Asphalt Contractor March/April 2019

MARCH/APRIL 2019

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WHAT YOU MISSED AT WORLD OF ASPHALT

ERGONOMIC ADVANCES

POSITION PAVING EQUIPMENT OPERATORS FOR SUCCESS

INNOVATION IMPROVES

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Engineered Innovation.

From innovative designs to Caterpillar dealer service and support, Weiler is paving the way to success for contractors across North America. Weiler’s material transfer vehicles, commercial pavers, road wideners, windrow elevators, static split-drum compactors, soil stabilizers, rock drills, tack distributors and front mount screeds are engineered with innovative features to increase productivity while reducing operating costs.

Weiler equipment is sold and serviced exclusively at Caterpillar dealers throughout North America. www.ForConstructionPros.com/10075409

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The Trusted Choice for Hotmix Plants in North America.

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TABLE OF CONTENTS |

MARCH/APRIL 2019

COVER STORY Innovation Improves Asphalt Plant Operations New technology helps plant owners inspect their silos in a matter of hours, not days, saving thousands of dollars and keeping crews away from harm. | 32 TECHNOLOGY MATTERS

10 5 Construction Technology Trends Shaping 2019 & Beyond The successful contractor in the future will operate quite differently than today.

16 Caterpillar Brings Safety Training to a New Level with Virtual Reality New VR Training Module provides in-depth training related to specific road construction hazards, helping reduce safety incidents at the jobsite.

SPECIAL REPORT: WHAT YOU MISSED AT WORLD OF ASPHALT 2019

18 Over 10,000 attend making the 2019 show the largest ever. Take a look at what you may have missed on the show floor.

PRODUCTION NOTES

34 Reduce Plant Energy Output

by Covering Aggregate Piles Wet aggregates increase asphalt plant fuel costs and create extra time and labor in order to stay on track with deadlines.

38 Cliff’s Notes This month, Cliff consults on a tragic accident, warning that diesel and heat don’t tend to mix well

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50 Production Products Plants, baghouses, mixers, dryers, automation systems & more to measure the quality of their asphalt.

JOBSITE INNOVATIONS

54 Ergonomic Advances Position Paving Equipment Operators for Success Safety, productivity and ease of use have been enhanced through ergonomic advancements in asphalt paver design.

64 Jobsite Products

A combination of Wirtgen machines was used to widen and in-place recycle a failing road in Seminole Count, FL

70 Chicago Suburb Invests in Pavement Repair This Off-Season Village of Winnetka uses 6-ton hot box to move away from cold mix, keeping crews busy year-round to perform long-lasting repairs.

72 Preservation Products Milling machines, reclaimers, infrared equipment & more.

Pavers, rollers, MTVs & more.

PRESERVATION UPDATE

68 In-place Recycling Fills the Void on Rural Florida Road

IN EVERY ISSUE 8

Editor’s Perspective

82 The Last Exit

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DIGITAL CONNECTION www.ForConstructionPros.com/Asphalt

Scientists Use Smartphones to Monitor Aging U.S. Infrastructure Researchers hope the large amount of data collected by crowdsourcing their technology will allow for better informed decisions about the health of roads and bridges.

[VIDEO] Case Displays New Small-Frame Vibratory Rollers at World of Asphalt 2019 New DV23D and DV26D Double Drum Rollers and DV23CD and DV26CD Combination Vibratory Rollers deliver productivity solutions for small- to mid-size paving applications.

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Caltrans Requesting EPDs During Bid Process

Multiple States Eyeing Gas Tax Increase Ahead of Construction Season

The California Department of Transportation (Caltrans) announced an initial list of four asphalt pavement projects that will request Environmental Product Declarations (EPDs) as part of the bid.

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Ohio, Minnesota & Alabama among states looking to make their own money for crumbling roadways.

Search: 21048571

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ASPHALT

MARCH/APRIL 2019 Vol. 33, No. 3

CONTRACTOR LATEST PROFESSIONALS LATEST INNOVATIONS FOR ASPHALTPROFESSIONALS PROFESSIONALS LATEST INNOVATIONS FOR ASPHALT

Published by AC Business Media.

Asphalt CONTRACTOR

201 N. Main Street Fort Atkinson, WI 53538 (800) 538-5544 • www.ACBusinessMedia.com www.ForConstructionPros.com/Asphalt

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Published and copyrighted 2019 by AC Business Media. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage or retrieval system, without written permission from the publisher.

Asphalt Contractor (ISSN 1055-9205, USPS 0020-688): is published ten times per year: January, February, March/April, May, June/July, August, September, October, November, December, with an additional Buyer’s Guide issue published in August by AC Business Media, 201 N. Main Street, Fort Atkinson, Wisconsin 53538. Periodicals postage paid at Fort Atkinson, Wisconsin and additional entry offices.

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THE MIGHTY NEW TV450. Bring hard-hitting power to the jobsite while still benefitting from the smooth stability, low ground pressure and productive comfort of a CASE compact track loader. Featuring a rated operating capacity of 4,500 lb*. and bucket breakout of nearly 9,200 lb., the TV450 easily handles pallets of pavers and loads of almost anything. And with 4,000 PSI, you have ample power for chippers, stump grinders and the most demanding attachments. Learn about the largest track loader in our lineup. See what it can do for your business at CaseCE.com/TV450

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*ROC is based on 50% of tipping load **For commercial use only. Customer participation subject to credit qualification and approval by CNH Industrial America LLC or CNH Industrial Canada Ltd. Only at participating dealers, see your CASE dealer for details and eligibility requirements. Down payment may be required. Offer good through March 31, 2019. Not all customers or applicants may qualify for this rate or term. CNH Industrial America LLC or CNH Industrial Canada Ltd. standard terms and conditions will apply. This transaction will be unconditionally interest free. Canada Example - 0% per annum for a total contract term of 60 months: Based on a retail contract date of January 1, 2019, with a suggested retail price on a new CASE SR200 of C$54,000, customer provides down payment of C$10,800 and finances the balance of C$43,200 at 0% per annum for 60 months. There will be 60 equal monthly installment payments of C$720 each.

