patching, bridge deck rehabilitation, milling and paving, the project also included replacing more than 29,000 feet of guardrail. They also removed more than 33,000 feet of single-faced concrete barrier wall and replaced it with more than 19,000 feet of new double-faced barrier.

Another hurdle was the weather. Because they were starting in February, they were still experiencing occasional snow. Kilian ended up hiring a snow removal crew to be on standby just in case of snowfall so their employees could get to work. Ultimately, this was only necessary for two days. “But if we’d had the same weather we had in February 2019, there’s no way we’d have gotten any bonus for early completion.”

Covid presented yet another challenge. “When the first shutdown started Feb. 1, we hadn’t even heard of Covid yet,” Williams said. The pandemic, and accompanying fear, quickly escalated. “Even though we were deemed essential employees, and that helped tremendously, we were having to convince people to come to work. We had to do a lot to alleviate peoples’ fear in those early days.” That included social distancing, wearing masks, setting up hand washing units throughout the job, and additional toolbox talks and safety instructions to ensure employees were working safely and also to alleviate fears.

“It's amazing we were able to get done as early as we did with what we were facing,” Williams said. “I’m proud of the fact that our company is somewhat fearless. A job like this requires confidence that you’ll be able to figure out a way around any obstacles that arise.”

With a deadline of Nov. 24, Kilian was able to get the job open on Oct. 28 and received the maximum bonus. Kilian earned an additional $345,000 in pay for performance (PFP) bonuses for various HMA mixtures.

For its performance on I-255, Kilian was recognized as IDOT’s Contractor of the Year. Although they’d won the award in 2011 for a similarly large, fast-paced project, Williams was as proud as if it had been the company’s first.

He attributes the project’s overall success to teamwork. “Everyone has to buy into the mission of not only constructing at a fast pace, but at high quality,” Williams said. “Our team borders on being a family, and that’s required to do something at this size, speed, quality and safety. We’re very proud of that and of our team.”

Living just 15 minutes from this section of I-255, and traveling it often, Williams is also proud of the pavement he and his crews so expertly paved. “Motorcycles scarcely used to ride on this section of interstate for fear of hitting one of the many potholes,” he recalled. “Now, they just love it. It’s a source of pride in this area.”

Furthermore, the project is a source of pride for the state as a symbol of early success in its effort to Rebuild Illinois.

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Track What You Pave

MMany original equipment manufacturers (OEMs) offer telematics and tracking systems to assist with everything from fleet management to material delivery. The article “Asphalt Industry OEMs Target What Each Operator Needs” is a touch dated but contains a baseline for you to check out at theasphaltpro.com. Definitely peruse any of the more recent New Tech department articles that dive into predictive maintenance technologies for a litany of options available these days. Most recently, freelance writer Del Williams, Torrance, California, submitted the following piece on how real-time, 24/7 tracking helps to optimize turnaround of your rented equipment, and how that continuous tracking can deter theft and reckless use by encouraging user accountability. He used Advanced Tracking Technologies, Houston, Texas, to illustrate his points.

Construction contractors frequently rent heavy equipment for big jobs, Williams wrote. When renting equipment, job profitability depends on efficiently renting out equipment, keeping it in good working order and returning it on time, whether that involves lowboys, cranes or scissor lifts, haul trucks, and so on.

To maximize profitability, contractors need to keep track of the equipment to ensure timely return when the job is complete especially when multiple equipment is being leased with multiple jobs occurring in a variety of locations.

To protect and preserve these rented assets, contractors also must deter theft and reckless use as ultimately the responsibility for the equipment rests on their shoulders. On top of this, if the contractor’s name or logo is emblazoned on vehicles for the public to see, it is vital to prevent any dangerous actions, such as speeding, that could hurt their brand or even invite liability in the case of serious accidents.

As a proactive response, a growing number of contractors are turning to real-time, 24/7 GPS tracking of their heavy equipment rentals to ensure better fleet management and faster rental turnaround. In addition, the same approach provides clear driver and operator accountability, which helps to reduce asset damage and prolong its usable life.

“Continuous GPS tracking enables contractors to instantly see where all of their heavy equipment assets are at any given moment, so they can know as soon as possible which will be ready to return with minimal downtime,” said Ben VanAvery, director of sales and marketing at Advanced Tracking Technologies, a designer and manufacturer of GPS tracking products.

Compared with typical GPS tracking devices that may only update every few minutes, a system like ATTI’s Shadow Tracker provides real-time location updates every 10 seconds, as well as location, speed and idle time alerts if something is amiss. This data is transmitted via satellite and cellular networks to a smartphone or PC on a 24/7 basis. The system has access to nationwide speed limits in its database.

