Better Production = Better Bottom Line
Lakeside Industries Symbolizes Stewardship
Stay Safe: Granite’s Ergonomics APAC Solves Milling Issue Rescue QC at the Baghouse Xtreme Plant Maintenance II RAS Expands Family Business january 2012
Letter from the Editor 5 White House Blocks Canadian Oil Around the Globe 6 Safety Spotlight 8 Millions of Hours of Safety Granite Construction gets safe ideas off the ground for award-winning programs by Sandy Lender 10 Cat, Powermoon Shed Light Together by AsphaltPro Staff Producer Profile 20 LB3 Grinding Co-Locates for RAS Success by Sandy Lender Mix It Up 16 Keep Baghouse Surges from Disrupting Mix Quality Elam Construction managers go ghost busting to solve fluctuating problems by Sandy Lender Equipment Maintenance 12 Save Big Money on Your Plant’s Heating Bill Annual utility costs fluctuate depending on insulation damage, repair by Sandy Lender Equipment Gallery 58 Get Your Part Overnight by AsphaltPro Staff
Articles 26 Ecological Plant Prowess Garners Attention Stewardship, company pride continue long after accepting awards for Lakeside divisions by Sandy Lender 32 APAC Crew Solves Universal Milling Problem Innovative workers find the solution that keeps millings from sticking to truck beds by John Ball
36 Eubank Asphalt Loads on Stockpiling Benefits by KPI-JCI and Astec Mobile Screens 24 Top 10 Reasons I’d Rather be Fishing by Sandy Lender
42 Meet 2012 NAPA Chairman Kurt Bechthold by Sandy Lender 54 National Level Programs Seek Participation What are these wide-ranging programs and what do they mean for average contractors? by AsphaltPro Staff
56 Elliott Joins the Solution by AsphaltPro Staff
Better Production = Better Bottom Line
Lakeside Industries Symbolizes Stewardship Stay Safe: Granite’s Ergonomics APAC Solves Milling Issue Rescue QC at the Baghouse Xtreme Plant Maintenance II RAS Expands Family Business JANUARY 2012
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48 Plant Checks Now Mean Uptime Later Part II: Drum Plants by Cliff Mansfield
56 Enrich Employees by AsphaltPro Staff
Resource Directory 73
32
44 International Night Paving by AsphaltPro Staff
Here’s How It Works 70 Astec’s Real-Time Quality Control System 72 Wirtgen’s Level Pro Leveling System Last Cut 74 Oil Disputes Impact Arctic Circle to Texas by AsphaltPro Staff
contents
20
Departments
66 Work Truck Goes to Washington by AsphaltPro Staff
On The Cover…The Lacey and Monroe divisions of Lakeside Industries have come up big ecological winners most recently for the family owned asphalt business. See related article on page 26. Photo courtesy of Lakeside Industries and Astec Industries.
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48 www.theasphaltpro.com | ASPHALT PRO 3
editor's note JANUARY 2012 • Vol. 5 No. 4
White House Blocks Canadian Oil
2001 Corporate Place Columbia, MO 65202 573-499-1830 • 573-499-1831 www.theasphaltpro.com publisher
Chris Harrison associate publisher
Sally Shoemaker sally@theasphaltpro.com (573) 499-1830 x1008 editor
Sandy Lender sandy@theasphaltpro.com (239) 272-8613 Art Director
Kristin Branscom operations/circulation manager
Cindy Sheridan business manager
Renea Sapp AsphaltPro is published nine times per year: January, February, March, April/May, June/July, August/September, October, November and December by The Business Times Company, 2001 Corporate Place, Columbia, MO 65202 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 or Business Times Company staff, 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 and $175.00 all other countries (payable in U.S. funds, drawn on U.S. bank). Single copies available $17 each.
President Barack Obama signed into law Dec. 23 a bill that barely delays the fate of the TransCanada Corp’s $7 billion Keystone XL oil sands pipeline. What Canada’s Prime Minister Stephen Harper once said was a “no-brainer” has turned into another political game in Washington. The pipeline is supposed to carry oil sands crude from the boreal forests in Northern Alberta, Canada, to refineries along the Gulf Coast. Environmental groups expressed realistic concerns about potential leaks in the pipe. Nebraskans pointed out the fragility of the soil above the Ogallala Aquifer where the pipeline was originally to be routed through their state. Both issues gave Obama clear motivation to put off rendering a verdict on the project’s future until his own future was secure. Popular sentiment in the U.S.A. right now demands both parties cooperate to move product to generate economy sooner than post-Election Day 2012, even if most sources show the end user of that economy is the Asian marketplace. So Congress slipped some wording about the pipeline into the Payroll Tax bill to force a faster fix. This was immediately met with derision from mainstream media, which seems unaware of what inactivity has done for infrastructure so far in the United States. The U.S. Energy Information Administration (EIA) stated in its Nov. 30 This Week in Petroleum report that “Energy transportation is an increasingly critical component of energy markets and energy security.” That report referred specifically to the Seaway crude oil pipeline reversal between Texas and the U.S. Midwest, which caused the price discount of West Texas Intermediate (WTI) crude to hasten its narrowing in relation to other grades, such as UK Brent. According to EIA, the BrentWTI spread went from an average of $23/bbl in October to around $10/bbl Nov. 21. That’s a big deal, but you can see in the “Crude Oil Activity” chart in this month’s The Last Cut (page 74) that it didn’t significantly lessen crude oil spot prices around the middle of November. The economy continued even as crude oil prices saw mild fluctuations. The point from EIA is “energy transportation” played a significant role in keeping economy moving. TransCanada recognizes this, and pundits already speculate the company will continue to move its oil sands crude by tankers to a hub in Cushing, Okla., where the product will be transferred to existing pipelines for transport to Texas, whether the XL pipeline is a go or not. The company isn’t going to bypass its southern route to the Gulf of Mexico if Obama should cave to his constituents and let American pipeline builders go longer without jobs. It’s a territorial dispute with environmental and cost impacts to those who would engineer and build the pipeline, to those who would refine the oil sands in Texas refineries, to those who would ship the products, and to those overseas (again, rumors of Asia) who would purchase and use the products. By forcing the president to adhere to a deadline, Congress has put that dispute on the political playground for all to watch—if we weren’t already watching what Nebraska politicians did with the issue. Now Obama has 60 days (from Dec. 23) to make a decision on how the XL pipeline “no-brainer” will play out. Stay Safe
Obama had clear motivation to put off rendering a verdict on the project’s future…
Sandy Lender www.theasphaltpro.com | ASPHALT PRO 5
around the globe
Industry News and Happenings from Around the World Bahrain
Six events in six days are expected to draw more than 500 participants from 50 countries. Conference Connection and Petrosil host the 1st Base Oil and Lubes Middle East Conference (BLM 2012) May 9 through 10 in the Kingdom of Bahrain. BLM 2012 runs back to back with the 20th Annual Middle East Petroleum and Gas Conference May 6 through 8, also in Bahrain. Both are held during the Middle East Petroleum & Gas Week, which runs from May 5 through 10. There’s a U.S. $200 discount if you register for BLM 2012 by Feb. 20. Contact abby@connection.org for sponsorships or exhibitions. Visit www.cconnection.org.
Japan
Hitachi Construction Machinery Co. intends to increase mining-equipment parts. Reuters reported Dec. 15 that the company will invest about U.S. $512.10 million to get a new facility in full operation during 2013 and to add a wing to its Hitachinaka plant in Ibaraki Prefecture. This, Reuters reported, will allow the company to produce 2.8 times as many parts for supersize dump trucks and 40 percent more parts for super-large hydraulic shovels.
Russia
The Bryansk region of Russia is set to generate big oil. Vyacheslav Dubinnikov is the general director of OOO Slavneftegaz, Moscow, and he says the company will build an oil refinery with a capacity of 3.7 million metric tons a year in 2015. Source: Bloomberg
Spain
Argus Media’s Europe/Africa Bitumen Conference takes place in Barcelona, Spain, May 16 through 17, 2012. Visit http://www.argusasphalt.com/index.html.
United States
• State highway and bridge projects have clearance for innovation after the Federal Highway Administration (FHWA) issued some clarification at the end of November about federal regulation 23 CFR 635.411. The FHWA directive allows the use of proprietary and patented products on federally-aided projects; DOTs can use federal funds to pay for new technology, even if it starts out a little pricey. The state just needs to certify that the new product is “uniquely suitable for particular purposes or projects.” Source: ARTBA 6 january 2012
Alabama Learn how this round of mixes is performing at the National Center for Asphalt Technology (NCAT) Test Track Conference Feb. 28 through 29, 2012, in Auburn. Visit the Upcoming Events at http://www. eng.auburn.edu/research/centers/ncat/ for details.
Colorado • Dynapac, Commerce City, Colo., has expanded the utility of its website at www.dynapac.us to include more product and service information grouped with each machine model. It includes a Knowledge Center tab for end-user support for both soil and asphalt compaction. • Come to Denver for the 39th Annual Rocky Mountain Asphalt Conference and Equipment Show Feb. 22 through 24, 2012. Visit www. rmaces.org for all the info and attend Editor Sandy Lender’s social media marketing for asphalt business seminar.
Connecticut Check out the redesigned site at www.PavementRecyclers.com where Pavement Recyclers/Bagela USA, LLC, Shelton, Conn., has new info and easier contact features.
Hawaii According to a Nov. 29 Associated Press article, the Honolulu Authority for Rapid Transportation has signed a $1.4 billion contract with Ansaldo Honolulu, which is owned by Finmeccanica of Italy, for the design and construction of train cars for a planned commuter rail line. After the rail line is built, Ansaldo will perform maintenance and operation of the rail line under the terms of the contract. Despite Finmeccanica’s financial problems, which include its stock prices falling 65 percent in the past year, it is a guarantor for the rail contract. Source: AP
Kentucky The annual PAIKY Winter Training School is scheduled for February 1 through 3, 2012, at the Downtown Louisville Marriott in Louisville, Ky. Visit the http://www.paiky.org/ homepage for information.
New Mexico Richard Champion took on the position of director of international sales for CEI, Albuquerque, Jan. 3. He’s been with the company since late 2009 and will now handle its international sales efforts,
including CEI’s presence in the emulsion plant market. You can reach him at (800) 545-4034.
North Carolina Prepare for the industry’s largest asphalt offering at the World of Asphalt. The conference and exposition will be held March 13 through 15, 2012, in Charlotte, N.C. Visit http://www.worldofasphalt.com/ for reservations and the conference schedule.
Pennsylvania • WQLN-TV of Erie, Pa., inducted the founder of Eriez® into the Erie Hall of Fame. Orange Fowler Merwin is now among the people WQLN-TV recognizes for having made global contributions while living or working in the Erie region. Merwin devised a permanent magnetic separator in 1942, sold it to a grain miller and his company was on its way. Now Eriez has manufacturing facilities in Australia, Brazil, Canada, China, Europe, India, Japan, Mexico, South Africa and its Erie, Pa., headquarters. • Producers south of the boarder in need of high plant maintenance or component installation can call on two new Hirschmann dealers for help. Hirschmann Automation and Control, Chambersburg, Pa., has named Grúas & Tecnología SAS, Columbia; and Gruas, Kranes, Cranes & Equipment, Inc., Peru, new dealers of the company’s entire line of PAT, Krueger and Hirschmann branded crane operator aids.
Tennessee • The 18th annual C&D World, which is the annual meeting of the Construction Materials Recycling Association (CMRA), will be March 25 through 27, 2012, at the Nashville Convention Center. Visit www.cdrecycling.org for more information or contact mbohan@mining-media.com.
Washington, D.C. • “The Green Book” from AASHTO is out and expensive. Official title: A Policy on Geometric Design of Highways and Streets, 6th Edition. Official content: current design research and practices for highway and street geometric design. Official page count: 912. Visit www.aashto.org to order your copy. • For up-to-the-minute funding and legislative updates that impact the asphalt industry, follow http://twitter.com/AsphaltPro.