The total amount payable will be C$54,000, which includes finance charges of $0. This offer may not represent actual sales price. Taxes, freight, set-up, delivery, additional options or attachments not included in suggested retail price. Offer subject to change or cancellation without notice. Š2019 CNH Industrial America LLC. All rights reserved. CASE is a trademark registered in the United States and many other countries, owned by or licensed to CNH Industrial N.V.,its subsidiaries or affiliates.

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CONTRACTOR

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MARCH/APRIL 2019 • Vol. 33, No. 3

ASPHALT

EDITOR’S PERSPECTIVE

CONTRACTOR LATEST INNOVATIONS FOR ASPHALTPROFESSIONALS PROFESSIONALS LATEST LATEST INNOVATIONS FOR ASPHALT

Published by AC Business Media

Jessica Lombardo, Editor jLombardo@ACBusinessMedia.com 920.542.1247

Why Doesn’t Society Value Dirty Jobs?

L

ast month at the National Asphalt Pavement Association annual meeting, attendees had the privilege to hear Mike Rowe, notorious host of Dirty Jobs, speak to a crowd of over 1,000 asphalt industry professionals. Not only was he funny and entertaining to listen to, but he also used his platform to engage the audience in thoughtprovoking ways.

Our country is currently sitting with nearly 7 million unfilled jobs. Sure that’s a lot, but what’s worse is that 75% of these open jobs don’t require a four year degree. These jobs require will, work ethic and training. Three things that seem to be in short supply in today’s work force.

“Our country has become profoundly disconnected from the definition of a good job,” Rowe says. “I hear it all the time that companies can’t find the people they need to show up early, stay late and learn a job that’s in demand. Instead, we have $1.5 trillion dollars of debt for student loans that earned degrees that don’t exist in the real world anymore. The country needs an awakening to make a more persuasive argument for the trades.”

Exactly Mr. Rowe. We’re not sure when it happened, but at some point the idea of earning a living by completing a hard day of work became frowned upon. Why? What is so wrong with doing a job that really matters?

Each and every person in our country relies on our extensive highway network to get them to and from their jobs and to make sure their families have the food and supplies they need to live comfortably. So why on earth do we not encourage our kids to do something that absolutely impacts our world for the better?

Rowe suggests a fundamental change in the conversation about these jobs deemed “unattractive” by certain facets of our society.

And that conversation starts with you.

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WHAT CAN YOU DO? Reshaping the ideals of Millenials and other naysayers for the trades isn’t going to be easy, but we need to start a new conversation now if we’re going to change anything. As an asphalt professional, you know the value of what you do. Sure it may not always be easy, but isn’t it always worth it? Maybe you don’t feel accomplished at the end of every day, but once a project is complete? I’ve seen first hand how much pride every worker takes in contributing to that job well done.

In fact, a recent survey by Reester & Associates for the asphalt industry showed that 75% of new hires were coming from current employee referrals. Once you’re in, you love it.

That means a good place to start that new conversation is right there; by making sure you talk about what we do in a positive light.

If we only talk to our friends and family about the negative aspects of our jobs, the long hours, heat and exhaustion that sometimes occurs, we are never going to make what we do seem attractive.

So focus on the good things when talking about our jobs. The competitive pay, the training opportunities, the camaraderie of the team and that amazing feeling of a good crew finishing a great job. What we do matters.

Let’s make the rest of the world understand.

How are you attracting people to your job for the 2019 season? I’m always open to hear what’s working, and what’s not: jlombardo@ acbusinessmedia.com.

Asphalt CONTRACTOR

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

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13333 Highway 24 West Fort Wayne, IN 46814 Tel. (260) 672-3004 Fax. (260) 672-3020 www.almix.com www.ForConstructionPros.com/XXXXXXX www.ForConstructionPros.com/10071910

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TECHNOLOGY MATTERS

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Construction Technology Trends Shaping 2019 & Beyond

The successful contractor in the future will operate quite differently than today

H

op in a car and drive anywhere in the U.S. and chances are the drive will be on roads and highways that need patching, resurfacing, or widening, and bridges often show signs of needed maintenance.

Sadly, things are in bad shape.

On the last two report cards from the American Society of Civil Engineers, the U.S. infrastructure scored a D+.

This year’s report urges the government and private sector to increase spending

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by two trillion dollars within the next 10 years, in order to improve not only the physical infrastructure, but the American economy as well. The roadway infrastructure is badly deteriorated.

According to Statistics Canada, in partnership with Infrastructure Canada, Canadian roads are in better shape due to the fact that nearly one in four kilometres of roads have been constructed since 2000. Newer roads means roads in better condition.

As Robert Puente, writing for the Brookings Institute, observed, "Infrastructure enables trade, powers businesses, connects workers to their jobs, creates opportunities for struggling communities and protects the nation

The aware construction contractor will exploit the opportunities provided by technology to ensure greater productivity, better quality and longer lasting results.

from an increasingly unpredictable natural environment... infrastructure is the backbone of a healthy economy."

In many respects, the future of construction is bright. Construction workers, contractors and people who know how to design, maintain, rehab and construct the roadways that people rely on everyday are in high demand. The care and maintenance of America's road network have been ignored too long and with the increased population, the needs have changed.

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TECHNOLOGY MATTERS The construction industry will be crucial to fulfilling the requirements and goals of North America's future. Construction has been changing and evolving rapidly during the past 20 years and its dynamic advances will continue. The successful contractor in the future will operate quite differently than today.

"Construction contractors have experienced tremendous benefits in newer, more technologically advanced machines and equipment," Kris Maas, director of construction product development for Topcon Positioning Group says. "And the highly successful contractor has adopted precision measurement systems, GNSS machine control and geospatial management and collaboration software to ensure seamless coordination among all involved in their projects—which have revolutionized grading, excavation and paving."

There appear to be five technology trends shaping the future of construction:

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1. DATA: Acquiring, using and sharing data in real time gives contractors advantages of enabling their machines to "talk."

Through connected machines, contractors can remotely monitor progress, communicate with the operator, diagnose and repair problems, track machine location and provide support. Data collected can confirm quality results and help with bidding on future similar projects. There will be the time when a job site or highway can tell how it should be built through instant data, seamless communication, exact material amounts. "Our MAGNET software solutions suite, currently provides real-time connected support for hardware as well as integration with our Sitelink3D service for instant data transfer and connectivity into active project sites," Maas said. "Additionally, Sitelink3D allows customers to plan, schedule, assign tasks and get reports, all in real time."