According to VanAvery, via a PC or smartphone app dealers can display the real-time location of the entire fleet on a map and zoom in on any specific vehicle. At a glance, they can see if a vehicle is moving (displays green) or stopped (displays red). If they touch a vehicle icon, the app will display where the vehicle has been, where it stopped, and how long it has idled.

Such GPS tracking helps not only to prevent the theft of heavy vehicles and equipment, but also aids in its swift recovery, if it is ever necessary. Law enforcement, for instance, could be provided a relatively precise location of anything stolen.

Because supervisors can be notified when posted speed limits are exceeded, this capability can also serve as deterrent to speeding and help to minimize the risk of accidents, damage, and excess wear and tear. This facilitates extending the equipment’s usable life, while minimizing pre-mature repair and maintenance.

With better renter driving encouraged by active monitoring, this approach could also reduce tickets and potential liability, and may even help to lower the cost of insurance.

Advanced GPS tracking dramatically streamlines the process of returning rental equipment. It does so by making the entire fleet’s location and availability instantly visible, so no equipment is sitting idle and not in use. This, in conjunction with the ability to encourage greater user accountability, can significantly enhance profitability, while prolonging the usable life of the fleet.

For more information, contact Advanced Tracking Technologies at (800) 279-0035.

Additional OEMs who offer data tracking and monitoring services alongside their proven iron can be found on the next few pages. These companies have shared their newest offerings to enhance your bottom line. Let them know you saw them in AsphaltPro magazine.

AMMANN

ServiceLink from Ammann Group, Langenthal, Switzerland, has been updated to simplify customer access to machine data that makes jobsites more transparent, productive and profitable. ServiceLink is available for light equipment, including plate compactors, and for heavy machines, such as rollers and pavers.

ServiceLink for light equipment uses a new generation of hardware to ensure the most crucial machine data is consistently available to customers. “This is all about reducing downtimes and opportunity costs,” said Bernd Holz, vice president of light compaction at Ammann. “This simplifies logistics and distribution of machines to jobsites.” ServiceLink also provides customers with machine data so they can spot trends and adjust accordingly.

Key information includes battery charge. “It’s not a problem if you have to charge a battery before using the machine, as long as you know it,” Holz said. “It is, however, a bad situation if you arrive at a jobsite and only then discover you can’t start the machine—for example, a light compactor. This is particularly important if other facets of the job depend on completing the compaction.”

A one-time fee covers the cost of the light equipment hardware (also known as the TCU), portal access and data transmission. Customers say machine location is the most important information. “They also want to know if the battery voltage is sufficient,” Holz said. “They want information about how many hours the machine has worked, too. Those

The ARX 26-2 light tandem roller can be equipped with ServiceLink from Ammann.

three—location, battery, hours—that’s what they need.”

That information requires little bandwidth. That led the ServiceLink development team to use a specialized data transmission technology called narrowband IoT, or NB-IoT. First, it requires little power. NB-IoT also has a strong penetration signal, meaning it can connect in rural areas and for long distances. Data transmission is also secure.

“The data transfer is automatic,” said Wladimir Drisner, product manager—light equipment at Ammann. “There is absolutely no manual interaction required of the user. This is a breakthrough for a small, light and affordable device.”

Crucial to data transfer, and ServiceLink in general, is the revamped hardware. It is compact, fully enclosed to prevent penetration from dust and water, and rugged to withstand harsh jobsite environments. The TCU housing contains all the electronics: a microchip, GPS module, NB-IoT module and sensors. It comes factory-mounted or can be added later as a retrofit. It can be installed on all current and older Ammann light equipment machines. Installation is extremely easy. After the installation, ServiceLink is ready to work. “You activate the TCU by simply plugging in the dedicated TCU battery or the machine’s starter battery,” Drisner said.

Light equipment that is not equipped with starter batteries, such as small plate compactors, will be powered exclusively from the TCU battery. It lasts between two and four years, depending on the transmission frequency and various external factors, and is easily replaced. “You just unplug the old one and plug in the new one,” Drisner said.

Accessing ServiceLink is simple, according to the manufacturer. ServiceLink users first register the machine. “Customers can log onto the platform through myAmmannn.com,” Holz said. “Once there, they register their machines and TCUs.” The process is fast. “You can access telematics data within seconds of a registration,” Holz said.

Subsequent visits are even easier. “All customers have to do is click on ServiceLink. All Ammann applications are a single sign-on. It’s one click, and you’re on the portal. There’s your information.” Also available is a ServiceLink mobile app for iOS/Android.