safety spotlight
Millions of Hours of Safety
Granite Construction gets safe ideas off the ground for award-winning processes by Sandy Lender
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t’s difficult to imagine the number of construction companies that could tally up 8 million man hours and still be considered one of the safest companies in America. During 2010, Granite Construction Co., Watsonville, Calif., exceeded that number. Granite’s commitment continued in 2011 with an award-winning program that garnered the International Risk Management Institute’s (IRMI) attention. The safety culture starts at the top with Director of Safety Bob Johnson. He works out of the headquarters office in Watsonville and reports directly to CEO James H. Roberts. From there, the company has approximately 60 safety managers nationwide that work in Granite’s regional operations. When Johnson has a change in the corporate program, he relays that to regional employees through the safety managers. Granite Construction’s Director of Safety Bob Johnson holds the ARTBA The combined employees’ diligence garnered a Contractor and CNA Contractor Safety Award the company garnered Oct. 3, 2011. Safety Award Oct. 3, 2011, from the American Road & Transportation Builders Association (ARTBA) and CNA, a leading naThat level of commitment makes a difference when it comes tional property and casualty insurance firm. Granite’s specific to engendering a safety culture in a group, especially a group award was in the “more than 1 million hours” category. spread across a nation. Encouraging the company’s “Motion is Money” program re“Everyone at Granite, from our CEO to our working sulted in a second award. Johnson and Deb Boyd, claims manforemen, has inspection requirements,” Johnson explained. ager for Granite, received the 2011 Gary E. Bird Horizon Award “Every supervisor inspects his job daily. Every employee from at the 31st IRMI Construction Risk Conference in November, the foreman to the president of the company has safety rewhich recognized them for their lean construction techniques in quirements to meet. For instance, the president goes on sevthe Granite risk management program. According to IRMI, “In eral trips each year specifically to the three-year period since the lean in the safety processes.” concepts program was coupled with They found that 68 percent participate Granite Construction also offers a rigorous workers compensation incentives for safety and safe ideas. claims management initiative, the orof workers compensation From something as reassuring as a ganization has seen significant reducclaims—and 62 percent of handshake to something monetary, tions in claim count, claims costs and associated legal costs.” total claim costs—came from employees know they’ll receive positive reinforcement for participating in “I attribute our success to our emmusculoskeletal injuries. the safety culture or for going above ployees who participate in our proand beyond in the safety realm. cesses and get involved,” Johnson “We do a lot of things,” Johnson said, “but the most imporsaid. “We, and they, care for each other. ‘Make it Personal/ tant thing is a hand shake and a ‘well done’ for doing things Take it Personal’ is more than our slogan; it’s what we believe. right.” Our strongest area is our people. Everyone has programs; we The lean construction initiative for which IRMI recognized have people who care.” Granite is an excellent example of doing things right. Johnson Different Granite operations around the country have this explained that it is, essentially, an ergonomics program to get slogan posted on banners or signs or hardhat stickers to keep items up off the ground. It’s a way of staging a project or a job workers aware that safety is a personal commitment. Johnson so people don’t have to bend over all the time or walk long said that the “Make it Personal/Take it Personal” program distances to collect tools. This prevents wearing out the body will have expanded exposure on the company’s new website, and prevents cumulative injury. which should be live by the time this issue hits the streets. “For many of the industry’s veteran employees, they don’t For Granite employees, management has taken a genuine have an injury, but they hurt all over,” Johnson said. “By making interest in safety. From bringing in safety consultants once in ergonomic changes, we’re taking care of our workforce. That every three or four years to participating in the most basic of differentiates Granite from other companies.” safety inspections, management is involved. They’re self-built. 8 january 2012
Lean concepts look at improving quality, eliminating waste, reducing delays and minimizing risk factors that result in workplace injuries. At the IRMI luncheon where Johnson and Boyd received the Gary E. Bird award, attendees could learn about the lean concept through table-top literature. “Granite, in concert with our insurer, looked at a process that would apply the concepts of Lean manufacturing to the job site environment. Lean concepts look at improving quality, eliminating waste, reducing delays and minimizing risk factors that result in workplace injuries.” They found that 68 percent of workers compensation claims—and 62 percent of total claim costs— came from musculoskeletal injuries. “We identified setting up the proper work flow and providing the employees with a well-designed work environment to create value. This, combined with embracing ergonomics that considered the capabilities of employees in terms of movement, strengths and their vulnerability to muscle fatigue and physiological stresses, allowed us to set the work plan in place and better design and manage the work flow.” Johnson spoke proudly of the all-inclusive nature of the safety culture at Granite. “All of my safety managers make an impact,” Johnson said. “They care for our people. It’s not just a job to them; it’s a way of life.” That way of life has become part of the fabric of Granite Construction’s workforce. “We don’t list safety as a standalone part of our mission statement,” Johnson explained. “It’s woven into our culture through many processes; our core values, our strategic plan, our management systems, our star processes. We believe it’s part of everything we do.” For the ARTBA and CNA award, other safety winners to be congratulated were Bruce & Merrilees Electric Co., New Castle, Pa., in the “500,000 or fewer hours” category, and both Blythe Construction, Inc., Charlotte, N.C., and C.F. Jordan Construction LLC, El Paso, Texas, in the “500,001 to 1,000,000 hours” category. All companies demonstrated a low “OSHA Recordable Rate” as measured against benchmark metrics established by the Bureau of Labor Statistics, according to ARTBA. A panel selected eight finalists based on their achievements as evidenced by recordable rates below the industry average and low workers compensation experience modifier rates. From there, the panel of industry professionals judged the finalists’ programs based on corporate safety culture, operational safety plans and worker training programs. For the IRMI Gary E. Bird Horizon Award, the 2011 finalists to be congratulated were Allan M. Yokoyama, safety administrator, on behalf of Albert C. Kobayashi, Inc.; Lillian Mendez, insurance coordinator, W.E. O’Neil Conwww.theasphaltpro.com | ASPHALT PRO 9
safety spotlight struction Co. of California; Shari Natovitz, vice president and risk manager, Silverstein Properties; and Vicki Harkleroad, director, corporate insurance, on behalf of The Tennessee Valley Authority. IRMI presents the Gary E. Bird Horizon Award, sponsored by Marsh, annually to recognize a demonstrated commitment to improving construction risk management through the implementation of innovative, cost-effective and efficient risk management techniques. The panel of industry experts that judged the award submissions made comments about Granite’s submission that included: “This was a great way to ‘sell’ safety, by marrying production efficiencies with safety efforts,” and “Consistent culture and commitment of all on the team to protecting employees is applicable in all project environments.”
One of the facets of Granite’s lean construction initiative is getting tools and equipment off the ground so workers aren’t forced to bend, sort through heavy items on a garage floor and lift as often. This illustration gives an idea of the pegboard in one of Granite’s tool sheds where tool outlines help workers get the right item back in the right spot for the next shift’s ease of use. While this image shows asphalt density gauges and large, heavy-duty wrenches, the Granite workers hang just about everything the wall will support and place heavier items on easy-to-reach shelves. It’s all part of the ergonomics that protect workers from fatigue and musculoskeletal injuries.
Cat, Powermoon Shed Light Together by Sandy Lender
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ontractors will see more work zone safety products now that POWERMOON Enterprises, Ltd., Roswell, Ga., will make lighting products available through Caterpillar Paving Products, Inc., Peoria, Ill., and its worldwide dealers. The two companies signed the marketing agreement in December 2011 that grants Caterpillar the rights to market select Powermoon® brand lighting products such as balloon lights and lighting accessories for night paving. Due to their compact size, light distribution and glare-free lighting, Powermoon systems are typically used on portable setup systems such as stands and tripods or on construction machinery, according to the manufacturer. Powermoon systems are built from heavy duty materials such as stainless steel, aluminum, Kevlar, etc. The lighting balloons are weatherproof and designed to remain in all kinds of conditions over long periods of time. The agreement expands the product line that Cat® Dealers offer to paving customers and expands Powermoon’s reach. Vice President Sales & Marketing for Powermoon, Ingmar Hansen said, “Being listed with Cat Paving and the extensive dealer network it offers surely augments Powermoon’s reach to customers worldwide. Powermoon Enterprises is very excited about this agreement. Caterpillar not only offers an extensive distribution network, but also stands for high quality products and great service—a business philosophy we share and an agreement that confirms Powermoon offers user-oriented high quality lighting technology. “Caterpillar offers most of our products and those are readily available for all Cat dealers. Depending on one’s local dealer, he might already have some Powermoon items in stock or will be able to get them from us within a few days time.” To see more products, visit www.powermoon.com.
10 january 2012
The crew wants the flagger to stand in a pool of light, which the tripod-mounted Powermoon® balloon light offers. Remember that your work zone at night is only as far as you can see into the dark.
This paving crew works in a bath of light courtesy of two Powermoon® balloon lights. Notice that the illumination covers the entirety of the hopper, allowing the dump man to monitor material delivery, while other crew members can clearly see the head of material and condition of the mat.
equipment maintenance
Save Big Money on Your Plant’s Heating Bill Annual utility costs fluctuate depending on insulation damage, repair
In the foreground, you see an example of insulation skin in good condition. If you begin to see weather or rodent damage, damage from ladders or other equipment resting against piping, or heavy, bulging insulation from a leaking pipe, make sure it’s something you address before it becomes an energy drain. When in doubt, use a temperature gun to assess the area. A contractor can easily see a 10 percent or more energy loss when insulation isn’t doing its job. Photo courtesy of Stansteel/Hotmix Parts.
by Sandy Lender
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f the ambient temperature where you produce asphalt doesn’t typically remain above the temperature of your liquid asphalt cement (AC) or transfer oil, you’ll want to insulate piping and tanks. As you do with any equipment or accessories, you’ll then want to monitor and maintain that insulation. Ron Henry, the service manager at Heatec, Chattanooga, reminded owners: “Insulation of jacketed asphalt piping—or any other piping with heated materials—is extremely important. The first reason is fuel savings. Some customers tell us that insu-
12 january 2012
lated piping saves them about $15,000 per year. The second reason is conservation of energy.” (See “Insulation by the Numbers” on page 13.) The good news for plant owners is normal weather doesn’t destroy insulation. Ground men performing maintenance checks should include the condition of insulation on their checklists after high winds or hail storms and of course during annual winter maintenance. Rick Rees, the technical director for Stansteel/Hotmix Parts, Lexington, Ky., assured owners, “Once insulation and protection covers have been installed correctly, the system should last for
years.” But consider what your plant upgrades entail. “Additions to hot oil circuits are sometimes made and not insulated,” Rees said. “This decreases the efficiency of the hot Insulation by the Numbers oil circuit.” Be aware of the actual costs involved in operating without “The aluminum skin is critical to protecting the insulation,” at least 1-inch insulation in your piping. Look at the heat Jim Grida of Reliable Asphalt Products, Shelbyville, Ky., said. loss comparison between a typical HMA plant with 300 “Make sure there are no breeches in the skin that could cause feet of piping and no insulation versus 1 inch of insulation. the insulation to deteriorate and the pipes to corrode. The The plant with no insulation on its pipes suffers a heat joints of the skin should be silicone, or paste them regularly. loss of 213,500 BTU (per 100 feet of pipe). Multiply that Check them to make sure the seals are intact. by 3 to equal 300 feet of pipe and you have a loss of “Also, the hot oil lines can leak and further compromise the 640,500 BTU per hour, for a total heat loss per day of insulation and lines,” Grida continued. “Make sure all jumper 15,372,000 BTU. lines are attached correctly and not leaking. Replace older inThe plant with 1 inch of insulation on its pipes sees a sulation when it’s lost its value. Inspect sections of insulated natural heat loss of 15,000 BTU (per 100 feet of pipe). pipe with a temperature gun to see if there is any significant Multiply that by 3 to equal 300 feet of pipe and you see heat loss. Those sections should be reinsulated using a newer a loss of 45,000 BTU per hour, for a total heat loss per insulation and skin.” day of 1,080,000 BTU. As Rees pointed out, insulating the piping on the HMA You can save 14,292,000 BTU per day with the addition plant conserves fuel consumption, which minimizes the fuel of 1 inch of insulation on pipes. costs of operating the hot oil heater. That means the hot oil system operates efficiently. If you convert that to fuel, lack of insulation costs you “With non-jacketed hot oil lines the transfer oil loses heat at 117 gallons of extra fuel/day (hot oil heater output), a much more rapid rate, which in turn causes the hot oil heater which means you spend about $350 more per day (at to run constantly,” Grida concurred. “The hot oil heater isn’t $3/gallon). That’s $87,000 in extra fuel costs per year allowed to run through its normal cycle and therefore greatly (at 250 days of operation) and doesn’t include upgrading to a bigger hot oil heater to accommodate all your increases the heater’s fuel consumption. The contractor can fuel waste. easily see a 10 percent or more energy loss. Constant heating and reheating can cause a breakdown of the thermal transfer Source: Stansteel/Hotmix Parts, Lexington, Ky. oil as well as build-up in the hot oil lines. He should also consider the condition of the hot oil heater and its efficiency.” Pipes aren’t the only insulated portions of a plant that can affect costs. Take a look at the tank farm. Heatec’s Henry “Adding insulation to an old tank is very difficult to do in the takes us back to a time when the thickness of insulation field even if the tank is in top condition,” Henry said. “It’s very around asphalt tanks was not what it should have been. labor intensive. When buying a new tank, never get one with “Years ago, three inches of insulation was standard and six three inches of insulation with the thought of adding more insuinches was an option. But three inches is less than optimum. lation later,” he cautioned. “Increasing Six inches is close to optimum and the insulation thickness is far more has been standard on our [Heatec] "Some customers tell us that cost effective when done at the factanks for at least 10 years.” tory instead of the field.” “New equipment generally uses insulated piping saves them Grida set producers’ minds at ease newer insulation technology,” Grida concerning maintenance, saying the about $15,000 per year." said. “The older tanks were priowner always has the option to let marily covered in asbestos, wool or -Ron Henry, Heatec someone else do the labor. “Most fiberglass insulation, and the new suppliers offer installation of the insuequipment comes equipped with lation as a service. We [Reliable Asphalt] have completed several mineral fiber or dense foam insulation in thicknesses from 4 jobs that involved skinning and insulating an existing tank. It not to 10 inches.” only diminishes heat loss, but it also provides a better aesthetic Depending on your take, insulation of thicknesses beyond look for the tanks as well. There are several factors when considsix inches is overkill—and could be detrimental to your purering a tank for refurbishing such as amount of coke in the tank poses. “Thickness greater than six inches provides dimincurrently and condition of the direct fire tube or coils.” ishing returns,” Henry said. If you decide an older tank is a good candidate for updated inTank insulation rarely sees damage, but older tanks may sulation, you have options that could save big bucks on heating have new insulation needs. Rather than getting rid of an costs. Of course, the insulation you see every day around pipes older tank, a producer may opt to re-insulate. Henry pointed and elbows deserves a close look for leaks or severe weather out that this is something plant personnel, an outside condamage so you can keep high utility costs at bay there. Take a tractor or the original manufacturer can perform, but he said moment to consider your insulation condition around the plant it’s sure easier to plan ahead and let the tank manufacturer and see what you save. do it at the factory instead of doing it in the field. www.theasphaltpro.com | ASPHALT PRO 13
mix it up
Keep Baghouse Surges from Disrupting Mix Quality Elam Construction managers go ghost busting to solve fluctuating problems by Sandy Lender
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onsider for a moment that your quality control (QC) team has perfected a mix design for a state project. Everything is seamless from the aggregate to the binder to the percentage of RAP. The test strip your paving crew placed on the back lot gave beautiful compaction numbers. Then the department of transportation quality assurance inspector ran a test and your air voids were all wrong. Your crew paved an extra test strip and couldn’t get density to save their lives. What on earth went wrong? Jeremy Dade is the plants manager for Elam Construction in Grand Junction, Colo., and told a similar story. “We’d either have too much 200s in the mix or not enough.” It took more than a year of trial and error to realize the problem came from the baghouse fines. “We even turned the baghouse return off,” Dade said. Nothing seemed to give them a consistent result. Instead, they saw a big swing of 1.2 to 1.7 tons per hour (TPH) in the 200s, Dade said. By installing a device from Clarence Richard Co. that weighs and meters the dust going into the drum, the plant personnel slowed the rate to a steady 4.2 TPH, according to Dade. Elam Construction personnel had found a problem with the sags and surges in the baghouse’s normal operation. A typical pulse-jet baghouse has about 64 rows of 10 to 15 bags that pulse three rows at a time on a timer. The dust that falls to the bottom of the baghouse gets augered out in surges, thus the fines returning to the drum move in surges. This gives varying amounts of fines in your mix design. A rotary air baghouse could be considered “worse” as it can stop sending material for up to a minute at a time. But a plant operator can’t blame the baghouse. It’s operating as it was intended. “The primary purpose of the baghouse is for emission or pollution control from the plant process,” Rick Rees said. He’s the CEO of Stansteel/Hotmix Parts, Lexington, Ky. “Some contractors over the years have used the baghouse hopper as a temporary holding device to feed the fines to the plant. Most producers today have much more sophisticated feeding and metering devices to properly proportion the dust/fines back to the material feeding and mixing operation.” David Fife, the QC manager for Elam Construction, spelled out his experience in detail. “There are many aspects as to how dust effects mix designs,” Fife began. “I can remember standing next to a hot plant several years ago with a Colorado Department of Transportation (CDOT) inspector trying to 16 january 2012
Here’s How It Works: Material slides down the EZ-Flo flow scale’s feed throat and impacts a suspended plate (plate suspension is patented). The material impact force on the plate is transferred to a load cell, which converts the gravimetric force to digits on the readout. It displays both the flow rate in tons per hour (pounds per minute, etc.) and the tons of material that has passed through the scale since the totalizer was last zeroed. Photo courtesy of Clarence Richard Co.