2. CONSTRUCTIONEERING: Constructioneering is a term Bentley Systems uses to refer to automating the digital construction process through surveying, engineering design, constructible model development and as-built data collection within a connected data environment to improve construction execution and reduce project costs. It is the creation of collaborative systems to bring all the data into digital models that can be seamlessly shared with machines, operators, supervisors, civil engineers and project owners. Unmanned aerial Technology can help with the labor shortfall and fill the skills gap of new employees. Take a smart, inexperienced worker and place them in the cab of a dozer or motor grader governed by GPS machine control with a 3D site plan displayed, and with proper training they will become even more productive.

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TECHNOLOGY MATTERS

vehicles or drones are an example of the type of data that will be collected.

Drones can provide virtual reality perspective and data about job sites too difficult or dangerous to reach.

3. SMART ROADS: Roadways will do more than carry traffic in the future. As solar collector ribbons they may very well be contributing to fueling the vehicles of the future. Or embedded wireless technology could maintain an electric car's charge.

Metal street name signs will become nostalgic artifacts of times past, since the self-driving pods will be told by the road what street it is on. Roads will heal themselves as cracks form since the concrete or asphalt mix will be embedded with tiny capsules of sodium silicate. When a crack forms, the capsules rupture and release a gel-like healing agent that will harden to fill the void.

4. OVERCOMING THE SKILLS GAP: Technology can help with the labor shortfall and fill the skills gap of new employees. Take a smart, inexperienced worker and place them in the cab of a dozer or motor grader governed by GPS machine control with a 3D site plan displayed, and with proper training they will become productive. Technology has not only proved to save time and improve

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accuracy, but it's impact on productivity has been significant. As technology permeates the construction industry, there is a need for university and technology school graduate technicians.

The need and challenge is there.

5. INTERNET OF THINGS: The Internet of Things (IoT) refers to the communication connectedness of machines and objects through sensors via online. Think of IoT as the data aggregation and collection going into a central repository where intelligent decisions can be made based on what has been collected in real-time. Workers can be tracked in the field and ensure that they are protected from, or at least aware of, job site hazards and other potential injuries. Equipment sensors can monitor whether machinery is being productive or in need of repair or preventive maintenance.

"The future is getting closer to us... it's inevitable," Maas says. "We continue to develop new technologies and refine the innovations we've brought to the market—all with the objective of helping construction contractors to be more efficient, accurate and productive in what is referred to as ‘The Intersection of Infrastructure and Technology.’ The future expects that of us."

As the World Economic Forum said: "Over the past decade, digital progress

Acquiring, using and sharing data in real time gives contractors advantages of enabling their machines to “talk.” Through connected machines, contractors can remotely monitor progress, communicate with the operator, diagnose and repair problems, track machine location and provide support.

has transformed whole industries, ushering in a new technological era now known as the Fourth Industrial Revolution...These new technologies are satisfying consumer demand for better entertainment, shopping and transport.

Innovation has improved companies’ productivity and sustainability and redefined the skills and competencies needed to thrive."

Clearly, the aware construction contractor will exploit the opportunities provided by technology to ensure greater productivity, better quality and longer lasting results.

Jeff Winke is a business and construction writer based in Milwaukee, WI. He can be reached through jeff_ winke@yahoo.com.

For more information on advancing technology, visit ForConstructionPros.com/ construction-technology

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TECHNOLOGY UPDATE |

BY JESSICA LOMBARDO, EDITOR

Caterpillar Brings Safety Training to a New Level with

virtual reality

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New VR Training Module provides in-depth training related to specific road construction hazards which can help to reduce safety incidents at the jobsite

W

e all know road construction jobsites are full of hazards and distractions that create risks for employees, especially new workers.

Tens-of-thousands of traffic accidents and hundreds of deaths are logged annually during road construction throughout the United States.

In-depth training related to specific road construction hazards, along with learning the importance of following proper procedures and effective communication among workers, can help to reduce safety incidents at the jobsite.

To help facilitate those training efforts, Caterpillar Inc. launched the new Cat Safety VR virtual reality safety training module at World of Asphalt 2019. Designed for paving contractors, Cat Safety VR immerses the trainee into a virtual four-lane rural highway construction site so the employee learns to interact with coworkers and identify hazards in a safe and controlled environment.

"You might consider hiring a new employee that may have never been on a paving crew and now you're going to put them out on a four-lane highway with traffic flying by? The Cat Safety VR simulator is a great way to screen employees, for example at a job fair, along with helping to train those new hires before they ever go out to the jobsite," Justin Ganschow, Caterpillar Safety Services business development manager says.

The new Cat Safety VR comes complete with everything a company needs to conduct the safety module.

The kit includes a gaming laptop preloaded to run the program, HTC VIVE virtual reality headset system

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(including hand controls), mount stand kit and transport case. In addition, Cat Safety VR is mobile, so users can easily transport the kit anywhere to conduct training with employees.

"Cat Safety VR is all about engaging and involving employees in processes that govern the way they work every day," Ganschow adds. "Cat Safety VR represents the principles that we are trying to instill in our organization that safety isn't the job of just the safety guy or the foreman, it's everyone's job. It helps people understand some of those principles from their very first day on the job."

LEARN IN REAL SCENARIOS Once putting on the VR headset, the trainee is immersed in the virtual fourlane highway project for a site flyover and a pre-shift “huddle” with coworkers. A series of five scenarios then plays out during the training session, which is designed to show employees the many potential hazards associated with paving a highway adjacent to live traffic.

After receiving instructions from the foreman, the user advances to the taper to inspect and installs traffic control devices, which helps employees to focus when encountered by unpredictable traffic traveling at a high rate of speed.

Module scenarios at the paving train help the user to identify and negotiate blind spots, safely navigate around and between equipment, and improve communication with workers. As the module progresses, another setting features an excavator and coworker using a concrete saw to teach the importance of always wearing the proper personal protective equipment (PPE).