From start to finish, Ammann made simplicity a priority. Drisner said, “Customers expect that telematics is not complicated.” Knowing a machine’s location removes guesswork for the customer. “If you have to manage multiple jobsites at once, it makes it much easier to track where all the machines are,” he said.

ServiceLink provides anti-theft protection, too. A “geofence,” or a virtual perimeter, can be defined within the portal, Drisner said. An alert can be sent if the machine leaves the perimeter. If the equipment is being relocated during a routine time of the day, the customer will assume an operator is moving it. “But if it’s Friday night at 11 p.m., you would have a different reaction,” Drisner said.

Recovery of stolen equipment is more likely because the GPS will continue to send the machine’s location after the theft.

The data on a machine’s working hours can be used to schedule maintenance. Customers can make their own evaluations based on that information or rely on alerts from Ammann that a machine is due for service.

“Grouping the light equipment is essential to ensuring proper maintenance,” said Heiko Graber, global aftersales and service director. “It can be inconvenient to bring in a single machine for maintenance, so there is a logistical element. In addition, customers are more likely to see the importance of maintenance when they see how many machines are impacted. In the end, that maintenance extends the life of the machines.”

ServiceLink for heavy equipment, such as rollers and pavers, offers additional functionalities, including fuel consumption data. “The customer can evaluate fuel usage on an ongoing basis and also evaluate specific time periods to spot trends,” Holz said.

Heavy equipment users use myAmmann. com the same way as light equipment users. “There is one consolidated telematics portal for all machines,” Holz said.

All heavy machines from Ammann come equipped with the necessary wiring and linkages. Customers can have ServiceLink installed at the factory or add it later.

For more information, visit https://www. ammann.com/en/.

ASV

ASV Holdings Inc., Grand Rapids, Minnesota, has grown its presence in the United States with the introduction of 21 new dealer locations across six dealers. They include ROMCO Equipment Co., Carrollton, Texas; Volvo Construction Equipment and Services, Corona, California; Stone Equipment Co., Montgomery, Alabama; J.W. Turf, Chicago, Illinois; Sherlock Equipment Sales, Bremerton, Washington; and Rowe’s Tractor, Wenatchee, Washington. The dealers will offer ASV’s full line of Posi-Track® compact track loaders.

ASTEC

The Astec Industries RP-250 is a heavy-duty 10-foot (3-meter) asphalt paver that combines the advantages of rubber tires with the tractive effort of a crawler paver. This large footprint 250-horsepower machine has increased traction and flotation with a smooth ride, according to the manufacturer.

The RP-250’s unique augmented steering is assisted by the rear wheels and operators have precise control, especially in turning, according to the manufacturer. The paver’s unique frame-raise ability allows the operator to control and adjust the frame position as needed.

The RP-250 features Astec’s exclusive anti-segregation design of the feed tunnel, the feed tunnel discharge and the rear augers. • Delta Plate defines the front wall of the material tunnel, preventing mix from rolling forward under the paver. • Augers are kept close to the discharge of the conveyors, so material is always kept

The RP-250 from Astec Industries features a 252-cubic-foot hopper capacity.

moving. The auger assembly pavers can be hydraulically raised, lowered and tilted. • Electric flow gates are designed to be simple to operate and to give precise control over the head of material. • Features include: • Cummins QSB 6.7, Tier 4F engine • 250 hp @ 1,900 rpm • Up to 233 fpm paving speed • 252 cu ft hopper capacity • Frame raise capability

For more information visit https://www. astecindustries.com/products/details/roadtecrp-250-highway-class-asphalt-paver.

CATERPILLAR

Caterpillar Inc. announced the availability of “The Fundamentals of Equipment Economics” web-based training course, designed to help construction business owners and fleet managers reduce equipment costs, extend and optimize machine life, and improve profitability through proven, data-driven principles. Built on over 50 years of experience, Caterpillar has partnered with industry expert Mike Vorster to develop an equipment economics curriculum.

An eight-part online program offered by Caterpillar University, “The Fundamentals of Equipment Economics,” is designed for a wide range of businesses, from large contractors that manage diverse fleets with hundreds of machines to small construction and landscaping firms using a single piece of equipment. It uses a pragmatic, step-by-step approach to teach essential skills and best practices for: • Predicting and managing owning and operating costs; • Determining when to repair, rebuild or replace a machine; • Measuring the value of reliability and utilization; and • Mastering quantitative tools and advanced economic concepts.

In other news, Caterpillar received gold for its Cat® Command for Construction system during the 2021 Edison Awards program. It was recognized as being the best of the best for the Smart Productivity Tools–Living & Working Environment category. Named after Thomas Alva Edison, the Edison Awards have recognized some of the most innovative products, services and business leaders in the world since 1987.