figure out why the properties of the mixture where fluctuating. I hadn’t been making changes in the percentages of materials at the hot plant, and we religiously had run crusher control on the aggregates as they had been manufactured. I told the inspector that I was chasing ghosts. Every time I had my fingers on the problem it would disappear and show up again on the other side of the specification. “At that time I had a pretty good idea this problem was based on dust but I couldn’t put my finger on exactly why it
With the VMA floating around, a mixture with a varying demand for oil is being created. was appearing then disappearing without changes at the plant,” Fife continued. “I had run enough gradations on the stockpiles to know the crushing or inconsistent materials did not create the problem. Over the next several years, through trial and error I found it was not a ghost; it was fluctuation in the dust being returned to the mixture via the Baghouse. “To sum up the problem, a dust feeder that is allowing the dust to be returned into the mixture in sags and surges is creating a mixture that does not have a constant demand for oil. In other words, when excessive dust is being pumped into the mixture the Voids in Mineral Aggregate (VMA) is generally decreased, creating less room in the mixture for oil. When the dust is being starved in the mixture, the VMA generally is increased creating a mixture with more room for oil. With the VMA floating around, a mixture with a varying demand for oil is being created. “The hot plant has no way to track the problem, and continues to add consistent oil. With the percent oil staying the same and a changing VMA, the voids fluctuate with the changing VMA. As a result to the fluctuation in the mixture’s
This custom dust runaround was built to prevent the surge of baghouse fines. Photo courtesy of Stansteel/Hotmix Parts.
voids, the crews in the field are continually adjusting the roller patterns to achieve the required density. After all, density is just a measurement of in place voids. This problem is often magnified by volumetric tests being produced by the testing department, and adjustments to the mixture being made based on sags or surges in the Baghouse.
www.theasphaltpro.com | ASPHALT PRO 17
mix it up cause sags and surges are eliminated by the use of the flow scale and large variable speed auger feeding the mixer. The large volume auger substitutes the need for a bin. When the auger is adequately sized, the automatically operated auger can eliminate the sags by speeding up during the times the baghouse is not delivering enough dust. Elam Construction’s Dade operates the system differently depending on whether or not the job mix calls for dust to be rejected. If dust is not rejected, the surge elimination mode returns all the dust back into the mix evenly. In the end, Elam Construction mixes can remain consistent throughout production with metered and monitored fines introduction while the baghouse continues its proper and expected operation. This keeps the QC team and the paving team working with something they can rely on throughout production.
Scott Thompson, formerly of Austin Bridge and Road, bought the first flow scale developed by the Clarence Richard Co. in 2003. Photo courtesy of Clarence Richard Co.
“As all of us in the asphalt industry have experienced, the key to producing quality asphalt mixtures is to be able to find the right combinations of materials, and consistently produce at these combinations. The search for consistency is easier created in the lab than produced in the field. We have many obstacles to overcome when attempting to recreate every ton exactly as the prescribed mix design calls for. A system that supplies a continuous flow of dust to the mixture helps overcome one of these obstacles,” Fife said. Fife is no longer chasing Ghosts. He now uses the Ez-Flo Continuous Weigh Control System as manufactured by Clarence Richard Co. The scheme Elam used on their portable plants is significantly different than what Richard suggests for stationary plants. Surge control normally requires the addition of an auger and storage bin. Richard eliminates the need for a surge bin (silo) and associated auger for portable plants with a flow scale being fed by a variable feed auger. When in the dust rejecting mode, the dust surges move from feeding the mix process to feeding the reject pit while the amount of dust being returned to the mix is measured, controlled and fed evenly to the mixer. The system doesn’t need a surge bin be18 january 2012
“To sum up the problem, a dust feeder that is allowing the dust to be returned into the mixture in sags and surges is creating a mixture that does not have a constant demand for oil.” —David Fife, QC Manager for Elam Construction Photo courtesy of Clarence Richard Co.
Continuous reverse weighing can be retrofitted to the customer’s existing mineral filler, baghouse dust return, hydrated lime and other products, according to Rees. Comprehensive supply includes variable speed airlocks, dust blowers, electronics controls and new or used silos. Photo courtesy of Stansteel/Hotmix Parts.
producer profile
LB3 Grinding Co-Locates for RAS Success The B-66 horizontal mobile wood grinder from Rotochopper, Inc., located in St. Martin, Minn., is available in electric (at 700 hp) or diesel (at 765 hp) models and features the company’s Perfect in One Pass™ technology. Here the LB3 Grinding crew uses it for asphalt shingle grinding. Operator Ryan Biel says it’s as easy as switching out screens (in about 20 minutes) to go from C&D grinding to shingle grinding at their site.
by Sandy Lender
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alter Biel has been active in the construction industry all of his life. Within the past few years, he’s taken that involvement to a significant level with four companies that operate under his banner. 973 Materials, CD Recycling, Recon Services and LB3 Grinding keep him and his family busy, and keep him on target providing for the latest needs of the asphalt industry. His son Ryan Biel runs a Rotochopper B-66 horizontal grinder at the Austin LB3 Grinding facility where one of the companies’ targets is recycled asphalt shingles (RAS). The Biels purchased the B-66 and started up LB3 Grinding in June 2011. They’ve stayed busy since. Ryan said the machine is capable of 100 TPH, and they’ve had it going at 75 to 100 TPH on a good day. Business lined up quickly for a few reasons, according to Ryan. 20 january 2012
First, the collection facility in Austin is situated between two landfills on a 100-acre site where the other companies reside. Contractors taking roofing tear-offs to the landfills had no trouble finding LB3. “It was just a matter of getting out to tell these guys we would take the tear-offs,” Ryan said. “We take the shingles for free. It was a no-brainer for them.” The guys Ryan refers to are building contractors who bring tear-off shingles to LB3 instead of dumping them in the landfills—and paying a tipping fee to do so. “We don’t have any manufacturer waste,” Ryan said. “Most of the shingle manufacturers are up near Dallas. For us, it’s been all tear-offs from the get-go.” To keep the material clean, LB3 set some ground rules. “Once we started, we were proactive with the guys bringing material into our site. And they were very good about delivering clean product. Then we have a worker who checks ma-
The companies Walter Biel runs take elbow grease from the whole family. Here are a few of the workers. From left to right Ross Biel, Ryan Biel, Walter and business partner Jim Lozier pose proudly with the Rotochopper grinder.
The B-66 has a variety of options, including a magnetic head pulley or cross belt magnet. Here you can see the cross belt magnet that LB3 Grinding opted to use to catch any last bits of ferrous material from the tear-off shingle product. The bin collects material for recycling at a metal facility. The B-66 also offers a dust hood as an option, but Ryan Biel said the shingle product has proved heavy enough, and the machine’s standard water system has proved adequate enough, to keep dust from becoming an issue.
terial before it goes in so what’s coming through the grinder is really clean.” Even though Ryan is confident in his product, he takes no chances. The Rotochopper B-66 has the option of a cross-belt magnet, so he took it. “A magnet on the discharge conveyor catches anything else and we’ve never had any complaints.” All ferrous material is taken to a metal facility for recycling there. Second, the use of recycled material has rocketed onto everyone’s radar screen. Ryan’s been in the business for about 15 years, but he’s accompanied his father Walter on many a trip to the landfill for C&D recon over his lifetime. He laughs when he says the recycle business is going well. “It’s kind of funny how fast it’s come on.” Two years ago December, Walter acquired an existing concrete and asphalt recycling plant. The contacts they made selling on-spec RAP through that venture carried over into the
RAS venture. “The crusher we have can get the RAP to size,” Ryan said. The crusher 973 Materials uses is a 54-inch Pioneer Jaw Crusher. “We have relationships with those contractors; they know we’ll do whatever we need to do [as LB3] to get there to grind for them. Most of our business is going around to grind for other asphalt companies.” That means LB3 needs easy portability, which Rotochopper offers in a couple of variations for its B-66. With no special tools, the Track B-66 can drive on and drive off a dolly, and connect to a truck with the same ground clearance as a lowbed trailer, according to Rotochopper. Ryan pointed out that the model LB3 uses is not on tracks; they merely hook it up to a haul truck to move it when need be (see image at left). While Rotochopper offers a grinder developed specifically for the RAS market, the RG-1, and its electric version RG-1 E, LB3 Grinding’s Austin facility performs C&D grinding as well as asphalt shingle grinding with the B-66. The Rotochopper website states that its “two-piece screen design allows operators to quickly install screens to suit raw materials and finished product needs.” That’s something Ryan can attest to. To switch from one application to the other, Ryan said it’s just a matter of changing screens out. “I love that machine because that only takes about 20 minutes with one man to do it.” Even though LB3’s neighbors aren’t going to complain, Ryan said the machine has a watering system on it that not only keeps the rotor and product cool, it also keeps dust to a minimum. “There’s not a lot of dust to begin with,” he said. “The product is heavy enough that it’ll take a high wind to pick up any dust.” Walter Biel and family seem to have mastered two important segments of the asphalt recycling market in Texas, both RAP and RAS. The services they provide on both sides of the RAS game could prove invaluable to the right contractors. They’ll grind material for some companies, provide ground material for others. LB3 is positioned well with their equipment and expertise.
The B-66 trailer comes standard with three 22,500-pound axles and a detachable fifth wheel hitch. The crawler tracks (with or without transport dolly) are an option that LB3 Grinding didn’t require. When a client calls them to grind offsite, they hitch the machine to a haul truck as seen here and take their business on the road. As Ryan Biel explained, their long-time contacts know that the Biel family will do what they have to to take care of their customers’ asphalt needs. www.theasphaltpro.com | ASPHALT PRO 21
Top 10 Reasons I’d Rather be Fishing by Sandy Lender
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veryone at the plant can be proud of a job well done at the end of the shift. You have instant gratification when the paving superintendent calls the plant operator and tells her everything looks good and the QC/QA inspectors are smiling. Then there are days when the plant operator looks out the glass windows of the control house at thinly veiled mayhem and thinks to herself, “I’d rather be fishing.” Of course the typical plant crew works together to avoid the safety and quality mistakes alluded to in the list below, but any one of these would mess up a shift for the asphalt professional. These are the top 10 reasons the plant operator would rather be fishing… 10. A rat just grabbed part of your sandwich and ran behind the electrical control panel. 9. The ticket printer is out of paper. And ink. 8. The AC delivery has arrived and the driver wants to argue that a busted temperature gauge isn’t a problem. 7. The loader operator put 1/4-inch material in the 3/8-inch cold feed bin. (But only for the past hour or so!) 6. The DOT QC/QA inspector is scratching his head as he walks away from the lab…and toward your control house. 5. A haul truck driver bringing millings from the state paving project just popped his head in to ask where you keep the jackhammer. 4. The haul truck sitting under the silo has lost its timing belt. 3. And the other silo has been plugged with mix since November. 2. And the paving foreman’s cell number just lit up on your caller I.D. 1. The return duct from the baghouse has sprung a leak. But if you look at it just right, the spray of dust each time the pulse jet pulses almost reminds you of snow at Christmas.
Photo courtesy of ADM.
24 january 2012
Ecological Plant Prowess Garners Attention
Stewardship, company pride continue long after accepting awards for Lakeside divisions
26 january 2012
One of the ways Dean Smith keeps dust down at the Lacey division plant is by forming stockpiles close to the cold feeds. He also uses a clever system of conveyors. Notice the conveyors at the far right, upper corner of the image bringing aggregate from larger piles farther away. This lessens truck traffic as well as loader traffic, compaction and segregation.
by Sandy Lender
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s the company name implies, Lakeside Industries, Inc., headquartered in Issaquah, Wash., has an environmental edge to it that a national entity would make an example of. In fact, the National Asphalt Pavement Association (NAPA) has already done that. In 2009 and 2010 NAPA honored two Lakeside plants with its New Plant Ecological Awards. As a whole, the company strives to perform at this level of excellence while maintaining a family atmosphere and a commitment to the asphalt industry. Start by looking at the company’s track record. Lakeside Industries is one of the few remaining family owned construction companies of its size—and it’s focused solely on asphalt paving. Its 12 regional divisions spanning Western Washington, Northwest Oregon and Central Idaho offer a range of local products and services from state DOT work to commercial projects for private citizens. Within each division, the people bring local knowledge and focus to customers while using the expertise and resources of the larger company. That business plan reflects the company’s mission: “To provide quality asphalt products while serving the community as industry leaders.” The company has consistently won awards from agencies and organizations such as the Asphalt Pavement Association of Oregon (APAO), the American Public Works Association—Washington State Chapter (APWA-WA), American Society of Civil Engineers (ASCE), NAPA, Washington Asphalt Paving Association (WAPA), Washington State As-
Notice that the Durgin Road plant site is completely paved, which also helps keep dust down.
sociation of County Engineers (WSACE) and Washington State Department of Transportation (WSDOT). Management’s attention to quality doesn’t end with workmanship. It extends to the health and welfare of employees and environment. For example, Lakeside Industries divisions have won multiple certificates of achievement in safety from the Mine Safety and Health Administration and multiple certificates of honor from the Joseph A. Holmes Safety Association. In 2007, the Lakeside Industries online safety training program was a finalist for the NAPA Asphalt Operations Safety Innovations Award. In 2009, the Lacey Division Durgin Road Plant was a New Plant Finalist in the NAPA Ecological Awards. In 2010, the Monroe Plant took first place in the NAPA Ecological Awards. The company has more than 50 NAPA Diamond Achievement Commendations for Excellence in Hot Mix Asphalt Plant/Site Operations since 1999 when its Aberdeen plant achieved the first. The Aberdeen division has garnered its own NAPA ecological award for an existing asphalt plant in 1988 and again in 1998. When AsphaltPro contacted Aberdeen Division Manager Bob Glenn about the successes Lakeside has enjoyed, his immediate reaction was to shine the spotlight on the environmental advances two specific division managers have put in place. Dean Smith is the Lacey division manager; Gail Land is the Monroe division manager. Both spoke proudly of the plants and people they work with, and an impressive picture of Lakeside Industries began to emerge. These folks haven’t been building nice plants the past few decades merely to win awards. They put together environmentally friendly operations because it’s the right thing to do. Mike Peringer of Process Heating, Co., Seattle, summed that up. “It is very gratifying to see asphalt companies taking such a significant interest in community,” Peringer said. “Lakeside has a reputation for just that and that attitude is to be commended. I teach ‘Leaders Who Give Back’ at the University of Washington Public Affairs School and often refer to companies like Lakeside. Others should take note and realize that such community is like an asset in determining company value.” www.theasphaltpro.com | ASPHALT PRO 27
Not every new plant owner has oodles of spare cash to spend on beautification, but the county zoning authorities had specific ideas for Gail Land’s crew to meet. Her facility is behind an 8-foot berm and the native trees they selected reach their mature height in five years. With no water runoff, low NOx, a blue smoke recovery system and a landscaping scene to die for, Land went above and beyond to be a good neighbor.