Each decision made offers positive reinforcement for the correct action or a memorable negative consequence for an unsafe choice. The training module concludes with a daily wrapup to reinforce the positive lessons learned and stress that no production “emergency” at the jobsite is worth risking the safety of the worker or anyone else. Total program run time is approximately 20-30 minutes per session.

“Cat Safety VR helps the trainee learn how to interact with coworkers, other contractors and the equipment, all in a safe and controlled environment,” Ganschow says. “For both new and experienced employees, virtual reality is an effective and memorable experience to support the company’s overall safety training program and advances the safety culture.”

Caterpillar Safety Services is a consulting firm inside Caterpillar Inc. and plans to extend this training module to mining, quarries, forestry, manufacturing and more.

The Cat Safety VR Training Module helps instill the importance of safety into every employee, even before they hit the jobsite.

For more information and a video on Cat Safety VR, visit ForConstructionPros. com/21047117

MARCH/APRIL 2019 ASPHALT CONTRACTOR

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SPECIAL REPORT Photo Credit: World of Asphalt

OVER 10,000

Attend 2019 World of Asphalt, Shattering Attendance Records

A

ggregates and asphalt industries were out in force at the recordsetting World of Asphalt Show & Conference and AGG1 Academy & Expo, Feb. 12-14 at the Indiana Convention Center in Indianapolis.

Attendance hit an all-time high with registered attendance at 10,063 – a 28 percent increase over the 2018 show held in Houston. Attendees came from all 50 states, with the home state of Indiana represented with over 1,500 in attendance. International attendance also increased with all 10 Canadian

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provinces and 52 other countries worldwide- including delegations from Nigeria and Russia – coming for the world-class education and exhibit floor.

“It’s been a great show with a lot of interaction on the show floor and in the education sessions; this is where our industry comes together - competitors and peers, to prepare for future growth,” said Kevin Kelly, president of Walsh & Kelly and World of Asphalt 2019 chair.

Both World of Asphalt and AGG1 achieved record size, and spanned a combined 201,450 net square feet of exhibits

and 500 exhibitors. More than 145 of those were new to the shows. On display was the latest products and technologies for the aggregates, asphalt, pavement maintenance and traffic safety sectors.

In addition to presenting a robust schedule of educational sessions during the People, Plants & Paving Conference, the National Asphalt Pavement Association (NAPA) engaged with World of Asphalt attendees on a new level with an interactive “Know Your Asphalt” trivia game and a meet-and-greet with Dr. Audrey Copeland, NAPA President &

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SPECIAL REPORT Photo Credit: World of Asphalt

CEO, and NAPA Chairman John Harper, Senior Vice President of Construction Partners Inc. NAPA also participated in Ag2Asphalt Day on Thursday, wherein NAPA staff helped educate Future Farmers of America students about the asphalt pavement industry.

Also new to the exhibit floor this year was the Rock & Roads Talks stage, which hosted 30-minute panel sessions with industry leaders weighing in on

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GET READY FOR 2020 AND 2021 The next World of Asphalt Show & Conference and AGG1 Academy & Expo will be held in March 2021 in Atlanta, GA. The shows are held annually except in CONEXPO-CON/ AGG years – the next CONEXPOCON/AGG will be held in March 2020.

CONEXPO-CON/AGG spotlights the exhibitors and products of AGG1 and World of Asphalt.

Check out the new and improved products you may have missed on the show floor over the next few pages. topics such as the changing role of technology and ways to inspire youth to pursue careers in construction.

During one of the sessions, Copeland and Harper interviewed quarry and mining expert Dave Turin, formerly of the reality TV series Gold Rush, about workforce development issues. “It’s our responsibility to learn how to respond to them [millennials] and get them to be part of our organization,” said Turin.

For more information on World of Asphalt, visit ForConstructionPros.com/20988836

Photo Credit: World of Asphalt

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SPECIAL REPORT

Roadtec RX-700e/ex Cold Planer The upgraded RX-700e cold planer features the increased power of an 800-hp Caterpillar engine. The new Tier 4 Final engine does not require DEF fluid as a component of the after-treatment system, reducing the operation costs typically required at this emission standard.

• The updated half-lane cold planer provides even higher production and reliability through increased power and efficient design • Available in three-track and four-track versions • The RX-700 cuts up to 14-in. deep with standard widths of 6-ft. 7-in., 7-ft. 2-in., 8-ft. 2-in. and 10-ft. 6-in.

• Cutter housing includes angled moldboards which prevents material from accumulating around the drum, resulting in less wear • Track pads are bolted on which makes changing pads fast, saving time and money • Durable frame is made of A656 Grade 80 steel, which is twice as strong as the mild steel commonly used, yielding a stronger, lighter frame www.ForConstructionPros.com/10913568

Libra Systems NextGen Silo Safety System The NextGen Silo Safety System guards against the most dangerous and expensive accident that can occur at an asphalt plant – inadvertently opening the wrong silo.

Equipment damage, personal injury, litigation and lost production are all consequences of a silo accident. The NextGen3 Silo Safety System is designed to dramatically reduce these risks.

• Significantly reduces the possibility of opening the wrong silo • Independent of, and compatible with, existing automation and manual switches; it blocks attempts to open the wrong silo • No operator interaction normally needed – it’s always on guard • Fully graphic screen • Automatically detects space between cab and trailer • Auto-alerts for potentially defective sensors • Pedestal or panel mount options www.ForConstructionPros.com/21041587

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Carlson EZR208 Rear-mount Screed The 7,800-lb. EZR208 highway-class screed features a standard paving width of 8 ft. to 15 ft. 6 in.

• 20-in.-deep single-piece screed plates paired with state-of-the-art heating elements • Extension support system includes a highstrength tubular frame and firmly fixed chrome rods for optimal strength even at 22 ft. with bolt-ons • Low-profile extensions provide better line of sight to augers and material head • Standard vibration absorption pads located at each operator station • Deep telescoping walkways create a safer operating platform www.ForConstructionPros. com/20987452

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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SPECIAL REPORT

LeeBoy 4130 Road Widener The LeeBoy 4130 road widener is a versatile machine that meets your road widening needs.