Cat Command removes the operator from the machine, offering safe operation in hazardous areas. The Command console and station delivers remote-control operation from the comfort of an air-conditioned office, thousands of miles away from the project site. Eliminating shift-long machine vibration feedback, the system reduces the chances for operating injuries and fatigue-related accidents as well as increases productivity.

“We’re honored the Edison Awards panel of judges, comprising of more than 3,000 senior business executives and academics, chose Cat Command as a gold recipient. I’m extremely proud of how talent from the entire enterprise coalesced around the vision for Cat Command, and I commend them for their dedication to innovation and hard work on a solution that adds significant customer value,” commented Construction Digital & Technology Worldwide Product Manager Fred Rio.

“We were very impressed by the level of collaboration and discovery in this year’s entries,” said Edison Universe Executive Director Frank Bonafilia. “Somehow, while facing the unprecedented challenges of this global pandemic, companies around the world figured out how to work safely and smartly and still innovate at an award-winning level.”

For more information, visit the Caterpillar website.

CHEMTEK

Chemtek Inc., Morrisville, North Carolina, now offers a new disposable tote option for 275-gallon and 330-gallon quantities of its biodegradable asphalt cleaner, PavePro Green. The company stated one of its main objectives is to achieve maximum sustainability in its manufacturing processes and product offerings. The company now extends its sustainability efforts to include product packaging. The new disposable EarthWise totes are not only environmentally friendly, but are designed to provide space, time and disposal savings.

For more information, contact (888) 389-3189.

HAMPTON PRODUCTS

Hampton Products International Corp., Foothill Ranch, California, has announced that its Keeper® Combat™ ratchet tie downs are now available at The Home Depot. Keeper Combat ratchets feature a strong steel ratchet with “No Slip Grip” handles and vinyl-coated S-hooks to prevent scratching and marring. Leading the family of products is the 16-foot Combat ratchet tie down, which has a patent-pending, 1.25-inch webbing design to absorb shock and resist cut, rot and abrasion with a half-ton working limit. The 16-foot Combat ratchet has a 1,000-pound load limit and overall dimensions of 2.8 x 11 x 13.9 inches (D x H x W).

JOHN DEERE

John Deere, Moline, Illinois, introduced in May its construction equipment service program, John Deere Protect™ Service Plan. Through this program, routine maintenance is performed at every 500-hour interval by an experienced John Deere dealer. The program is designed to decrease long-term ownership costs and reduce customer risk.

LUTEC

Lutec of Germany offers the Comicat 140 machine for grinding asphalt, concrete and terrazzo. The company stated it’s used regularly to prepare floors in retail centers, industrial buildings, hospitals, and parking garages, as well as to prepare bridge, concrete road, and asphalt road surfaces for resurfacing.

Without a conveyor, it mills surfaces up to 3 inches deep and 14 inches wide in a single pass and leaves the millings for a skid steer to collect. It does this with a 31-piece milling tool. This allows for a production rate of up to 1,200 square feet per hour, according to the manufacturer. The low-impact, high-production Comicat 140 is small and maneuverable, according to the manufacturer; it also comes equipped with a Hepa filter and vacuum attachment for indoor use. It is available in North America via the dealer in Mississauga, Canada.

For more information, visit the Lutec website.

SAKAI

Sakai America Inc., Adairsville, Georgia, announced Frost Machines, Powell, Wyoming, as a new authorized dealer with areas of responsibility including Northern and Western Wyoming, Eastern Idaho and all of Montana. The dealership includes sales, parts, and service of the heavy equipment product lines of

asphalt rollers and soil compactors, as well as all light equipment lines. Their fleet also includes the model GW754, the only vibratory pneumatic tire roller in the market.

Owners Michael and Stuart Frost have over 40 years combined highway construction experience with Mountain Construction. That experience led them to create AXENOX Construction Solutions®, which manufactures and sells paving construction equipment and tools.

For more information, contact Kim Wilson at (307) 272-1011.

Sakai America also celebrated 20 years of assembling asphalt and soil rollers in Adairsville, Georgia, in May.

“Sakai America has experienced exceptional growth over the past 20 years in the United States,” said Yasunori Azumi, president of Sakai America. “We have proudly assembled over 3,500 machines here in our Adairsville, Georgia, facility, and look forward to being part of this community for many years to come.”

Fifty employees work at the Sakai America facility in Adairsville. The location serves as the North American headquarters, has a 175-foot-long assembly line, 97,000 square feet of office and warehouse space within two buildings, and over 40 acres of land for testing and machine storage. This summer, the company brings the SW774 series to the Adairsville facility for assembly as well.