28 january 2012
Lacey Division
Working toward bettering a community was on Smith’s mind when he spoke about the Durgin Road plant in Olympia, Wash. “It took us eight years to permit the Durgin Road plant, so we’re doing everything in our power to be great stewards of our neighborhood,” he said. His facility is a picture-perfect illustration of how to set your new plant up for environmental excellence, even when the neighborhood has limits to recycling. Believe it or not, the Thurston County zoning regulations currently prohibit reclaimed asphalt pavement (RAP) or recycled asphalt shingle (RAS) use. Because Smith wants to be a part of the movement keeping waste out of landfills, he’s working on changing that prohibition. “We are working with Thurston County and the neighbors to change the zoning to allow us to recycle both asphalt and shingles,” Smith said. Even with those limitations, Smith’s plant was a finalist in the NAPA ecological awards. Currently, asphalt plant owners don’t get official “credit” for lobbying their local officials to allow recycling. “The nomination forms do not include a question about this, but some companies write this in,” NAPA’s Margaret Cervarich said. “In that case, it is considered by the judges.” The awards that Cervarich described take a significant effort. “To receive the ecological award, the company must first earn the Diamond Achievement Commendation for Excellence in Asphalt Plant/Site Operations. This sets a high standard. Those who earn the Diamond Achievement may then apply for the ecological award. “A team of industry experts evaluates the nominations on a number of objective criteria. Plant operations, compliance, community relations and environmental excellence are considered. More subjectively, aesthetics are also taken into account. Thus, to be named as a winner or finalist in the ecological award competition means that the plant is the crème de la crème of the industry.” Thurston County officials already know of the Lacey division’s commitment to the environment. The division has a Thurston Green Business certification for the recycling its employees perform in the office. They’ve elected to recycle items such as office paper, ink cartridges, soda cans and the like, and Thurston officials have recognized them for it. Of course, Thurston officials and neighbors recognized their positive plant aspects, as well. “It’s a state-of-the-art 300 ton-per-hour Gencor Ultraplant,” Smith said. “It’s got all the bells and whistles—a great burner that’s a burner of choice and efficient. The plant can make foamed asphalt warm mix.” Smith uses a variety of good practices to mitigate dust. First, the crew paved the entire site. Something that works for fuel savings and noise mitigation, as well as keeping dust and material confusion to a minimum, is the use of conveyors. “We have minimized loader and truck traffic by having the stockpile close to the plant and the rock delivered by belt to the stockpile area from the crusher,” Smith said. Finally, they use a Dustex blue smoke baghouse, and baghouse dust is returned and metered back into the finished product. www.theasphaltpro.com | ASPHALT PRO 29
The Portland and Issaquah plants produce EZ Street cold mix that other divisions, such as the Lacey division managed by Dean Smith, sell.
The three 30,000-gallon liquid AC tanks (on the far right-hand side of this image) in Gail Land’s Monroe division tank farm feature scrubbers on top to assist in meeting air quality standards. The baghouse also features a metered return system to take dust back to the drum.
A natural gas hot oil system keeps 75,000 gallons of liquid AC hot at the tank farm and the silos can store up to 900 tons. Who keeps all this going? “Herb Milleson is my plant operator,” Smith reported. “Herb has worked for us for 30 plus years and has run plant for us since 2001. Herb does a great job for us.”
Monroe Division
Likewise, the Monroe division’s manager, Gail Land, praised her plant operator. “Gary Swanson is amazing. He was instrumental in picking out and setting up and calibrating our plant.” Land has worked for Lakeside for 16 years and knew the kind of work it would take to get an asphalt plant permitted. She knew it took working with the community to alleviate the neighbors’ worries and to build something she’s proud of. “A lot of forward thinking went into this when we moved,” Land said. “We purchased an existing gravel pit, cleaned it out and went from there to building the asphalt site. The county has rigorous water regulations, so we worked to accommodate that. None of the water that falls on my site can leave my site, so none of it does. The entire site is paved on a 3 percent slope. All water channels into a main water cleaning system.” 30 january 2012
As far as water is concerned, Land pointed out that the site stays mud-free. “We have a truck-washing station as well. Here in the Northwest we have mud everywhere, but not on my site. There’s no mud at this plant.” One of the ways to keep away mud is to keep away dust, and Land uses a baghouse for dust mitigation as her colleague Smith does. As mentioned above, her entire site is paved, which keeps dust from tires and fallen, crushed rocks to a minimum. She shared that her paving crew had just paved the road into the quarry with RAS, a product the Monroe division has recently embraced. “We have purchased a shingle grinder, so we’re talking with the scrap producers around here to set up and grind at their sites,” Land said. For now, the grinder, which consists of two pieces of grinder equipment and a trackhoe, travels to different divisions as needed. The RAS pile is kept inside, covered and contained. As if mirroring the Lacey division, Land’s Dillman DuoDrum plant has run both RAS and RAP, but Land is just looking into warm-mix asphalt now. The plant is capable of 400 TPH and Land said they’ve gotten production close to that limit. “In today’s market we don’t get to push it as much.” Her facility includes three 30,000-gallon liquid AC tanks and a 15,000-gallon diesel tank in the tank farm and three
“We have purchased a shingle grinder, so we’re talking with the scrap producers around here to set up and grind at their sites.” 300-ton silos for storage. A blue smoke recovery system and scrubbers atop the AC tanks help keep air quality up to standard. “I couldn’t be prouder of this place,” Land said. “It’s a neat, tidy-looking site.”
Good Business
Land and Smith have much to be proud of with award-winning operations to their credit. They also have much to live up to. Lakeside Industries doesn’t rest on its laurels. The company began a business relationship with EZ Street Co., Miami, a few years back, allowing two of its facilities to produce environmentally friendly mix for pothole and repair work. “Lakeside began producing EZ Street in 2000 in Issaquah under a licensing agreement with the EZ Street Company,” Rick Rawlings said. “We began to produce it in Portland in 2002. We began packaging it in 35- and 50pound bags in 2002 as well. Our sales demand is fairly uniform now year-round.” Lakeside remains committed to its local communities as well. For example, if you followed the company’s facebook page during December, you’d have seen employees were making and collecting donations for Issaquah children who needed warm clothing. They were also hosting a food drive and receiving accolades for sports equipment they’d donated and installed for schools. While it’s commendable and “good business” to go the extra mile ecologically speaking to get an asphalt plant permitted, it’s uplifting to see a large company keeping its environmental and community commitments. With priorities that include quality workmanship, quality asphalt products and serving the community, the regional divisions of Lakeside Industries have a multi-generational history to be proud of.
Gail Land’s Monroe division plant is a Dillman DuoDrum. www.theasphaltpro.com | ASPHALT PRO 31
APAC Crew Solves Universal Milling Problem
The APAC Midsouth team used an innovative spraying technique to ensure quality paving during a mill and pave operation in September.
Innovative workers find the solution that keeps millings from sticking to truck beds
by John Ball
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sing trailers that have just delivered hot mix to the paving crew to then collect millings further up in the work zone is an efficient way to manage equipment. That efficiency breaks down, though, when the truck gets back to the plant and workers have to use a backhoe to scrape stuck millings out of the bed. What’s worse is when the truck driver fails to get all the material out before he heads for the silo to get another load of on-spec mix. That’s not top quality material in his bed anymore. A hot truck bed—about 170 degrees F after unloading—isn’t the best place 32 january 2012
to pour asphalt millings. We have little choice on big projects with multiple haul trucks running back and forth to the plant. With the preservation and maintenance projects all over the country, mill and fill is happening more and more. To increase their quality paving on an Alabama highway, the crew I worked with at APAC Midsouth came up with a great way to keep millings from sticking in their hot haul truck beds. The crew now doubles up on release agent spraying. It’s normal to spray the truck bed at the plant before it goes under the silo for loadout, and that’s the best practice we used on the project in September. This helped the mix slide out of the trailer. To minimize material segregation we used
The use of a release agent leaves a clean truck bed after unloading.
a Shuttle Buggy SB2500. It took about three minutes and 22 seconds to empty each 22-ton truck bed. Then the truck went half a mile up to the milling operation with the body at 170 degrees F. On the project in September, we had 24 trailers hauling mix to the paver every five minutes. We were paving 16 feet wide at 1 ½ inches. Going about 21 feet per minute, we were shooting for 2,000 tons per day. We had a ride spec and a compaction spec to meet so we couldn’t have lumps from leftover millings in the mat. The second spray happened before the trucks got in line for millings. The crew equipped a flatbed service truck with tanks of release agent. They equipped a 16-foot aluminum straightedge with a PVC pipe and four nozzles that came off a roller to make a spray bar. They put an electric pump in between to pump the release agent from the tank through a hose to the pipe. And they put a worker with personal protective equipment (PPE) in the service truck bed to swing the spray bar out when it was time to lubricate a truck. The haul truck would pull away from the Shuttle Buggy, go to the designated cleaning area to ensure no clumps fell on the paving lane and then pull alongside the service flatbed for spraying. The worker in the truck then swung the spray bar out over the bed of the haul truck, adjusted the height of the bar up or down as necessary, turned on the pump and sprayed the bed with release agent for about 30 seconds. The actual spray section of the spray bar is eight feet and the nozzles direct the fan of spray straight down into the truck. The stream is not strong, so there was no danger of getting release agent on passing vehicles. There’d be no danger to passing motorists, of course, as we used a biodegradable liquid. After receiving its coating of lubrication, the haul truck would get in line to accept millings and carry them back to the plant. Thanks to the release agent, the millings didn’t melt to the truck bed, but slid nicely to their appointed RAP pile, leaving the beds clean and free of clumps. And that made the mix we put on the road smooth and segregation-free. John Ball is the proprietor of Top Quality Paving, Manchester, N.H. For more information, contact him at (603) 493-1458 or tqpaving@yahoo.com. 34 january 2012
The APAC Midsouth team built a method to keep millings from sticking to hot haul truck beds with this innovative spray bar.
The spray bar is made of a 16-foot aluminum straight-edge and four nozzles from a roller.
The spray bar operator can adjust the height of the bar with the orange pole, which raises up or down as needed.
Eubank Asphalt Loads on Stockpiling Benefits by KPI-JCI and Astec Mobile Screens
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usy asphalt plants, especially those that haul in their raw materials, often struggle to balance the need for materials with the need for space. Stockpiles share precious real estate with trucks, loaders, bins and the plant itself. Because of this, a logical way to increase stockpile volume is to take the pile higher. Traditional aggregate unloading and stockpiling methods usually require trucks to dump the material near the edge of the stockpile. A front-end loader or bulldozer then works the aggregate into the pile. These methods require additional handling of the material, which increases costs. Time plays a part in this equation, too, because trucks arriving to unload stone or sand must wait on the loader or dozer, as well as on other trucks. Eubank Asphalt Paving & Sealing, founded in 1970 by Mike Eubank, is headquartered in Charlotte, Tenn. The company has two asphalt plant sites. One hot mix plant is located 30 miles north of Charlotte in Vulcan Materials Co.’s Clarksville Quarry. The company’s Dickson, Tenn., asphalt plant, however, actually has two batch plants and an Astec portable Double Barrel drum mix plant on one site, with no nearby source of sand. In fact, for this plant, Eubank uses its fleet of trucks to haul in natural sand from the Tennessee River, almost 40 miles away. Needless to say, space is at a premium in the yard. “It’s a long haul for our trucks, so it’s important for us to keep a large inventory of sand on hand,” Michael Eubank, director of management, said. “We probably keep about 175,000 tons of sand in stock at any given time.” Eubank explained that a telescoping stacker had allowed the site to increase its sand stockpile height beyond the limitations of a front-end loader. The increased height had an added benefit of providing better drainage of the dredged river sand, which allows for drier material and reduced costs at the asphalt plant. The question still remained about the best way to feed the stacker. “For several years, we used a front-end loader that fed a bin, which then fed the telescoping stacker,” he said. “But we wanted to be able to eliminate the loader with its associated costs, stop handling the material twice and improve our hauling cycles at the same time. So we started to look at truck unloaders.” Truck unloaders typically consist of a hopper connected to a stacker, allowing trucks to dump material while the conveyor stockpiles it simultaneously. According to Michael Eubank, the truck unloader models he and his father Mike Eubank saw 36 january 2012
didn’t seem to solve the space and time constraints the company faced at the Dickson location. They either required a large ramp leading to the hopper, or they didn’t fit well with the telescoping stacker. “During CONEXPO-CON/AGG [last] year, we stopped at the Astec Industries booth and we saw that the KPI-JCI truck unloader on display there was exactly what we had been looking for,” he noted. continued on page 40
Here’s How It Works: An end-dump or belly-dump truck drives up the low (3-foot) dirt ramp to the Low Pro Drive-Over Truck Unloader. The truck stops and dumps its material into a 10foot by 6-foot hopper that has a flat grate with 6-inch spacing. Hydraulic pivoting sidewalls sweep overflow material into the hopper. An adjustable discharge gate controls the flow at the hopper. Material falls through the grate and onto a high-speed conveyor. The conveyor carries it toward the stockpile area, etc.
www.theasphaltpro.com | ASPHALT PRO 37
The KPI-JCI Low Pro Drive-Over Unloader features a low profile, compact design and quick setup. Capable of unloading end-dump and belly-dump trucks, the truck unloader requires a low (3-foot) dirt ramp, which takes the trucks over a 10-foot by 6-foot hopper into which they can dump the material. The hopper has a flat bar grate with 6-inch spacing. Overflow material is swept into the hopper with hydraulic pivoting sidewalls. Hydraulic power for the sidewalls is provided with a 10-horsepower electric/hydraulic power pack located above the kingpin. Flow at the hopper is controlled with an adjustable discharge gate. The material falls through the grate and onto a high-speed conveyor, which whisks it away for stockpiling. “We bought the KPI-JCI truck unloader right off the show floor,” Eubank said. “At the same time, we also ordered a new 36-inch by 150-foot KPIJCI Superstacker™ to gain even more height with our stockpile. In order to inventory more sand, taking it higher was the only option.” Eubank said it was a history of trust in Astec Industries and its companies that gave him and his father the confidence to purchase the unloader without seeing it run. Eubank Asphalt’s two hot mix plants are both Astec Double Barrel systems. “Dr. (Don) Brock has done so much with the industry, and also for our company, with his great knowledge. We have a longtime friendship with him, and we knew the truck unloader would do exactly what he said it would do.” Eubank Asphalt Paving & Sealing took delivery of the KPI-JCI Low Pro Drive-Over Truck Unloader a week after CONEXPO-CON/AGG ended, and started it up the next day. “I’m not surprised that the Eubanks had already set up the truck unloader and were using it when we arrived onsite,” Leon Luadzers, KPI-JCI regional sales manager for portable and stationary aggregate products, said. “We merely had to review the operation and maintenance of the machines with the Eubanks, and they have continued to use the units as intended ever since.” Eubank added that the equipment has spoiled his employees to a degree. “We set it up, turn it on and it takes care of itself. It might help that this is 40 january 2012
an asphalt plant, and the KPI-JCI equipment uses the same switchgear as our Astec asphalt plants, so we’re familiar with it. But that’s part of what’s built our confidence in all of Astec’s companies,” he said. In addition to taking its sand stockpile higher within the same footprint, the Low Pro Drive-Over Truck Unloader and Superstacker combination has allowed Eubank Asphalt to reduce its costs by eliminating the need for a front-end loader at the sand stockpile. The added height of the stockpile further improves water drainage, delivering a drier sand product and thus improving fuel costs at the asphalt plant. And Eubank noted a subtle benefit from the unloader combination in the reduction of truck traffic in the yard. “It’s interesting that dumping into the truck unloader actually takes a little longer than dumping right into the stockpile—say, a couple of minutes versus 30 seconds—but overall, it has helped eliminate the grouping or bunching of trucks,” he said. “It separates the trucks by about three to five minutes at the [aggregate] source and at the dump site in our yard. As an operator of dump trucks, we’re always seeking to eliminate the piling up of trucks. Our drivers learned quickly what pace they needed to take in dumping their sand. And we’ve eliminated…the double-handling of material.”