• The narrow width design allows for shipping without a permit while shiftable conveyor and foldable hopper wings allow precise placement of material to either side of the machine • Operator console easily shifts from side-to-side and allows a clear view into the front hopper and of the material flow to the strike-off • A tilting front hopper improves trailer load angle to 14.50 • Extendable push rollers insure a variety of trucks can be used to feed the hopper • 74 hp (55 kw) Cummings Tier 4 final engine • Width of spread up to 8-ft • 8-ft 6-in. shipping width, no permit required • 2.2 cubic yard hopper capacity www.ForConstructionPros.com/21039909

ADM Tank Level Indicator A shutdown may result if the levels sink too low without the operator noticing and ordering material in time, but the ADM tank level indicator gives operators the ability to see fuel or asphalt tank levels from the control house.

• Offered in a variety of types, including pressure gauges and radar, the indicators allow plant operators to see the levels from the control room rather than walking out to the tanks

VÖGELE ErgoPlus 3 Operating App Using a specially developed mobile app and the associated web special, job-site professionals can now get to grips with the Vogele ErgoPlus 3 operating concept quickly and easily with the aid of numerous animations.

• To achieve optimum paving results and efficient job site processes, paver operators need to know precisely when to use which operating functions and which automatic functions will make their work simpler and faster so VÖGELE developed a special app with an associated web special tailored to their ErgoPlus 3 operating concept • All the functions of the paver operator’s and the screed operator’s consoles are conveyed in a visual and practical way by means of short animations • Step-by-step videos give users an easy-to-grasp demonstration of entire work steps such as setting up the screed or requirements such as varying pave widths, as well as comprehensive automatic functions • Users can access the app at any time on their PC, tablet or smartphone – on the job site, in the office or from home – and can make direct use of the information in their work • The free app can be downloaded from the Google Play (www.voegele.info/ergoplus_android) or Apple (www.voegele.info/ergoplus_ios) stores and the web special can be viewed at www. voegele.info/webspecial/ ergoplus/ www.ForConstructionPros.com/21040136

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• This is useful on busy days when the operator may not have time to visit the tanks www.ForConstructionPros. com/21026261

Get fast, relevant product information in the Buyers Guide at ForConstructionPros.com

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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Wirtgen PCD Cutting Tools Help Improve Milling Results PCD milling tools are particularly suitable for surface layer rehabilitation thanks to their up-to-date tool geometry and materials.

• An exceptionally long service life can be achieved thanks to the highly wear-resistant tool tip made of polycrystalline diamond • The very slight lengthwise wear ensures optimum evenness over the milled surface and consistently high machine feed • Depending on the application, PCD milling tools are a useful addition to the existing pick range featuring conventional carbide tips www.ForConstructionPros.com/21045954

ArrTekk CRS Emulsifiers ArrTekk CRS emulsifiers deliver optimal emulsion viscosity characteristics which remain consistent through time and across a wide range of asphalts for more efficient and cost-effective chip sealing.

• ArrTekk 706 and 737 cationic rapid-setting (CRS) emulsifiers use cutting-edge chemistry to achieve desired chip seal emulsion viscosity across a broad range of asphalts, and at least 50% faster cohesive strength development between emulsion binder and chip aggregate, reducing asphalt costs, chip seal construction time and windshield damage claims • ArrTekk 706 and 737 emulsifiers deliver optimal emulsion viscosity characteristics which remain consistent through time and across a wide range of asphalts www.ForConstructionPros.com/21047877

HaulHub Analytics With HaulHub Analytics, material hauling executives are now able to track and utilize performance data and monitor operations costs to optimize and improve their businesses.

HaulHub Analytics metrics include driving, jobsite and plant cost breakdowns, jobsite costs per ton, costs relative to bid prices, fleet efficiency, fleet safety and average plant and jobsite wait times, among other key data points.

• HaulHub Analytics enables managers to view and utilize insights in real time to compare data on fleet, jobsite, plant, regional and national levels. Managers can now easily analyze their operations over time and even compare to industry averages.

• Platform can track material movement, wait times and costs per ton in real-time, saving time and money while improving safety

Volvo CE Expands ActiveCare Direct to Select Pavers ActiveCare Direct is now available on select Volvo asphalt pavers.

• ActiveCare Direct gives road equipment owners and managers access to so much more intelligence and understanding about their business than they would otherwise have • Starting February 2019, the P7110B and P7170B will be eligible for a one-year free subscription to ActiveCare Direct with a new machine purchase • The move to expand the managed telematics service into the Volvo road machinery line-up has been in large part due to the overwhelmingly positive response and rapid adoption of the service among Volvo dealers and customers • ActiveCare Direct is already available for certain asphalt and soil compactors. www.ForConstructionPros. com/21046812

www.ForConstructionPros.com/21045959

www.ForConstructionPros.com/Asphalt

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SPECIAL REPORT

Caterpillar Launches Virtual Reality Training Module at World of Asphalt Caterpillar Inc. has launched Cat Safety VR, a new virtual reality (VR) safety training module customized for paving applications.

• Customized for paving applications, the new VR safety training solution immerses the trainee into a virtual four-lane rural highway construction site, so the employee learns to interact with coworkers and identify hazards in a safe and controlled environment • Cat Safety VR comes complete with everything a company needs to conduct the safety module.

The kit includes a gaming laptop preloaded to run the program, HTC VIVE virtual reality headset system (including hand controls), mount stand kit and transport case • System is mobile, so users can transport the kit anywhere to conduct training • Once putting on the VR headset, the trainee is immersed in the virtual four-lane highway project for a site flyover and a pre-shift “huddle” with coworkers. A series of five scenarios then plays out during the training session, which is designed to show employees the many potential hazards associated with paving a highway adjacent to live traffic • After receiving instructions from the foreman, the user advances to the taper to inspect and installs traffic control devices, which helps employees to focus when encountered by unpredictable traffic traveling at a high rate of speed. Module scenarios at the paving train help the user to identify and negotiate blind spots, safely navigate around and between equipment, and improve communication with workers • Each decision made offers positive reinforcement for the correct action or a memorable negative consequence for an unsafe choice. The training module concludes with a daily wrap-up to reinforce the positive lessons learned and stress that no production “emergency” at the jobsite is worth risking the safety of the worker or anyone else. Total program run time is approximately 20-30 minutes per session www.ForConstructionPros.com/ 21047107

BOMAG Introduces BF 300 Commercial Class Paver to North American Market The BF 300 offers hydraulically variable paving widths from 5.6 ft to 11.2 ft with BOMAG screed extensions available in 13.8- and 19.7-in. widths.