SPEEDBINDERS

The Crosby Group, a lifting, rigging and load securement hardware manufacturer headquartered in Richardson, Texas, has acquired Speedbinders, which is a manufacturer of load binders for heavy duty load securement.

Robert Desel, CEO of The Crosby Group, said, “We are thrilled to expand our best-inclass load securement portfolio with Speedbinders. The torque drive technology’s dual focus on enhancing worker safety and improving productivity for drivers is a winning combination for the industry.”

STACOOL

StaCool Industries, Lecanto, Florida, maker of the StaCool Vest™ core body cooling system, unveiled its new website to allow users to search for cooling vests for personal use or industrial applications, compare models available, find and replicate past orders, purchase online, track shipments, and even manage payments. Packed with information, the online home to the originator of the Cool Vest educates users about heat stress and includes details about cooling vests worn under- or over-clothing, fire retardant vests, and more.

Whether elevated ambient temperatures are due to the summer heat or to manufacturing processes like welding, working near furnaces, boilers, or other heat process equipment, maintaining a consistent core body temperature is vital to user safety. According to the manufacturer, supplying cooling technology, like cool vests, is safer than exposing workers to possible heat related illnesses, and because wearers do not require cooling breaks, they are considerably more productive.

For more information, check out the StaCool website.

TAKEUCHI

Takeuchi-US, Atlanta, Georgia, has hired Shann Cooke as its new Midwest regional product manager. Cooke will now be responsible for supporting all the company’s dealers and national rental accounts in the Midwest region, which includes the states of Kentucky, Illinois, Indiana, Michigan, Minnesota, Tennessee and Wisconsin. He will also train the region’s salesforce on product features, benefits, applications and how to perform effective machine demonstrations.

“Shann has a long and proven track record in sales,” said Shay Klusmeyer, divisional sales manager for Takeuchi-US. “He also understands the heavy equipment market, having owned and operated his own machines for more than 20 years. His knowledge of the entire sales process, from managing teams and logistics to closing the deal will help us develop our salesforce throughout the Midwest. We’re very pleased to have Shann on board.”

WEILER

The SE10F front-mounted screed from Weiler Inc., Knoxville, Iowa, offers a rigid frame to prevent flexing and in-line extension cylinders with full wrap-around slider bearings to reduce extension deflection. Trailing edge screed plate adjusters are easily accessible for quick leveling, according to the manufacturer. 675-volt, U-shaped heating elements provide 20-minute heat up time and reduce cold spots. Zone monitoring allows heating to continue in the event of a sensor failure.

Cat® F-Series controls are conveniently located and monitor screed heat, adjust feeder system ratios, and are integrated with Cat Grade and Slope control system. The platform features an 18.5-inch-wide folding walkway with extensions, dual side 4-foot level holders, built-in cup holders and lockable toolbox.

For more information, contact (641) 8282334.

WILEY

Protecting eyes at the workplace or jobsite is of critical importance. Wiley X®, Livermore, California, offers an assortment of ANSI-rated protective eyewear for 2021. Founded in 1987 by Myles R. Freeman Sr., a proud U.S. veteran with a simple idea: provide superior protective eyewear to the brave men and women who defend our country. Wiley X got its start producing protective, premium eyewear for the U.S. Military.

While Wiley X hasn’t lost sight of its original goal, their mission has evolved. The same technologies that continue to keep the military and elite special forces safe, also protect those who seek safety on the job.

Key features of Wiley X eyewear include ANSI Z87.1 safety ratings that are OSHA approved for maximum protection, high-wrap frames to prevent unwanted light from obstructing peripheral vision, and models with removable Facial Cavity™ seals that block dust, debris, and harmful substances, according to the manufacturer. Some models come in expanded rim system options, allowing wearers with prescriptions from -7.00 to +5.00 to have premium safety rated eyewear as well. The Worksight™ Series styles come with removable side shields to protect when on-the-job or be removed when wearing in the office or at home.

Top new styles for 2021 include the CCS Breach, AS Peak and WS Epic.

For more information, visit the Wileyx website.

– BY ASPHALTPRO STAFF

Step 3

The Spective display shows the operator his plantʼs efficiency in real time. Step 4

The display will show the operator on a visual representation of the plant where any fault may be occurring. Then he can select the “information” button to access troubleshooting tips to correct and clear the fault.

Step 2

Spective walks the operator through start-up with a step by step sequence on-screen. Step 1

The operator presses the blue and white start buttons under the 12-inch touchscreen display.