While Eubank Asphalt Paving & Sealing currently operates from two asphalt plant sites, the company is always looking to add more plant sites where it can operate its portable Astec asphalt plants. Eubank said the portability benefits offered by the unloader and the stacker will allow the company to operate them at multiple sites as needed. “If you can find a piece of equipment that improves your quality overall while reducing your costs, it’s absolutely necessary,” Eubank added. “Our KPI-JCI truck unloader and Superstacker have done just that.”
(From left) Plant operators Lee Choate, Phillip Donegan and Steven Warren pose in front of their new truck unloader.
The Low Pro Drive-Over Truck Unloader and Superstacker combination has allowed Eubank Asphalt to reduce its costs by eliminating the need for a front-end loader at the sand stockpile.
Meet 2012 NAPA Chairman Kurt Bechthold
Kurt Bechthold, President, Payne & Dolan 2012 Chairman, NAPA
by Sandy Lender
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s a company that has remained loyal to the asphalt industry for more than 80 years, Payne & Dolan, Inc., Waukesha, Wis., now offers its third-generation president to the industry’s national organization. Kurt Bechthold turns 49 in February and takes the gavel as the 2012 chairman of the National Asphalt Pavement Association (NAPA) at the annual meeting in Palm Desert, Calif., this month. Kurt joined the family business as a part-time worker at age 15 and kept that status during his high school and college years. After earning an engineering degree at the University of Wisconsin Madison, he spent a year as a project manager for the company. He then achieved his MBA from Northwestern and worked for a year at Amoco Oil in Chicago. In early 1990, he returned to Payne & Dolan and has worked full-time for the company the past two decades. “The reality is I’ve spent my life around this industry, laboring and running equipment early on,” Kurt said. “I learned pretty quickly that those are skilled positions. The people who run that equipment are artists in their own right. The person on the back of the paver is really flying that screed. He needs to understand how the speed, temperature, angle of attack 42 january 2012
and head of material affect the mat thickness. That takes skill.” To listen to Kurt speak, you get the impression that he takes his own skills lightly. In fact, he has an important lesson to bring to the chairmanship this year. “I get up, I come into work and I deal with the issues that come up each day,” he said. “You don’t run from problems; you run at them. I learned that from my father; if you do nothing else, you work hard. Pay attention to what you can control and don’t worry about what someone else is doing. If you work hard, you can succeed. But if you don’t work hard, you certainly won’t be successful. My father spoke about that a lot and I took it to heart.” As a company president, and now a national organization’s chairman, Kurt takes hard work seriously, but he also makes time for the important things in his life. “When I read about people who have hobbies outside of family, I wonder how they do it. I set aside a few hours a week for exercise because I believe that’s important, but all my time outside of work I try to spend with my wife and kids.” Kurt’s three children are ages 18, 13 and 8, so they keep him and his wife, Lori, hopping with carpools to different activi-
ties. Kurt said he skis with the kids every year. His wife is involved with his daughter’s horseback riding. When his son plays hockey, Kurt can be found at the rink. When his son is ski racing, you’ll find Kurt on the ski hill. Family vacations are a must. “We believe in following each child as they pursue their passion. We’ve always encouraged them to look for what drives them and we try to support them. We try to spend time on that.” Kurt and Lori take time for what drives them as well. “My wife and I have spent a lot of time with volunteer organizations because we believe in giving back. People follow what they’re passionate about. At the company, we hire a lot of people out of Milwaukee’s central city and as a family we are passionate about central city youth education. A lot of people there don’t have a safe, nurturing environment during their childhood. People do need help. That’s one of those things that drives me and hopefully I’ve helped.” Kurt doesn’t spend time looking for additional motivation or quotable quips. “The common sense part of leadership is easy; the challenge is having the hard conversations that put a person to the test and hopefully lead to success.”
Kurt Bechthold (green hat) visits with a co-worker in open, face-to-face communication. It’s the kind of communication Kurt says wise leaders learn and apply in day-to-day operations and the kind he values in the people he has around him.
ASK ABOUT NEW LOWER PRICE
U.S. Patents 6,672,751 and 7,044,630
Photo courtesy of Astec Australia Pty. Ltd.
International Night Paving
by AsphaltPro Staff
Boral Asphalt uses a Roadtec SB1500 to feed a Roadtec RP150 paver equipped with Carlson electric screed for this night project. The crew has used a multitude of lighting options for optimum safety on the Pacific Motorway in Brisbane, Australia. 44 january 2012
Plant Checks Now Mean Uptime Later
Of course you’d notice something this blatant during production. The problem is air system restrictions causing blow-back of combustion gases.
Part II: Drum Plants by Cliff Mansfield
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s we began in the December issue, here is my winter season inspection checklist for drum plants. I’ve developed this checklist over 19 seasons of involvement with numerous asphalt plants in various parts of North America. Please note that I am by no means familiar with every possible combination of equipment used on contemporary asphalt plants; omissions are bound to happen. This article is intended as a guideline to minimize surprises in the coming paving season. The following inspections are done with pen and paper in hand. No repairs are made at this time. The purpose of this activity is to formulate a list of observed problems and to facilitate a strategy to address them. A can of orange marking paint is handy to tag components slated for later repair. Every component should be made safe per the Occupational Safety and Health Administration (OSHA) lockout, tagout regulations prior to inspection. On particularly dangerous units I’ll include a reminder. To begin, I want to draw your attention to the general maintenance issue of oiling components as detailed in Part I in the December issue of AsphaltPro. Be sure to complete a thorough greasing regimen prior to plant restart. Let’s pick up where we left off last month.
DRIER/MIXER
Whole articles have been written on the subject of drum maintenance, covering a wide variety of topics including flight design and internal air flow relating to veil patterns. This discussion deals with inspecting and scheduling repairs for the components that you already have. To that end, no mention will be made of the various configurations of flights that are available. We begin with the internal components of the unit. Because the inspection detailed in No.6 of the burner section is performed 48 january 2012
from inside the drier, perhaps it would be a good idea to read that section also before entering the drier. Make sure all maintenance personnel follow OSHA confined space entry protocol at all times. The unit should be as clean as possible inside for this inspection. Before setting out on a manual cleaning mission, consider heating 20 or 30 tons of coarse aggregate to around 400 degrees. Sometimes this will clean a surprising amount of accumulated material out of a drum mixer, slat conveyor, batcher and storage silo. 1. Inspect each and every flight of a cooled drum for the following problems: A. excessive wear B. heat curling C. impact bending D. cracking or absence Mark for replacement any flight that exhibits these problems. Obviously, any that are cracked can probably be welded, and those that are missing must be replaced. 2. Examine the mounts for each flight, noting and marking any cracked or broken components. 3. While you’re in the drier, with your safety lanyard firmly attached, have an assistant cover what openings he can with plywood. Extinguish your light and look for sources of light that shouldn’t exist. Pay particular attention to the knock-out box and its associated ductwork. These leaks reduce the amount of air available to the drying process, cause excessive burner fuel usage and, under certain conditions, leak dust into the atmosphere.
An over-fueled condition is evidenced here by fuel dripping on the ground from the nozzle. Take time to note this type of situation, but don’t let this kind of situation go. A bucket under the problematic nozzle keeps this from looking like more of a hazard than it is until the maintenance man comes through to fix any leaks or until the plant operator gets fuel ratios straightened out.
4. Check the rakes at the mixer discharge. Note any bent or missing rakes. 5. Inspect the discharge collar, looking for worn-out liners. Also examine the upper end of the discharge chute. 6. Look at the oil injection tube. Is it wearing badly on top? Are there any holes or cracks? Mark for repair anything that is wrong. On a unit that exhibits wear on the top, which is caused by cascading mix abrading the pipe, consider installing a small trough on top of the injection pipe to catch a quantity of mix. On a 3-inch pipe, a 4-inch channel welded on with the upright sides of the U pointed skyward will quickly fill with hot mix. Because the mix is constantly being replaced as it wears away this operation will effectively end any future wear problems.
7. On plants with a recycle collar, examine the inlet chute and the kicker flights. Look for excessive wear, missing parts or product build-up. The external inspection of the drier mixer follows. 1. Examine the drier barrel end seals at the inlet and discharge collars. These often overlooked components can contribute significantly to fuel efficiency if they are in good condition. If your plant has a recycle collar you should examine its seals also at this time. 2. On plants with inlet chutes, check the air dam and see that it seals off the area over the incoming aggregate. If it’s excessively worn, mark it for repair. 3. Examine the air dam in the discharge chute, noting any problems and marking them for repair. 4. Examine each trunnion for excessive wear or damage. To check the bearings it’s a good idea to jack the drum up and use a bar to pry the units around. Proper trunnion adjustment is very important to over-all drier operation. It’s difficult to maintain the proper settings with worn-out components so any
loose bearings or abraded trunnions should be marked for immediate action. 5. On those units that use thrust bearings to control drier position, examine them to be sure they’re in good shape. Excessive contact can indicate improperly adjusted trunnions. If this is the case, schedule some time to make the necessary adjustments per factory instructions. 6. Drive methods vary from plant to plant. For chain driven units, inspect for the same things as any other chain drive. On friction drive units, the condition of the trunnions is more important. To avoid slippage they must be smooth and flat. On both drive styles, check the condition of the gear boxes and any belts used. 7. On driers with a hydraulic jacking and leveling option begin by inspecting the power/pump unit. It should start easily and operate with a minimum of headaches. Hook the unit to each individual jacking station and check operation. On driers with screw jacks on the end of
the set-up supports, check each one for proper operation. 8. Oil as suggested above. When moving and resetting the plant the previous devices can substantially reduce the amount of time the crane is on the job.
RAP SYSTEM
On plants with this option the inspection procedure is, essentially, the same as for the cold feed system to the inlet to the drier. Follow those directions. Remember to schedule a thorough calibration sequence for your scale belt.
SLAT CONVEYOR
Slat conveyors can be unforgiving, lethal units if not treated with respect. Before beginning this inspection follow OSHA lockout, tagout regulations. 1. Inspect the condition of the floor, the flights and the chain. Obviously, the most important consideration here is whether or not they will operate trouble-free for the amount of tonnage you expect to run next season. This is a judgment call, but it’s a good idea to remember how hard it is to dig 300-de-
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gree mix out of a stalled or broken slat conveyor. 2. Inspect the main drive sprockets at the top of the slat. If worn, can they be turned? If not, mark them for replacement. Don’t take chances on these guys. If they’re segmented sprockets then they’re relatively inexpensive and easy to replace. If they’re not, you don’t want to tackle changing them in the middle of a paving contract. 3. Examine the reject gate. Look for excessive wear, misalignment or any other condition causing a poor seal. 4. Inspect the reject gate’s air actuation system. Look for frayed or cracked air hoses, excessively worn air cylinders and pivots. Check the system’s air solenoid and oiler. Do they work reliably? A thorough cleaning and tune-up would be a good start. 5. Oil as suggested above.
ASPHALT HOLDING SILO
The batcher is one of the most important pieces of equipment on an asphalt plant when it comes to battling mix segregation. As such it should be treated with a high degree of respect. 1. Inspect the batcher’s sides and cone for thin spots. Mark them for plating. 2. Look closely at the gates and their pivots. Use a bar to pry the gates around. Are they loose? Have they been greased? Mark for repairs any abnormalities you find. 3. Meticulously examine the air actuation system. Failures here are the primary cause of batcher problems. Check the air cylinder(s) for excessive wear. Substandard air hoses should be slated for replacement. As with the reject chute controls, target the batcher’s air solenoid and oiler for a thorough cleaning and tune-up. Kits for these items are inexpensive and easy to install. Stock a spare solenoid at least, and an oiler if possible. 4. If your batcher uses high-level indicators test them for proper operation. Refer to the factory manual for specific procedures. In general: If you have limit switches, activate them and have someone watch the appropriate warning light in the control room. If you have a torque stall type indicator, simply hold it from rotating and have someone check the light. Target for repair any system that fails to work. 50 january 2012
Often overlooked drum seals are a huge source of fugitive air. Burners get about 70 percent of their air from the main exhaust fan making any leak significant. This leak at the drum seals reduces the amount of air available for combustion. If you didn’t notice the reduction in efficiency during production, then be sure you mark this down as a spot to fix before you start up again.
The same inspection protocol is used for the holding silo as for the batcher. 1. Check the iron, especially in the cone area. Mark any thin areas for repair or replacement. 2. Examine the gate and all its actuating controls. Schedule the air solenoid and oiler for a cleaning and tune-up. As with the other gates, a spare solenoid should be on hand. Spare air hoses can be time savers here, too. 3. Get on an aerial work platform (be sure to use an OSHA approved safety restraint belt) and have yourself hoisted up next to the gate. Check the pivot pins by prying the gates around with a bar. Schedule repairs for any found lacking. Look at the grease zerks and pins for grease needs. 4. Check the operation of the silo’s high and low warning alarms. Use the same procedures as with the batcher.
BURNER, FUEL SYSTEM
Each burner manufacturer has written a maintenance manual for its specific product. Find that manual and study it. Following their recommendations might well avert a breakdown. In general and for older units: 1. Test and verify the operation of all safety systems. 2. Examine all fuel and propane lines. Schedule for replacement any that raise a question in your mind. Also look at the propane bottle for the igniter. Check for signs of leakage and damage.