• Equipped with BOMAG’s patented SIDEVIEW system, the paver’s operating console and seat are fully adjustable • The entire operator’s platform shifts to the left and right and the seat can be swiveled to offer up to a 23.6-in. overhang, giving the operator an unobstructed sightline to the hopper, side of the paver and screed.

• MAGMALIFE technology heats the screed plates to paving temperatures in approximately 20 minutes • Redefining screed heating, MAGMALIFE heat elements are cast into a single aluminum block that offers superior thermal conductivity and delivers more uniform heat distribution through the screed bottom for a tight mat texture without scuffing or tearing • Delivers the power and traction to pave up to 10-in. thick mats • Proprietary BOMAG Load Control System (LCS) enables the operator to securely lock the screed into position for a set duration after paver restart to eliminate bumps in the mat www.ForConstructionPros.com/ 21047106

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Case DV Series Small Frame Vibratory Rollers The DV23D and DV26D double-drum and DV23CD and DV26CD combination vibratory rollers are designed with a high curb clearance, no overhangs and a narrow drum width of 37 in.

• 33.5-hp Tier 4 Final engine delivers high centrifugal forces and frequencies at lower rpms • 4,600- to 5,490-lb. operating weights • Selectable dual frequencies of 3,480/3,960 vpm • Offset tapered drums reduce asphalt tearing during operation around curves • Standard 50-gal. water tank with pressurized water system

• Feature an iso-mounted operator platform with lateral-sliding seat for visibility to the drum edges on both sides www.ForConstructionPros. com/ 21047164

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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When you’re ready to take control of your asphalt production, we have you covered. ADM’s full line of asphalt plants, ranging from 60 – 425 tph, give you the power to lower production costs, increase profitability and grow your business. When you own the plant, you call the shots.

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EX SERIES

Asphalt Drum Mixers

www.ForConstructionPros.com/10072036

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SPECIAL REPORT

Weiler E2850B Remixing Transfer Vehicle

KPI-JCI Upgrades Kodiak Plus Crushers with K350+ Model Johnson Crushers International Inc. has expanded its Kodiak Plus cone crusher series with the new K350+ which offers higher production with a smaller footprint.

• In comparison to the K300+, the K350+ features increases in drive train, stroke, horsepower, weight, head diameter and hold-down force, resulting in an up to 10% capacity increase • With the same bolt pattern, the new cone can be mounted in most current K300+ applications • Like other cones in the Kodiak Plus cone crusher series, the K350+ will feature an industry-leading tramp iron relief system, fully-protected internal counterweights, precision roller bearing design, patented liner retention system and 360° thread locking ring for consistent product quality www.ForConstructionPros. com/ 21047704

The Weiler E2850B Remixing Transfer Vehicle combines innovative features with proven components to increase productivity while reducing operating costs.

• 25 tons of onboard storage, triple pitch remix augers and 600 tph discharge capacity provide non-stop, non-contact paving with reducing particulate and thermal segregation • Variable speed elevator and conveyors allow chain speed to match production, minimizing wear and material segregation • Auto dump and dump assist features optimize truck exchanges for continuous paving • The rear steer option provides an inside turning radius of 14-ft. with crab and coordinating steering and auto center • 18-in. shifting operator platform, with conveniently located controls, provide the operator with excellent visibility and comfort • Optional paver hopper management system maintains the distance to the paver www.ForConstructionPros.com/ 21047850

Superior Tire & Rubber Patent Pending Hopper Flashing New Patent Pending Hopper Flashing from Superior Tire & Rubber features a proprietary polyurethane compound that resists heat better than standard OE flashing, allowing more asphalt to be kept inside the paver instead of on the ground.

• Flashing maintains its original form about 3 times as long as standard OE UHMW compound, with excellent rebound • Stands up to constant contact with asphalt trucks and keeps asphalt from spilling out onto the road saving time, money and labor www.ForConstructionPros.com/ 21047732

TennaGO Tracker Offers Aftermarket Digital Monitoring for Heavy Equipment TennaGO is an IoT hardware tracking device that is ideal for tracking heavy equipment and machines that provide power sources.

• Cellular trackers provide precise GPS tracking and management for high-value heavy iron machines • TennaGO cellular trackers use IoT technology to connect equipment to the Tenna App on a mobile device for autonomous real-time tracking and monitoring • Now available for customers nationwide, TennaGO’s tracker technology generates asset data from multiple sensors that feeds into Tenna’s robust platform for analysis on equipment usage and location • Tenna has a variety of trackers that attach to equipment or plug-into vehicles, with TennaGO being the newest. These trackers not only identify the location and GPS position of an asset, but also show the frequency of use and length of operation. This helps industrial companies make informed decisions about asset management in all areas of the business • Employees can quickly search for inventory by type or site, find asset locations on a map, immediately view asset details and maintenance status, setup alerts based on maintenance reports and geographic boundaries and simplify allocation with pick lists • Available in both rechargeable plug-in and long-life battery models, the TennaGO is flexible, durable, easy to install and long-lasting for reliable equipment tracking and management • Device includes multiple sensors to effectively and accurately detect and relay the asset data that managers want to see. This helps companies reduce costs, save valuable time and generate meaningful data to improve their equipment management and operations processes • Tenna’s Asset Tracking Software and integrated hardware can track, process, automate and inform customers on how to manage everything from small tools and heavy equipment to temporary materials and client stock systems together into one platform www.ForConstructionPros.com/ 21046321

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ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES |

BY GREG UDELHOFEN, CONTRIBUTING EDITOR

INNOVATION

Improves Asphalt Plant Operations New technology helps plant owners inspect their silos in a matter of hours, not days, saving thousands of dollars and keeping crews away from harm

F

or an asphalt producer, the tedious process of erecting scaffolding inside an asphalt storage silo to manually inspect it for damage can interrupt production for three days to complete the dangerous task of checking for holes and other wear-related problems.