Kleemann’s Spective Control System

NNew mobile crushing plant operators can face a daunting task at the jobsite as crushing technology and plants increase in complexity. The engineering team at Kleemann, a division of Wirtgen Group, Antioch, Tennessee, has designed the Spective user interface system to make crushing plant controls easier to manage from day one. Here’s how it works:

In automatic mode, the Spective display guides the operator through the process of starting up the plant. First, the operator presses the blue and white start buttons under the 12-inch touchscreen display. The system then shows the operator, step by step, how to engage each additional function. Because the system is sequential, the operator can learn the process for startup merely by performing his job.

Next, the impact crusher or cone crusher has the ability to “zero” the crusher closed side setting/gap. This allows the operator to adjust for the previous day’s wear in seconds to maintain a consistent end product.

Along the bottom of the 12-inch Spective screen, important information such as production utilization, gap setting and fuel consumption are displayed during operation. Other relevant data can be accessed as needed because the logical menu navigation is designed with clear operating instructions.

For example, in the event of a machine caution, the Spective display will show the operator on a visual representation of the plant where the fault is occurring. If the operator needs further assistance, he can select the “information” button and a list of trouble-shooting steps will appear. This will expedite the resolution of the fault and get the machine back up and running.

If the plant operator so chooses, he can use the Spective Connect App on his phone or tablet to monitor the information on the Spective display from the safety of his wheel loader or excavator cab. This allows one operator to manage the crushing operation from raw material to final product while staying connected to the operation of each machine.

For more information, contact Matthew Graves at (629) 395-5314 or visit www.kleemann.com.

Get Ready for MSHA to Tackle Crystalline Silica

Equipment manufacturers have taken worker exposure into consideration in newer equipment updates which, if properly maintained and included in a Table 1-like control method, could streamline implementation of a new MSHA crystalline silica rule. Photo courtesy of Caterpillar

AAsphalt pros and others under the Occupational Safety and Health Administration’s (OSHA) jurisdiction have had several years to learn how that agency’s crystalline silica rulemaking affects their operations. Now, their counterparts in the aggregates industry are watching and waiting for Mine Safety and Health Administration (MSHA) to release its own rule, which seems likely to parallel OSHA’s more stringent permissible exposure limits.

“The OSHA rule is really already out there and it’s kind of a blueprint,” said Libby Pritchard, construction materials safety director, National Stone, Sand & Gravel Association (NSSGA). “We assume that there will be some similarities between the two rules, but that doesn’t mean the MSHA rule will be a copy/paste version of the OSHA rule.” Provisions likely to carry over include the lower permissible exposure limit and the inclusion of medical surveillance, she said.

SETTING THE PRECEDENT

In 2016, OSHA published a final rule on crystalline silica requiring worker protection over the permissible exposure limit (PEL) of 50 micrograms per cubic meter, averaged over an 8-hour day, which is half the current MSHA standard PEL of 100 micrograms per cubic meter. Other provisions include measuring worker silica exposure, limiting access to high-exposure areas, using effective methods for reducing exposure, providing medical exams to workers with high silica exposures, training workers about the hazards and how to limit their exposure, and, of course, recordkeeping.

During the Trump administration, the rule was challenged in a number of court cases, including one in the U.S. Court of Appeals, D.C. Circuit. There, Merrick Garland, now the U.S. Attorney General under the Biden administration, upheld challenges to the rule. He also ruled in favor of union objections to the absence of medical removal provision, which was in the proposed rule, but eliminated from the final rule without comment. Garland directed OSHA to reopen the rule and reconsider medical removal. While the agency is not required to include it, it must articulate support for its stance on the issue.

“This medical removal issue is kind of a ticking time bomb over in the corner that nobody’s really talking about,” said Adele Abrams, president, Law Office of Adele L. Abrams P.C., explaining that there is no bio marker to determine a level to trigger medical removal.

“Lung damage is not reversible,” she also noted. “There’s no going back to a point where it would be safe to resume work in that silica-exposing position. That person is never going back to mining again; they’re probably going to be out on permanent partial disability. That’s huge from a worker’s compensation perspective.”

LOOKING FOR OPPORTUNITIES

As both OSHA and MSHA consider crystalline silica, asphalt and aggregate producers have an opportunity to argue for facets of their operations to be addressed like construction industry jobs regulated in Table One of OSHA’s rule. The table specifies exposure control methods for various equipment uses and tasks. If the control methods are used for those tasks, the operator is not required to measure the worker’s silica exposure and is not subject to the PEL.

Abrams explained that the construction materials industry would like to see those exposure control methods applied across the board. Currently, she said, an asphalt producer could be using the same protective measures outlined in Table One, but would technically still be required to perform periodic sampling, which is more complicated and expensive.