3. Check the fuel pump and drive mechanism. Mark any frayed belts, worn couplers or leaking seals. Schedule the fuel filters for replacement, regardless of how long they’ve been in place. 4. Check the piping and valving from the supply tank. Verify that shut-offs do work. Don’t take them for granted. Also take a minute and inspect the tank’s filling apparatus. Note any leaks or unsafe practices. 5. If your fuel system uses a water separator, consult the manufacturer’s literature on maintenance procedures. In general they should be drained and cleaned. 6. If you have a poured ignition port and combustion chamber check them for signs of damage. These units are often easiest to check from inside the drier/ mixer. Because these items can fail all at once sometimes following relatively minor damage, it’s best to schedule repairs on any area that raises questions in your mind.
EXHAUST FAN AND DUCTWORK
Inspection of ductwork is not for the claustrophobic. It can be a tight, confining area. Remember your OSHA confined space training here. 1. Inspect the ductwork from the outside first. Look for loose or misaligned joints and any physical damage that might lead to an air leak. On portable plants with a wet wash you should check the seals around where the venturii enters the knockout-box and the scrubber. The same holds true for the ductwork between a baghouse and the knockout-box. 2. Double-check to see that the exhaust fan is locked out and tagged out per OSHA regulations. Once you’ve done that, crawl inside the ductwork and inspect it for any signs of damage. Mark anything that raises questions. Now turn off your light. Look for any source of light that shouldn’t exist. Obviously, these are leaks. Note any you find and mark them for repair.
3. Check for material build-up in the ductwork. Such accumulations often offer evidence of air flow deficiencies that should be analyzed and the root problem corrected to maximize plant efficiency and minimize fuel usage. You’ll find many styles of exhaust fans in use in contemporary plants. Because the focus of this discussion is catching problems, the following checklist is general in nature. 1. Examine the fan for any signs of excessive wear. On paddle fans pay close attention to the hub area where the fan blades attach. Look for cracks that could be precursors to a catastrophic failure. 2. On wet fans look for excessive scale build-up, which can lead to an out-ofbalance condition. After you clean the fan and find no flaws, schedule a vibration analysis. Fan balancing companies can come to your facility, balance your fan and electronically examine the bearings, leaving you with a clear picture of your unit’s condition. I recommend that lower production facilities (under 100,000 tons per year) test their
fans every other year. For higher production operations yearly is a good choice unless the fan is exhibiting chronic balance problems. Wet fans presenting chronic balance problems due to a build-up of mud on the fan blades can sometimes be helped by the simple addition of a regulated water spray nozzle directed at the center of the fan on the inlet side. This washes away the accumulated mud and extends the life of a balancing job. Only add as much water as needed to keep the fan clean because the excess goes out the stack as muddy rain. Done properly, you shouldn’t see any change in the stack. 3. Inspect the fan housing for worn and leaking areas. Mark any abnormalities. 4. Closely inspect the exhaust damper and its associated operating system, including the actuator. Mark for attention anything that raises questions in your mind. 5. Examine the fan motor, motor mount and belt guard. Mark anything that catches your eye. 6. Be sure the fan is locked out, and then remove the belt guard. Examine the
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belts and sheaves. Excessive wear here reduces fan efficiency and can lead to belt burn-up when starting. It’s a good idea to carry spare belts for this unit because new ones this size aren’t always readily available. Note: If you have a wet wash system, visit www.theasphaltpro.com for an additional maintenance checklist.
BAGHOUSE
Refer to the manufacturer’s maintenance manual for your specific unit prior to beginning this survey. The following checklist is general in nature. Before you begin, use a powder test to locate leaking bags. 1. Examine the baghouse from the outside. Note any signs of damage. Look for leaking covers on top, disconnected solenoids or by-passed sections. Make notes on any deficiencies. 2. Most units are fitted with their own air compressor. Refer to the compressor’s manual for the yearly maintenance schedule. In general, this is another place where spares could mean the difference between a short break in production or days of downtime waiting for parts. 3. Inspect all air lines. Look for cracking, heat damage, weather damage or anything that raises doubts. Schedule your air driers for cleaning. Mark damaged ones for replacement. Examine the electronic controllers. If anything is by-passed or “jumpered,” schedule repairs. Check the air solenoids for proper operation; schedule any that fail for repair or replacement. Lastly, look at all the air cylinders. Mark any that raise questions. 4. On reverse air units check the doors, seals, actuating cylinders and solenoids. This is a time-consuming job, but one that is necessary to insure the correct operation of these units. 5. Open the lids on top of the baghouse. Check the bag seals, cages and venturiis if so equipped. 6. Modern baghouses use either augers, drag chains or a combination of the two to get rid of 200s (fines or dust). On both units check the bearings and flights. On the drag chain you need to look at the chain and sprockets. You are looking for excessive wear of the sprockets. Schedule repairs for anything you find amiss. 7. Most baghouses use dust return systems to put the fines back into the 52 january 2012
drier. These can be air pumps or augers. Check these units for excessive wear and for proper operation. 8. On systems using air pumps, check the air box and the hoses used to pump the fines to the drier. 9. Most baghouses use either a slam damper or a similar device to shut off air flow through the baghouse in the event of excessive heat. Check the operation of these safety devices. Also check other safety devices such as temp monitors and pressure drop gauges for proper operation. Check out the “miscellaneous” section for information on calibrating thermometers. 10. If your exhaust stack uses a profiler to straighten the air flow and correct stack cyclonics (required by DEQs in most states) you should examine it and its supports. Look for corrosion and rust, which could lead to the profiler falling into the bottom of the stack.
HEAT TRANSFER OIL SYSTEM
Two types of heat transfer oil heating systems are in use on today’s asphalt plants: electric and oil fired. Some units are standalone, others have most of their components built into the asphalt cement (AC) oil storage tanks. Please note that this examination should be done on a cold system. General: 1. Examine your unit’s overall condition. Has the control box been hit by one too many loaders, leaving the electrical components exposed to the elements? Does the unit still have insulation? Is the unit clean? These are safety issues and should be addressed accordingly. 2. Examine the hoses over the entire system. Are they brittle, cracked or leaking? Any that fit this description should be marked for replacement. Look at the oil pump. Is the seal leaking? Are the drive belts and guard in good condition? 3. Hot oil holding tanks have a low-level shut-down device. Check to see that yours works properly. 4. Test the control temperature sensor to verify accuracy. 5. Also test the overtemp protection thermometer. 6. Have the heat transfer fluid analyzed by a reputable company. It’s also wise to change the oil every couple of years.
7. Inspect and test the auto start system. Does the time clock keep accurate time? Does the unit start and stop at the appointed hours? Oil fired units: 1. Examine the fuel system. Check for leaking lines and seals. Schedule a fuel filter change. 2. Check the exhaust damper system for proper operation. 3. These units use several safeties similar to those found on your main burner, such as an ultraviolet “flame-eye,” which is used to detect burner combustion. The unit also uses a step timer to control things during the start-up/shutdown sequences. Refer to your operator’s manual for specific procedures for testing yours. Electric units: Be aware of electrical shock hazards; disconnect the electricity before performing this examination. Check the wiring and connections. Schedule repairs on any that are loose or corroded. Do you have spare fuses handy? How about the small fuses used on the control circuits? These little guys are often hidden and the plant operator is unaware that they exist until one fails and production grinds to a halt. It’s also a good idea to stock the contacts and a pull-in coil for the motor starter and for the heater relays.
ASPHALT OIL HOLDING AND DELIVERY SYSTEMS
Pump pallet: 1. Check the general condition of the asphalt pump. You want no leaks in the shaft seal, case gaskets or pipe connections. 2. On belt driven units you should check the condition of the sheaves and belts. Make sure the guard is in place and in good condition. 3. On hydraulic units, schedule an oil and filter change. Also, examine the hoses, seals and the coupler between the pump and motor. If the unit is covered in grime, schedule a cleaning session paying particular attention to the oil cooler. 4. Pay close attention to the flow indicator or tachometer that provides a signal to the ratio computer to regulate oil percentage. Have a spare pick-up, drive belt or tachometer on hand. 5. Examine the flex lines from the tank to the pump and from the pump to the drum. Mark for replacement any that
are frayed or kinked or that raise any questions in your mind. AC oil holding tanks: In general, you should examine the overall condition of the tanks. Make sure the insulation and covering skin are in good condition. Keep the tanks clean. Make sure you don’t have accumulated oil beneath the tanks and perform the following steps. 1. As with the heat transfer oil system, you should schedule testing to determine the accuracy of the AC tank’s temperature controls. 2. Check your tank vents to see that they are not plugged or obstructed. 3. Inspect the tanker off-loading pump and associated plumbing. Use the same protocols as for the pump pallet. Remember that oil haulers will start and stop pumps with their asphalt-covered gloves on. You want to clean your switch buttons to get that material off, and schedule a toolbox talk with the truck drivers on how to carry and use clean gloves.
Do you have a stock of crucial spares such as control voltage fuses and possibly a regulator? 4. Examine the control van/room. Is it clean and neat or are there jumper wires sprouting from every panel and fuse box? Make sure all the motor starters work as designed and not through creative re-wiring. Schedule repairs as needed. This may look like a lengthy finish to a winter repair regimen, but your asphalt plant will perform better for it. Start with
the December list so you don’t miss the collecting conveyor, scale belt and such, but follow up with this month’s list so you have a thorough drum plant checklist. We’ll take a look at your dratch plant in February. This month’s list should keep you busy until then. Cliff Mansfield is the proprietor of CM Consulting, Odell, Ore. For more information, contact him at (541) 354-6188 or send him your question through the “Ask the Plant Expert” form on the home page at www.TheAsphaltPro.com.
MISCELLANEOUS COMPONENTS
1. Air compressor: This unit should be scheduled for a complete service. Clean any associated air driers and lubricators at the same time. Examine all air lines, noting any problems. 2. Schedule a test session for all the thermometers on your plant. One easy way to calibrate them is to boil water, immerse the sensor end and adjust the thermometer to read 212 degrees, the boiling point of water at sea-level. Adjust the temperature for the altitude of your plant; i.e. 208 at 1,000 feet. Another way is to find a thermometer you know is accurate, such as an infrared hand-held unit, and then set all the others to match it. On the heat transfer oil system and the AC tanks you can check the operation of the high-temp shut-downs by immersing the sensors in the boiling water and then slowly turning down the set-point controls until the unit shuts off. Record the setting and compare it with the boiling point of water at your altitude. Make the appropriate adjustments. 3. Portable AC plants usually rely on generators. Examine the radiator. Is it full of gunk? Schedule a thorough cleaning. Look at all the hoses and belts. Mark any that raise doubts. Schedule a complete service that includes testing and adjustment of the generator output. www.theasphaltpro.com | ASPHALT PRO 53
National Level Programs Seek Participation
What are these wide-ranging programs and what do they mean for average contractors?
by AsphaltPro Staff
M
any charitable organizations sent end-of-the-year letters requesting donations last month, hoping to capitalize on donors’ desires to get a tax deduction in FY2011. While a deduction is an extra incentive to give, hopefully donors graciously pour their offerings on a charity of their choosing out of the kindness of their hearts. Members of the asphalt construction industry are not strangers to this concept. Communities with the honor of having an HMA plant in their midst know the generosity of a freshly paved road when the plant overruns mix or a new playground when the old one looks rusty or boxes of food when the local food drive is running low. The list goes on. But how do industry members know when national campaigns are of local or personal interest? What do wide-ranging charitable programs offer to average contractors? Here’s a look at a few that may be on your radar screen in 2012.
Construction Angels
Construction Angels is a newly forming charity that held its first 50/50 raffle to raise more than $1,000 for a family in need this fall. The board participated Dec. 10, 2011, in the Seminole Hard Rock Winterfest Boat Parade in Ft. Lauderdale, Fla., to raise awareness for its cause, which is to help families that have lost a loved one while working in the road and bridge construction industry. President and Founder Kristi Ronyak explained that as soon as Construction Angels receives its 501(c)3 status, the board will organize fundraising activities such as biker runs, golf and fishing tournaments, and more. The intent is to raise awareness and bring in donations from anyone inside or outside of the construction industry. Monies raised will be available to families when a tragedy occurs. “When there’s an accident, often communication between the company and 54 january 2012
family is hindered,” Ronyak explained. “When Construction Angels is in place, the construction company or family of the deceased can contact us and we can provide immediate assistance and support to the family in need.” Ronyak anticipates expeditious growth from a local to a statewide charity. “We envision a nationwide Construction Angels organization with regional chapters holding their own fundraising activities. The venture is one that will help any road construction worker, but has the potential to outgrow even that limitation to include any construction worker in the nation,” Ronyak said. For more information, visit www.constructionangels.org and watch for the launch of their facebook page this month.
I Make America
The I Make America website homepage states “We need to dramatically increase jobs for America’s equipment manufacturers so they are able to prosper and grow right here in the U.S. When they succeed, America wins.” The equipment manufacturers AEM refers to, and is made of, includes the asphalt paving and production and aggregates mining and moving industries from which you purchase products, but it also includes farming, forestry, utility and building equipment that you may or may not be interested in supporting. Of course, united we stand. By combining the interests of equipment manufacturers across the board, we can speak to legislators with one voice. “Every $1 billion invested in highways supports 27,823 jobs and generates $6.2 billion of economic activity.” That includes the construction of roads and bridges that get farmers’ goods to market. Our fates entwine on some level. We create an economic foundation for America and for our colleagues and partners overseas under the auspices of I Make America. If that’s a program you can get behind, then visit www.IMakeAmerica.com/home to learn more.
NAPA Care
The Associate Members Council of the National Asphalt Pavement Association (NAPA) has raised money in the past to purchase equipment for the National Center for Asphalt Technology (NCAT), but more recently looked for a cause that people could respond to and feel excited to support no matter what the economy, according to council member Roger Sandberg. What the group came up with is a charity run through the NAPA Research & Education Foundation, Inc. (NAPAREF), 501(c)3 organization. NAPA Care will provide financial assistance to NAPA member employee families who have suffered a fatality in an asphalt work zone or plant site. Due to legal restrictions, only NAPA members can donate to the NAPA Care Emergency Benevolent Fund and only NAPA member employee families can qualify for the funds. Sandberg anticipates the program will officially launch this summer when the council expects it will reach a minimum funding level of $300,000. While every donation is tax-deductible, the NAPA website explains that recipients will not need to record the gift as income. As Sandberg explained, “Research has shown that those families are living paycheck to paycheck. The last thing they need to worry about when they lose a family member is buying groceries or the little bills that mount while waiting for the insurance money to show up.” Sandberg explained that the associate members will pick up the tab for overhead so 100 percent of the donations to NAPA Cares will go to the program. As of press time, he shared that Charles Boan of Flint Hills Resources, Wichita, gave $10,000 to NAPA Cares and challenged all AC suppliers to step up with a similar amount. The Texas APA pledged $5,000 and offered a similar challenge to the other state associations. If you or your company is a member of NAPA, feel free to visit the easy donation form under NAPA Care at the Research and Education Foundation tab at www.asphaltpavement.org.