Chuck Simpson, lead product development engineer for Astec, has been on a four-year quest to develop a safe and efficient way to inspect the inside of an asphalt storage silo. The determination and hard work Simpson and other Astec associates put into that effort has come to fruition with final field testing completed this summer.

32

The Silobot, featuring magnetic wheels that allow it to travel vertically up and down the interior wall of a storage silo to record a video inspection, as well as an ultrasound measurement of wall thickness, was an idea the late Don Brock wanted to pursue to safely provide an inspection service to plant owners. “Inspecting the inside of asphalt silos has always presented safety concerns for technicians who had to take a day to set up scaffolding, a day to manually

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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s

The Astec Silobot team, from left: Kris Robertson, Ben Shell, Chuck Simpson, Charlie Phillips and Alex Harrison. Not pictured are Albert Covington and Naaga Kodiboyana.

conduct the inspection, and a day to take down the scaffolding,” explains Simpson. "It’s a harsh, hot environment with asphalt buildup and oil covering the surface a technician is trying to evaluate. So, we really had to start from scratch in designing and manufacturing a hands-free robotic device that could perform in that type of environment.

There was no off-the-shelf product we could use to build what we needed.”

But after several years of testing and modifying the device that was needed, Simpson and his associates were confident they had a proven technology ready to demonstrate at CONEXPO 2017.

“We took a prototype to that show, demonstrated and gathered input from plant operators for further enhancements,” Simpson notes. “With some modifications, we were ready to take our Silobot out into the field and actually test it on inspections to make sure it delivered everything customers wanted. With a high definition (video) camera and the ultrasound capability to measure wall thickness, we’re able to quickly inspect and assess the condition of a silo’s interior without ever having to place the operator inside that dangerous environment.”

As Simpson points out, asphalt is a very abrasive material that can cause a lot of wear and tear to silo’s spool sections, seam welds and ceramic liner of the loadout cone.

Using goggles that control the Silobot’s position and camera direction simply by the operator moving his head in the direction he wants to inspect, a complete inspection of one silo can be completed in a matter of hours, not days, saving plant owners thousands of dollars.

TECHNICIAN’S PERSPECTIVE “I’ve completed seven silo inspections (earlier this year) and the efficiency has been an important benefit for plant operators who want to maintain production levels during peak construction,” explains Alex Harrison, Astec technician who was hired to perform inspections with the Silobot technology. "It’s amazing the details we can record with the cameras onboard.

When you visually see a clump of asphalt in a certain area of the silo, you conduct additional testing (ultrasound) to see if there’s a hole in the silo that should be repaired.”

For Simpson and Harrison, additional inspection applications inside other equipment is likely as more inspections at asphalt plants are conducted and more data is collected.

“I don’t see technology limited to just asphalt storage silos,” Simpson says. “I think it can be easily adapted to inspect the interiors of other material production-type plants.”

For more information on the Silobot, visit ForConstructionPros. com/12315408

Silobot At a Glance Astec Silobot inspection service uses an innovative, wireless, remote-controlled robot that analyzes, evaluates and inspects asphalt silos for imperfections.

• With a fully immersive first-person view, there is no need for an individual to be inside the silo.

• An experienced Astec technician utilizes the patent-pending Astec Silobot inspection device to inspect the silo interior.

• The technician examines and photographs the silo interior using the device’s headtracking HD camera.

• Any areas for concern are marked and a report is generated.

• The report includes a graph of the silo that maps the areas of concern.

• Video footage of the inspection is provided along with the report.

• Using the Silobot, a technician measures silo wall thickness, performs a visual inspection of the cone, checks for build-up in weld seams and checks for holes.

Silobot’s magnetic wheels and remote control capability allow for safe and easy work of inspecting the inside of asphalt storage silos.

Alex Harrison, Astec technician, has been working with the Silobot technology.

www.ForConstructionPros.com/Asphalt

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MARCH/APRIL 2019 ASPHALT CONTRACTOR

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PRODUCTION NOTES

Reduce Plant Energy Output by Covering

AGGREGATE PILES

Wet aggregates increase asphalt plant fuel costs and create extra time and labor in order to stay on track with deadlines

34

I

t’s a Monday morning, you’re headed to your construction aggregate plant after a weekend full of rain. That following Friday, all your stockpiles were covered in preparation for a wet Saturday and Sunday, but your nerves are still high.

Negative scenarios are playing through your head, such as, what if the covers got

blown-off resulting in the piles getting soaked?

You know the answer, but you don’t like what the outcome will be. It will increase your fuel costs and create extra time and labor in order to stay on track with your deadlines. However, there is a way to ease the mind of business owners.

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES to the outside weather, allowing them to withstand high winds, heavy rain and snow loads. A bonus is that during daylight hours, the covers let in natural light cutting artificial lighting costs.

Keeping your aggregate piles sheltered in a fabric structure not only eliminates the possibility of the piles getting wet, but it also allows for peak plant productiveness.

ESCAPING THE PROBLEMS OF WET PILES Asphalt mixes are based on dry aggregate, so whenever there is moisture in the aggregate the mix must be adjusted to account for the moisture in the aggregate. Therefore, moisture management in aggregate piles is significant. Thankfully, fabric structures offer natural benefits to eliminate the possibility of coming in on Monday after a rainy weekend to soggy and contaminated piles.

Superior ventilation is a major benefit of fabric structures and helps maintain low moisture levels. A little bit of moisture is common in aggregate piles and is helpful to prevent materials from blowing around while being stored. Healthy ventilation prevents the chance for high humidity levels, and an increase in moisture buildup. For the best air-circulation, owners can place the structure in the direction of the prevailing winds at their location. They also have the choice of an open or fully enclosed design. Some companies offer ridge vents and fans to provide adequate airflow if more is needed.

Contamination is a big problem that owners run into when piles are exposed to inclement weather. High winds and

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heavy rain naturally blow around contaminates, such as leaves, causing them to mix with the piles. Cross-contamination also happens frequently from bad weather moving oversized aggregate into finer aggregate piles or vice versa.

This can be avoided with these structures, because of their open-floor design. Owners can arrange the floor layout and use dividers to make sure there is appropriate distance between each pile of aggregate. Owners often opt for a one-sided design structure, so machinery can easily access each pile individually, since the structure can easily be divided into separate bays.