“We think there is a place for (Table One) in an MSHA crystalline silica standard,” added John Ulizio, director of NSSGA’s Industrial Sand Division. “We have a lot of jobs that have control booths. If you work in a control booth and you have adequate door seals, ade-

quate filtration for incoming air, practice good housekeeping, and the booth is under positive pressure, it really doesn’t make sense for the operator to spend money and time and effort on sampling. It’s better for the operator to spend the sampling efforts on other jobs.”

GEARING UP FOR A NEW STANDARD

If they have not already done so, aggregate producers should benchmark their silica programs to OSHA’s current standard, Abrams advised. California producers should adhere to the CalOSHA standard, which includes an additional injury and illness prevention program.

With many operations that share workers between asphalt and aggregate operations, it’s best to ensure that all worker exposure falls under the OSHA threshold, she said. “From a moral perspective, how do you justify affording your people on the asphalt side of the road under OSHA twice the protection you’re giving your miners on the quarry side of the road who are making raw materials for the asphalt plant,” Abrams added, noting that it could be inviting litigation to maintain different standards for asphalt and aggregate operations.

Operators should also implement the hierarchy of controls to reduce worker exposure. Begin using all feasible engineering controls such as ventilation, dust suppression, and enclosures. Then move on to administrative controls and work practices such as worker rotation. Use of personal protective equipment should be the last resort to minimizing worker exposure. Finally, equipment maintenance is essential.

“Employers need to upgrade their tools,” Abrams said. “Don’t nurse the old stuff because, in the end, you’re going to spend a lot more energy trying to use alternative engineering methods rather than replacing it with one that has been designed to help you achieve the standard.”

As MSHA collects data and formulates its approach to crystalline silica, industry leaders are engaged in ongoing dialogue with the agency.

“We have a substantial interest in what MSHA does with respect to crystalline silica,” Ulizio said. “We want to be a partner with MSHA...and share the experience and insights our members may have learned over the course of their operations and work toward getting a good rule that’s going to enhance worker protection and allow us to continue to provide our essential materials.”

“We support a silica standard that improves worker health and safety and works for operators,” Pritchard added.

– BY THERESE DUNPHY

Therese Dunphy has covered the aggregates industry for 30 years. As owner of Stone Age Communications, she provides communications consulting services to help producers build strong relationships within the communities they serve. She can be reached at therese@ stoneagecommunications.com.

HIGH-PERFORMANCE, NEXT GENERATION TECHNOLOGY FOR PAVED SURFACES

Liberty SmartMIX™ is an easy-to-use rubber additive to enhance asphalt mix for improved compaction, flexibility and durability. SmartMIX ™ is made from recycled tires – featuring sustainability, cost-effectiveness, safety and performance – without the expense and complexity associated with liquid modifiers.

To learn more, contact: Doug Carlson Vice President, Asphalt Products (602) 751-6039•dcarlson@libertytire.com LIBERTYTIRE.COM

Cost-effective

Up to 15% lower per ton cost and up to 50% reduction in modifier costs.

Durable

Flexible, long lasting and low-maintenance.

Sustainable

Made from recycled tires, allows use of more RAP, and can be recycled.

Proven

Field-tested in both hot and cold climates.

Scalable

Order quantities for projects of any size, large or small.

EarthCam Delivers DOTS Visual Data

TThe suite of live streaming webcams and related services from EarthCam, Upper Saddle River, New Jersey, have been used on thousands of infrastructure construction projects around the globe.

Within the United States alone, more than 40 state departments of transportation (DOTs) and numerous towns, municipalities, engineers and contractors have used EarthCam technology for project documentation, security, traffic monitoring and real-time live streaming to keep the public informed about their infrastructure projects.

“From time-lapse documentation of the country’s largest projects, to temporary mobile trailer cams for work zone safety monitoring, EarthCam provides webcam solutions that increase productivity and efficiency for the toughest jobsite applications,” said Bill Sharp, EarthCam’s senior vice president of product development and strategy.

In the spring of 2021, EarthCam announced a new partnership with Infotech, Gainesville, Florida, that aims to deliver critical visual data directly into DOT workflows, streamlining the ability to use visual data in project management. This integration creates a visual timeline from the project site, offering documentation for inspections and daily reporting while enhancing the audit trail.

Images can automatically be pushed to specific contracts in Infotech’s construction administration solution, such as compliance reports. For efficient data visualization, image upload frequency can be set according to activity levels and includes metadata such as time, date and weather conditions.

“Visual data is the way of the future to increase productivity and efficiency for infrastructure construction projects,” said Ron Perkins, Infotech senior manager of strategic partnerships. “By integrating EarthCam cameras with our contract management solution, we are helping DOTs and engineering firms create a more informed jobsite with real-time visual assets that add key value for the overall success of the project.”