Enrich Employees by AsphaltPro Staff
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ore than 260 company employees and their children sat down to “Breakfast with Santa” courtesy of Kolberg-Pioneer, Inc., Yankton, S.D., Dec. 3. They held the annual event at Minervas in Yankton and gave every child who attended a chance to visit with Santa (played by Curt Peterka, advertising manager for KPI-JCI and Astec Mobile Screens) and Mrs. Claus (played by Marcy Brown, accounts payable processing leader for KPI-JCI). Everybody enjoyed a buffet breakfast and the kids all Santa and Mrs. Claus visit with one of the Kolberg-Pioneer emgot presents from Santa. ployees’ sons. Joe Vig, president of KPI-JCI and Astec Mobile Screens, said the employee appreciation event is a way to connect with employees and their families and to thank them for a year of hard work. “Kolberg-Pioneer, Inc., is fortunate to have hundreds of talented employees that work extremely hard…” Vig said. “This is a way for us to reach out to not just the employees, but their families, and provide them with some holiday cheer.”
Elliott Joins the Solution by AsphaltPro Staff
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n icon for more than 40 years in the asphalt industry, the past 32 with Payne & Dolan, Glenn Elliott now takes on another leadership role. He joins Odor Solutions Group of Litchfield Park, Ariz. Owner and founder A.J. Ronyak speaks highly of his new vice president of international and national sales, and invites industry friends to visit with Glenn at the 57th National Asphalt Pavement Association annual meeting in California and at the Odor Solutions Group booth #2371 at the World of Asphalt March 13 through 15. Glenn’s extensive experience running and managing asphalt plants merely laid the foundation for all he achieved with Payne & Dolan. As he moved up through management there, he built and ran terminals and tank farms and put in two SBS farms for polymer blending. That’s a tough act to follow. But Glenn says his relationship with his colleagues at P&D remains strong. He gave a six-month notice before moving to his new post with Odor Solutions Group and even assisted in finding his successor at P&D. “That job is 24/7,” Glenn shared. “To try something new at my age is like being born again. I’ve worked with many people who reach their 60s and move to something new and increase in productivity. I think I’ll increase in productivity myself.” You can contact Glenn at (262) 366-5395 or elliottglenn@asphaltsolutions.com. 56 january 2012
equipment gallery
Get Your Part Overnight by AsphaltPro Staff
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owntime means you’re losing money. If your mechanic’s shed doesn’t have the part you need to get equipment back up and running, you don’t necessarily have a catastrophe on your hands. If it’s a popular part, you can probably get it sent to you overnight. And you might be surprised by what qualifies as popular these days. Just about anyone can get bearings to you overnight. The folks at Emerson Industrial Automation have a new 932-page catalog of unmounted and mounted bearing products from McGill, Rollway, Browning and Sealmaster brands at their www.emersonlinecatalog.com site. Get your order in by 11 a.m. and you get your bearings the next day. Authorized customers can order from the www.emerson-ept.com site; other contractors can easily find a distributor by visiting that site. If you need something more complex, consider these options. EriezXpress™ offers a variety of aggregate, recycling and other products for next-day shipping. It’s not
Emerson’s latest catalog helps customers find the bearings they need. 58 january 2012
Order by 4 p.m. and these items get shipped the next day through the EriezXpress program.
quite as fast as overnight, but it gets some vital components to consumers in a hurry. Eriez of Erie, Pa., identified the products most often ordered with fast shipment requirements and that included, but isn’t limited to, plate magnets, grates, traps, small coolant cleaners, lifting magnets, high speed vibratory feeders, bin vibrators and magnetic rolls. Are you separating ferrous material before grinding asphalt shingles? No worries. If a magnet in the Xpress program breaks before 4 p.m., you can place your order and Eriez fulfills it and gets it out the door the next day. The recently launched EriezXpress program streamlines the order-to-ship process by simplifying product ordering, modifying inventory control and designating a dedicated team to make it all happen. In fact, Dave Heubel, the director of North American sales at Eriez gave examples of same-day shipping scenarios. “We have products that are available for same or next day shipment. Some locations, due to proximity, would see delivery next day with regular LTL or courier carriers as many of the magnets would be too large for air shipments. That all said, we have a variety
Eriez offers a guide to industrial metal detectors for the recycling, aggregate and processing industries.
of other magnets that may have application in RAS that would ship NDA, but they would not be as common as our stock Suspended Magnets.” To help users properly select an industrial metal detector for their par-
ticular application, Eriez offers a free 28-page guide titled How to Choose and Use Industrial Metal Detectors. “The Xpress catalog should apply very well to recycled asphalt applications,” Heubel said. Download the guide at http://eriez.com/Products/MetalDetectorsIndustrial/. Eriez isn’t the only company that’s considered customers’ downtime when it comes to delivering parts. Original equipment manufacturers (OEMs) take your time seriously, too. Dan Minninger, the parts manager for Roadtec, Chattanooga, said they deliver overnight direct to all their customers with a 96 percent fill rate. “We process and ship the same day, and we do a good job of getting it out of here,” he said. If you visit www.roadtec.com/support/parts.html, you’ll land at the home page for parts, but you’ll also see a menu for service and rebuild options. If the order weighs 150 pounds or less, Roadtec uses FedEx or UPS to get the product delivered. For larger orders, they select the best carrier depending on the circumstances. Minninger said they’ve shipped severalhundred-pound pieces overnight from Tennessee to Oregon with success. Aftermarket parts suppliers can handle large parts, too. In addition to the gaggle of augers and sprockets that ACE Group ships overnight or ex-
pedited they’ve also sent out a chain and bar assembly by overnight air for a customer. Proprietor Carl McKenzie said they sent out a full set of pads for a paver by overnight air for another customer. That kind of service is available to all ACE Group customers, existing and new, for in-stock items. “As long as the new customer’s credit is approved, or they can pay by credit card also, that service is available to all,” McKenzie said. Keep in mind, that service is available if you get your order in by noon to 1 p.m. Central. Start with a visit to www.asphaltace.com. Parts companies and OEMs have gotten savvy with their websites. If you’re in a rush, you can find the parts department’s phone number in a hurry on the company’s website. If you’ve got a little time to find a part on your own, you can browse and do site searches at the URL of your choice. One company that took this innovation to heart is Bullis Fabrication at www.bullisfabrication.com. Registered customers can see and compare prices of new and used parts on the site, and there are a lot of parts to see. Something Bullis has done to raise the bar involves better communication. They’ve created a blog at www.BullisFabrication.com/blog/ where Greg Bullis can post new items or new services. For in-
Bullis Fabrication not only offers 24-hour parts, the company’s site also features a blog where managers update customers on used plants or other sizeable equipment that has just become available.
equipment gallery stance, in October, Bullis formed a partnership with Rice Lake Scale Systems. You can now order scale parts through Bullis with the click of your mouse. And, of course, check out the company’s overnight availability. One of the ways companies meet your demands is through preparation. Roadtec’s Minninger said they keep the shelves stocked and ready. They also know that they experience roughly two seasons: paving season and maintenance/rebuild season. During paving season, they can send out several hundred small orders in a day. Right now as contractors are updating equipment in their fleets, Roadtec’s parts department is sending out larger orders than they typically do in the height of summer, but fewer orders per day. Another company stocked and ready for the winter maintenance season is Femco Mining Parts. Readers with heavy duty aggregate trucks can take advantage of Femco’s new parts liquidation right now by visiting www.femcomachine.com or by contacting lrichardson@femcomach.com. Tell them you saw it in AsphaltPro Magazine.
Astec’s V-Flights Make the Veil Uniform
New v-flights from Astec, Inc., Chattanooga, are designed to replace the showering flights in drums and provide a greater uniformity of the aggregate veil during the drying process. An Astec spokesperson reports that a reasonable expectation for fuel savings on a high RAP mix or open-graded mix produced with these flights in place would be about 10 percent. Using the v-flights in conjunction with an optional variable frequency drive (VFD) not only improves fuel efficiency and increases productivity, it also adds flexibility by extending the range of mixes that can be produced without requiring that the flights be adjusted, according to the manufacturer. With the VFD, a plant operator should have the ability to control exhaust temperatures regardless of the mix design.
60 january 2012
For the highest level of control, Astec is introducing a patent-pending stack temp control system package that incorporates the v-flights along with the VFD and PLC computer controls. The PLC is designed to automatically modulate the drum speed to maintain the set baghouse temperature. With the stack temp control system, producers should be able to accommodate more RAP in mixes. The v-flights are now standard in all new Astec drums and available as retrofits. For more information, contact Astec at (423) 867-4210. Tell them you saw it in AsphaltPro Magazine.
Talbert’s SSTA 5053 Trailer
Talbert Manufacturing, Inc., Rensselaer, Ind., showed off its flexible Talbert SSTA (traveling axle) 5053 Trailer at the American Towman Expo 2011 in Baltimore Nov. 17 through 20. The trailer then went to Talbert’s top dealer, Hale Trailer Brake & Wheel, which is one of the largest independent full-service trailer dealerships in the United States. He’s got 14 locations along the East Coast from Maine to Florida. If you’re interested, here are the specs on this trailer. The SSTA 5053 has a 50-ton capacity; a 41-foot 6-inch lower deck and 53 feet in overall length. It features a 6-degree loading angle and a 14-degree dumping angle. The particular trailer Hale will have on hand is equipped with a 20,000pound planetary winch, but the trailer usually comes with a 15,000-pound winch. The planetary winch is operated via a multi-function wireless remote, which allows one operator to load and steer a piece of non-operational equipment without having to leave the trailer.
The SSTA 5053 is comprised of a T-1 & 80K Steel beam constructed framework; 4-inch I-beam cross members on 9-inch centers; and 1 ½-inch apitong flooring. Among other standard features, it includes air-ride suspension, a two-speed landing gear, hub-piloted steel disc wheels, and both side and center tiedown slots for greater loading ease and application flexibility. For more information, contact Hale Trailer Brake & Wheel at (800) 232-6535 or Talbert Manufacturing at (800) 3485232. Tell them you saw it in AsphaltPro Magazine.
Cat Kits Extend Engine Life
Six new overhaul kits from Caterpillar are designed to economically extend the life of Cat medium-duty engines and are available through Cat dealers. If you have a Cat 3126B, 3126E or C7 mediumduty engine with serial-number prefixes of KAL, WAX or SAP, check out the new Cat® Precious Metals On-Highway engine-overhaul kits at www.cat.com/requestCatinfo.
Refer to Latest Agg & Recycle Guide
If you need general technical information for aggregate and recycle crushing, screening, washing or material handling equipment, there’s an updated guide for you. KPI-JCI and Astec Mobile Screens, Yankton, S.D., has released a 216-page, pocket-sized, fourth edition of its Facts & Figures book. To get your free copy, contact Kate Shoemaker at (605) 6689311, ext. 2212. Tell them you saw it in AsphaltPro Magazine.
Dynapac’s Compact Cold Planers
Dynapac, Commerce City, Colo., offers two compact cold planers with special drums for demarcation work and fine-spaced cutting drums designed for quick-and-easy change-outs. The Dynapac PL500T and PL500TD 20-inch cold planers are available as three- and four-wheeled units. They feature a maximum cutting depth of 6.3 inches (16 cm) and 7.9 inches (20 cm) respectively.
equipment gallery
Each model is powered by a step-3 compliant Cummins QSB 4.5 C110/ C130 diesel engine. The engine ratings are 110 hp/82 kW/112 PS at 2,200 rpm for the PL500T and 130 hp/97 kW/132 PS for the PL500TD. Dynapac’s patented hydraulically operated front sealing of the cutter
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housing, adapted to the shape of the cutting drum, is designed to minimize the accumulation of the milled material. The company has addressed operator ergonomic and safety issues by reducing vibration on the operator’s platform; orienting the controls and instrumentation to face toward the operator; and adopting a userfriendly control panel layout. As an option, the PL500T and PL500TD can be fitted with a 39.5inch conveyor for loading a wheel loader bucket, or with an 18-foot conveyor for loading trucks. An additional option for both models is the Dynapac-patented parallelogram front axle. This design is intended for increased traction, reduced wear and improved wheel control in case of a height difference for the front wheels. For more information, contact Dynapac at (303) 253-6922 or chris. fisher@us.atlascopco.com. Tell them you saw it in AsphaltPro Magazine.
Evonik’s Koldspray Gets Degaroute® Down
Evonik, a creative industrial group from Germany, purchased two Koldspray MMA 98:2 units from Dispensing Technology Corporation (DTC) to provide equipment to apply its Degaroute® road markings in the Eastern and Midwestern regions of the United States. Degaroute is Evonik’s solvent-free methacrylate resin used as a road marking binder. DTC is the maker of Koldspray, an airless spray system specifically designed for the application of methacrylate-based road markings with a 98:2 mix ratio. The features Koldspray offers include a changeable, disposable static mixing system, skid-mounted structures that enable compatibility with standard pick-up trucks, a 35-foot spray hose that allows for both stencil and short
For more information, contact Danielle Deluccia at the Evonik Degussa Corporation at (973) 929-8453 or Danielle.deluccia@evonik.com or visit www. evonik.com/north-america. Tell them you saw it in AsphaltPro Magazine.
Allmand’s MH-1000 Heater Trailer
line applications, off-the shelf parts, pressure compensated hydraulic pumps, and positive displacement fluid proportioning pumps. Additional Koldspray units can be purchased through Evonik’s equipment program or directly from DTC.