EarthCam has been working to develop integrations with partners like Procore and Autodesk to allow the company to bring powerful visual data into many more aspects of infrastructure construction management.

MONITOR THE JOB SITE REMOTELY

Remote job site monitoring has been particularly useful during the COVID-19 pandemic, but is also a valuable capability in its own right, Sharp said. Monitoring the job site via live streaming cameras is beneficial to the public, owner/agencies, and to the safety of construction workers themselves, he said. This screenshot was taken from the live feed of one of EarthCam’s work zone cameras.

EarthCam offers web based, responsive and mobile applications on iOS and Android, as well as drone, photogrammetry and mapping integration.

When building the Vrooman Road Bridge, the Ohio DOT relied on EarthCam to document progress of the project. Alan Exley, chief design engineer at the Lake County, Ohio, engineer’s office, said capturing the project’s construction enabled them to use time lapse movies during project presentations. When EarthCam was used to document the I-74 Mississippi River Bridge project, the live cameras kept the community informed and was a key component of the public outreach for the project. One resident said that watching the project being built made him feel a sense of ownership and pride in the project, as well as appreciation for the construction workers’ hard work. “Live streaming and time-lapse videos clearly demonstrate the complexity and planning involved with these unique construction projects,” Sharp said.

Additionally, archived imagery captured with EarthCam can serve as a historic record of how construction processes were completed, allowing detailed forensic visual analysis in the future. “Users can share images and site telemetry such as local weather, onsite sensor data, etc. via email or even with direct API integration into project management platforms,” Sharp said, referring to the new Infocore integration and other upcoming integrations.

Another recently added feature useful on construction job sites is the use of visual artificial intelligence to detect and identify more than 30 different classes of construction vehicles onsite, automating visual inspections and providing visual verification of vehicle locations.

The company also has experience mounting cameras on moving construction equipment, using high speed cellular internet and live streaming IP video cameras. “In the case of rapidly progressing roadway projects, we most often use self-contained autonomous solar powered trailer systems with 30-foot masts that can be quickly moved from one phase to the next,” Sharp said.

EarthCam is also interested in seeing how its thermal camera solutions could apply to paver-mounted thermal profiling (PMTP) activities in the future. They currently offer fixed-position thermal cameras and can schedule drone flyovers with thermal imaging cameras.

“We love to solve complex problems with elegant technology solutions and could envision working on [PMTP technology] with an interested party in the future for sure,” Sharp added.

– BY SARAH REDOHL

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Almix . . . . . . . . . . . . . . . . . . 7 Applied Test Systems. . . . . . . 17 Asphalt Drum Mixers . . . . . . . 22 Astec Industries . . . . Inside Front . . . . . . . . . . . . . . . . . . . Cover B & S Light . . . . . . . . . . . . . 37 Blaw Knox . . . . . . . . . . . . . . .9 Bomag . . . . . . . . . . . . . . . 39 Brock Industries . . . . . . . . . .66 CWMF . . . . . . . . . . . . . 35, 51 Dynapac . . . . . . . . . . . . . . .64 E.D. Etnyre. . . . . . . . . . . . . . 16 Fast Measure . . . . . . . . . . . .65 Gencor Industries . . . . . . . . . .4 Green Products. . . . . . . . . . . 27 HaulHub . . . . . . . . . . . . . . . 47 Komline-Sanderson. . . . . . . . 17 KPI-JCI. . . . . . Inside Back Cover Liberty Tire . . . . . . . . . . . . .59 Meeker . . . . . . . . . . . . . . . .43 Minds. . . . . . . . . . . . . . . . .29 NCCP . . . . . . . . . . . . . . . . .62 Pugmill Systems. . . . . . . . . .49 Reliable Asphalt . . . . Back Cover Roadtec . . . . . . . . . . . . . . . 11 Sapphire Blue Roads . . . . . . .45 Sripath Technologies . . . . . . . 12 Stansteel . . . . . . . . . . . 33, 57 Systems Equipment . . . . .21, 61 Tarmac International, Inc . . . 50 Teleradio . . . . . . . . . . . . . . . 15 Top Quality Paving. . . . . . . . .65 Willow Designs. . . . . . . . . . .65 Wirtgen America. . . . . . . . . . 19

AsphaltPro’s advertiser index 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.

BUILT TO CONNECT

Power and Portability

Our portable plant configurations feature a variety of components including jaw crushers, cone crushers, impact crushers and a variety of screening plants. Without sacrificing power or productivity, portable options deliver efficient and reliable performance with extra portability and adaptability.