The Allmand Maxi-Heat MH-1000 heater trailers from Allmand Bros., Inc., Holdredge, Neb., now feature three smaller molded poly fuel tanks instead of a single large steel tank, offering users more than 30 hours of continuous operation without refueling. The new fuel tank system has one 50 U.S.-gallon engine supply tank and two 100 U.S.-gallon heater supply tanks. As an added benefit, the new polymer tanks are not just corrosionresistant, but are also a lighter material that reduces the overall weight of the tanks. This partially offsets the ad-
ditional weight of the increased fuel capacity, which means no single tank is over 118 U.S. gallons or 450 Liters. This brings the trailer under the fuel capacity limits of Transport Canada regulation CGSB 43.146; no initial or subsequent tank certifications required means substantial cost savings over the life of MaxiHeat trailers that fall under Transport Canada regs. Maxi-Heat features twin heater units that produce a maximum of 1,010,000 BTUs and may be operated independently depending on heating requirements. A standard 1,800-rpm liquid-cooled Isuzu 3CD or optional CAT C1.5 diesel engine with regulated generator provides power for the heaters and electrical accessories. For more information, contact Allmand Bros. at (800) 562-1373 or info@allmand.com. Tell them you saw it in AsphaltPro Magazine.
www.theasphaltpro.com | ASPHALT PRO 63
66 january 2012
here's how it works
Astec’s Real-Time Quality Control System
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ggregate makes up about 95 percent of your mix, so the mix of gradations must be on target. One way to check that is through realtime sampling and on-site testing. The team at Astec Industries, Inc., Chattanooga, has a two-part Real-Time Quality Control System to take care of that. Here’s how it works. First, the Accu-Swipe™ Belt Sampler takes a cross-sectional sample of aggregate from the conveyor feeding the drum. The automatic sampler sits above the conveyor. As aggregate passes beneath it, the sampler’s piston-like arm presses its metal scoop across the belt in less than half a second to force a sample of 70 january 2012
aggregate out of the stream. The scoop drops the sample into a waiting hopper or bucket. The piston returns the scoop to its resting position for the next sampling of aggregate. Workers take the sample of aggregate to the lab for the next step in the Real-Time Quality Control System. At the lab, the Automatic Gradation Unit (AGU) weighs, screens and separates the sample that the Accu-Swipe belt sweeper collected. First, the lab tech tilts the AGU on an axle to pour the aggregate sample into the feed hopper at the top of a stack of seven sieves. When the tech tilts the AGU back upright, the sample falls to the first/top screen.
The tech tilts the AGU again and opens a flap to let the oversized material that stayed on the top screen fall to a weighing plate, and then to a waiting bucket below the unit. Next, the tech opens the second sieve’s flap, allowing oversized material to fall to a weighing plate below. After recording the weight of this material, the tech removes the plate for the material to fall into the bucket below and repeats the process with each sieve and flap. When all flaps have been emptied, the tech rights the AGU for the next sample. For more information, contact Astec at (423) 867-4210 or visit www.astecinc. com. Tell them you saw it in AsphaltPro Magazine.
RAP-13424 2002 CMI PTD-300 Portable CF Drum Mix Plant
PTD-300 - Drum Mixer 7’x8’-3”x42’ w/ Hauck SJ520 Burner RA-218P - Portable Roto-Aire Baghouse, 504 Bags, 9,072 Sq. Ft. PAB-532 - (5) 32 Ton Bin Portable Cold Feed System SE-195 - 95 Ton Self Erect Surge Silo CT20/10P - 30k gallon AC Tank, 20/10 Split CEI 1500 1.8mbtu Hot Oil Heater
RAP-13055 CEDARAPIDS E500 CF DRUM
• 114” x 52’ long w/ 126 mbtu burner • Shell thickness close to ½” throughout • Rap collar, trunnion drive, left side discharge
VIST US ON THE WEB OR CALL TOLL FREE
Inc.
PO Box 519, Shelbyville KY 40066 • Fax 502.647.1786
www.ReliableAsphalt.com 866.647.1782
here's how it works
Wirtgen’s Level Pro Leveling System
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utomatic leveling systems bring a new level of control to milling operations. In today’s pavement preservation and maintenance environment, the ability to regulate a pre-set milling depth and inclination electronically means a crew is closer to a smooth, bonus-worthy pavement. The engineers at Wirtgen Group have developed the Wirtgen Level Pro® system to give that kind of control over milling. Here’s how it works. First, combinable sensors—such as wirerope, ultrasonic, slope or laser sensors, the sonic ski, or a 3D system—take measurements from the roadway. The wire-rope sensor is fitted to a side plate that slides along a reference surface. The ultrasonic sensor can be fitted in various ways: at the side plate, at the side of, or in front of the milling drum. The multiple ultrasonic sensor Sonic Ski uses five ultrasonic sensors to provide precise results. The slope sensor is fitted to the chassis and is used for milling a pre-defined cross slope.
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A rotary transducer sensor uses a wand to track a stringline, or a linear transducer sensor incorporated into the side-skirt cylinders senses side-skirt location as it slides along the surface to monitor grade. The Multiplex system uses between three and seven sensors on each side, arranged at maximum distance to each other, to calculate the mean value; this is often used for fine milling. Optimum results are achieved by combining the slope sensor and Multiplex system to change the gradient across several traffic lanes. Next, the sensors send the measurements to a controller incorporated within the machine. The controller unit, as the “brain” of the system, evaluates all data transmitted by the sensors, and controls the machine’s height adjustment. From there, the controller sends a signal to the operator’s station atop the mill, or two monitors at the groundman’s stations. The Level Pro monitors are positioned externally on the sides of the mill
as required, and simply provide a window to all parameters within the controller. That way, monitors can be taken from machine to machine without having to reset parameters for each machine. On the Level Pro monitors the operator (or groundman) reads parameters such as target and actual milling depth values on the left and right machine sides, slope values, etc., from the graphics-capable display. With the monitors the operator or groundman then controls the milling depth from his position, and in fact the monitors also can be removed from the machine and used inhand away from the machine if a closer look at the drum is required, for example. He can input, store and retrieve pre-programmed target values from both sides of the machine as needed. For more information about the Wirtgen Level Pro Leveling System, contact Bruce Monical at (615) 501-0600 or visit www.wirtgenamerica.com.
resource directory ACE Group.................................55, 69 Contact: Carl McKenzie Tel: 888-878-0898 sales.enquiries@asphaltacesales.com www.asphaltace.com
C.M. Consulting................................66 Contact: Cliff Mansfield Tel: 541-354-6188 CMConslt@aol.com www.hotplantconsulting.com
Asphalt Drum Mixers............14-15, 59 Contact: Steve Shawd or Jeff Dunne Tel: 260-637-5729 sales@admasphaltplants.com www.admasphaltplants.com
CEI......................................................4 Contact: Andy Guth Tel: 800-545-4034 info@ceienterprises.com www.ceienterprises.com
Asphalt Solutions.............................45 Contact: Pat Ronyack Tel: 629-853-2273 Nosmellasphalt@msn.com www.asphaltsolutions.com
Clarence Richard Co...........62, outsert Contact: Clarence Richard Tel: 952-939-6000 Carrie@clarencerichard.com www.clarencerichard.com
Astec, Inc........................ 17, 38-39, 57 Contact: Tom Baugh Tel: 423-867-4210 tbaugh@astecinc.com www.astecinc.com
Dillman Equipment......................22-23 Tel: 608-326-4820 www.dillmanequipment.com
B & S Light Industries..................46-47 Contact: Mike Young Tel: 918-342-1181 Sales@bslight.com www.bslight.com Bullis Fabrication..............................24 Contact: Greg Bullis Tel: 866-981-8965 gregbullis@bullisfabrication.com www.bullisfabrication.com
Gilson Company…............................62 Contact: Jim Bibler Tel: 740-548-7298 Jbibler@gilsonco.com www.globalgilson.com Heatec, Inc.............Inside Front Cover Contact: Sharlene Burney Tel: 800-235-5200 sburney@heatec.com www.heatec.com Herman Grant Co., Inc.....................19 Contact: Paula Shuford Tel: 800-472-6826 hg@hermangrant.com www.hermangrant.com Homestead Valve.............................73 Tel: 610-770-1100 Sales@homesteadvalves.com www.homesteadvalves.com
Meadwestvaco.................................25 Tel: 800-458-4034 www.evotherm.com www.mvw.com NAPA…………..................................65 57th Annual Meeting www.asphaltpavement.org Reliable Asphalt Products.......................Back Cover, 71 Contact: Charles Grote Tel: 502-647-1782 cgrote@reliableasphalt.com www.reliableasphalt.com Rocky Mountain ACE Show.............68 Contact: Sue Wagner-Renner Tel: 970-222-4459 Sue@rmaces.org www.rmaces.org
Humboldt Manufacturing.................63 Contact: Robin Bailey Tel: 800-544-7220 Rbailey@humboldtmfg.com www.humboldtmfg.com
Roadtec..........................................7, 9 Contact: Sales Tel: 423-265-0600 Sales@roadtec.com www.roadtec.com
E.D. Etnyre.......................................56 Contact: sales@etnyre.com Tel: 800-995-2116 www.etnyre.com
Libra Systems...................................53 Contact: Ken Cardy Tel: 225-256-1700 Sales@librasystems.com www.librasystems.com
Rotochopper, Inc.....Inside Back Cover Tel: 320-548-3586 Info@rotochopper.com www.rotochopper.com
EZ Street.....................................49-51 Tel: 800-734-1476 Info@ezstreet-miami.com www.ezstreetasphalt.com
Maxam Equipment.....................35, 43 Contact: Lonnie Greene Tel: 800-292-6070 lgreene@maxamequipment.com www.maxamequipment.com
Dynapac US......................................11 Tel: 800-732-6762 www.dynapac.us
Stansteel AsphaltPlant Products......................33 Contact: Dave Payne Tel: 800-826-0223 dpayne@stansteel.com www.stansteel.com
Stansteel.....................................61, 67 Contact: Dawn Kochert Tel: 800-826-0223 dkochert@hotmixparts.com www.hotmixparts.com Systems Equipment.........................41 Contact: Dave Enyart Sr. Tel: 563-568-6387 Dlenyart@systyemsequipment.com www.systemsequipment.com Tarmac International, Inc............29, 31 Contact: Ron Heap Tel 816-220-0700 info@tarmacinc.com www.tarmacinc.com Top Quality Paving...........................66 Contact: John Ball Tel 603-624-8300 Tqpaving@yahoo.com www.tqpaving WRT Equipment...............................24 Contact: Dean Taylor Tel: 800-667-2025 or 306-244-0423 dtaylor@wrtequipment.com www.wrtequipment.com World of Asphalt..............................64 Contact: info@worldofasphalt.com Tel: 800-867-6060 www.worldofasphalt.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 | ASPHALT PRO 73
the last cut
Oil Disputes Impact Arctic Circle to Texas by AsphaltPro Staff
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n its discussion of Arctic oil and natural gas potential Dec. 21, 2011, the U.S. Energy Information Administration (EIA) showed parallels to the Keystone XL pipeline issue discussed in this month’s Editor’s Note. The parallels included energy transportation limitations and, as luck would have it, poor soil conditions. First of all, the TransCanada Corp’s Keystone XL pipeline is a $7 billion project that crosses the Canadian border and relies on the United States for real estate and workers. If completed, it would be an energy transportation pipeline that would carry crude sands oil from Northern Alberta, Canada, to Texas for the purpose of refining before exporting. The Keystone XL pipeline project ran into trouble in late 2011 when citizens in Nebraska pointed out the fragile structural integrity of the Hill Sands area where the pipeline would cross the state. Nebraskans successfully convinced their state legislators to prevent the pipeline project from going across the delicate sands. From there, the re-routing necessity became a federal issue that is currently under review and awaiting a presidential decision for direction. The This Week in Petroleum report from EIA concerning Arctic oil disputes almost read like an excuse for the high prices the world marketplace should expect to see from crude and gas from that region. The Dec. 21 report specifically mentioned that severe weather will require specially designed equipment and highly paid personnel willing to endure the isolation and “inhospitable Arctic.” The energy transportation alluded to above will include long supply lines and redundant equipment to accommodate the limited access way up there, which ultimately increases transportation costs. Luckily, engineers already consider the Arctic ground conditions, which Nebraskans would have legislators in the United States believe TransCanada’s employees neglected to do when planning the Keystone XL route. The EIA report stated: “On Arctic lands, poor soil conditions can require additional site preparation to prevent equipment and structures from sinking. Gas hydrates can also pose problems for drilling wells in both on- and offshore Arctic areas.” For the Arctic region, different producers and different countries appear to be working in harmony currently. Overlapping claims are a challenge for another day while companies work to come up with viable solutions to the costly issues mentioned in this article. As the Dec. 21 report stated, “With major territorial disputes not likely to have an impact on resource development in the near term, producers still need to find ways to extract oil and natural gas in an economic and environmentally acceptable manner, something that has and will continue to differ across countries and development tracts.” 74 january 2012
In the Arctic, it appears all those with a vested interest in success are working together for success. The same could be said of the Keystone XL pipeline if engineers and legislators figure out a way to get around a less-than-60-mile section of unstable ground. Both the Arctic and Keystone XL examples remind us that companies still have the responsibility of extracting oil and natural gas in environmentally acceptable ways. Liquid Asphalt Cement Prices—average per ton Company, State
Sep ’11
Oct ’11
Nov ’11
Dec ’11
ConocoPhillips, Tenn.
$550.00
$550.00
$550.00
$570.00
NuStar Energy, Ga.
585.00
580.00
580.00
580.00
NuStar Energy, N.C.
585.00
580.00
580.00
580.00
NuStar Energy, Va.
600.00
595.00
595.00
600.00
Assoc’d Asphalt Inman, N.C.
580.00
580.00
580.00
600.00
Assoc’d Asphalt Inman, S.C.
575.00
575.00
575.00
600.00
Assoc’d Asphalt Inman, Va.
590.00
590.00
590.00
605.00
Marathon Petroleum, Tenn.
555.00
540.00
540.00
560.00
Marathon Petroleum, N.C.
565.00
565.00
555.00
575.00
Valero Petroleum, Va.
590.00
580.00
580.00
580.00
Massachusetts Average
587.50
575.00
575.00
575.00
California Average
589.70
559.80
637.00
625.00
Missouri Average
510.00
510.00
510.00
526.25
Data for Southeast region, Source: ncdot.org; Data for Massachusetts, Source: mass. gov; Data for California, Source: dot.ca.gov; Data for Missouri, Source: modot.mo.gov
Crude Oil Activity (U.S. Crude)
Diesel Fuel Retail Price (dollars per gallon)
futures spot data
stocks
Sep 9
$87.24/bbl
346.4 m bbl
Sep 12
3.862
Sep 16
$87.96/bbl
339.0 m bbl
Sep 19
3.833
Sep 23
$79.85/bbl
341.0 m bbl
Sep 26
3.786
Sep 30
$79.20/bbl
336.3 m bbl
Oct 3
3.749
Oct 7
$82.98/bbl
337.6 m bbl
Oct 10
3.721
Oct 14
$86.80/bbl
332.9 m bbl
Oct 17
3.801
Oct 21
$87.40/bbl
337.6 m bbl
Oct 24
3.825
Oct 28
$93.32/bbl
339.5 m bbl
Oct 31
3.892
Nov 4
$94.26/bbl
338.1 m bbl
Nov 7
3.887
Nov 11
$97.78/bbl
337.0 m bbl
Nov 14
3.987
Nov 18
$97.41/bbl
330.8 m bbl
Nov 21
4.010
$96.77/bbl
334.7 m bbl
Nov 28
3.964
$100.96/bbl
336.1 m bbl
Dec 5
3.931
Nov 25 Dec 2
Sources: Energy Information Administration