Choosing the correct foundation is also significant to moisture management.

A popular option for aggregate storage is traditional poured concrete, because it doesn’t absorb moisture like the natural ground and eliminates the need for storage bins. Although this is a top foundation option an owner isn’t forced into this specific foundation; other foundation options are available, such as helical anchors, piers, shipping containers, among many others.

Lastly, business owners should look for a fabric structure that is covered with a durable fabric cover. The covers can be moisture-resistant and climate controlled.

This cuts down on moisture buildup and creates a comfortable climate inside the structure in any climate. The best covers feature a weave design that helps resist tearing and exposing the piles

ENJOY A MORE PRODUCTIVE WORKDAY When workers come into wet piles, instead of getting right to work on deliveries, workers must spend time going through the piles to see which have the least amount of moisture and can be used immediately. This causes a slower process because more moisture in the piles means more time needed during the drying process, forcing a stall in operations.

Having dry aggregate to work with every day increases production levels and is less of a financial burden. It leads to less fuel needed during the drying process and shortens the time needed for proper aggregate production. The drier the aggregate is, the smoother the overall drying process will go.

Moisture management is a major issue, but reducing aggregate moisture by one percent before drying can reduce energy use upwards of 11 percent and can increase plant production up to 11 percent.

On top of coming into dry piles, workers also get to enjoy the open interior of the fabric structure. Internal support posts aren’t in the design of many fabric structures, allowing workers to have all the room they need to maneuver machinery and equipment with ease for maximum work efficiency.

Storing aggregate piles in a fabric structure provides a healthy environment and helps owners maintain the moisture in their aggregate. This leads to a more productive operation, simultaneously creating a better-quality aggregate.

Dean St. Laurent is a content writer for ClearSpan, which specializes in fabric structures.

For more information on the importance of protecting your aggregate piles, visit ForConstructionPros. com/20996322

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES |

BY CLIFF MANSFIELD

Preventing Asphalt Plant

accidents

A properly jacketed Micro Motion System

Cliff consults on a tragic accident, warning that diesel and heat don’t tend to mix well

I 38

t had been a long day, in a month of long days. The portable drum mix plant had produced nearly 5,000 tons

of asphalt since daylight. The operator had shut the plant down and loaded out what he hoped was the last truck of the day ten minutes earlier. He sat at his desk, head down on his forearms, nearly exhausted.

The radio crackled to life. “21 to plant, we’ve got enough mix, go ahead and clean out. Same schedule for tomorrow.”

Cliff ’s Notes

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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ENGINEERING

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When you call, we answer.

Your call links you to the world’s largest inventory of in-stock parts for asphalt plants. links VISIT It US AT you to a seasoned team of experts, ready to help. It links you to world-renowned service, ready to deliver. It links you to Astec.

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PRODUCTION NOTES kozmoat98/ E+/Getty Images

“As a result of this accident, the career of the injured groundman was over and the asphalt plant was out of action for many months.”

The plant operator keyed the mike.

“Ok, thanks.” He keyed his walkietalkie and said to his ground man, “Switch the dieseling valves on the asphalt pump and then diesel out the silo.” As he spoke, the operator switched off the asphalt pump. As a warning, what happened next is not for the faint of heart.

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The ground man went to the asphalt tank and saw that the pump was stopped. He closed the suction line from the pump to the tank and opened another valve which led to a 55 gallon drum full of diesel. With this done, the ground man climbed the ladder to the silo top and grabbed the dieseling hose installed to allow him to clean the asphalt out of the corners of the silo. He heard the drag conveyor and drum start up as he directed the diesel spray into the corners of the silo.

Inside the control room the plant operator reached down and turned on the ‘inject’ valve to send the diesel to the drum, then started his asphalt pump. Immediately he saw a small puff of white smoke at the drum discharge.

It dissipated quickly, but was soon followed by a massive explosion. The blast traveled out the drum discharge, up the drag conveyor and down into the silo where the ground man was spraying the silo with his dieseling hose. He was

engulfed in a huge fireball, igniting the diesel in the silo and covering him in flames. He surged back to escape the flames and all but fell down the ladder to the ground. He screamed in agony as the flames seared his skin.

A water truck happened to be making rounds when the driver saw the explosion. Thinking fast, he raced to the plant with his truck and directed a stream of water onto the victim writhing on the ground. The flames subsided and as the water cooled his skin the groundman’s cries diminished.

It was a difficult 15 minutes for the groundman while he waited for the ambulance to arrive. At the hospital, the extent of his injuries was realized.

He had been severely burned over a large portion of his body. Those burns ended the man’s career; he would be on disability the rest of his life.

The damage to the asphalt plant was also severe. The baghouse was completely destroyed. Down each

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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www.ForConstructionPros.com/21048539

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AND YOU KNOW WE DO THIS...

You know Astec for durable, reliable equipment with proven performance. A pioneering team with decades of experience and a culture committed to putting the customer first has culminated in a range of options including drum styles, baghouse styles, and silo styles which allow you to configure the precise plant for your needs. Only Astec offers a complete line of portable, relocatable and stationary asphalt plants from 80tph to 600tph. Astec manufactures both Astec and Dillman brand equipment.

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PRODUCTION NOTES side of this unit, a 14-in. x 3/8-in. thick beam ran the full length. The explosion blasted these cross-welded beams THREE FEET out of straight.

The lids on top of the baghouse landed nearly a mile away. The flames burned away most of the wiring to the asphalt tank, drum and silo. As a result of this accident, this asphalt plant was out of action for many months.

WHAT WENT WRONG After this tragic event occurred, I was called in by an attorney for the plant owner’s insurance company as part of an accident investigation team. My job was to try and shed some light on what went wrong. Was there a design flaw in the asphalt plant which caused the explosion or did the plant personnel’s actions cause the accident?

“The first thing that jumped out in the accident report was the fact that the plant personnel used diesel in their clean-out routine.

Diesel is a very volatile fuel with a flash point around 165° F.” The first thing that jumped out at me when I read the accident report was the fact that the plant’s personnel were using diesel in their clean-out routine.

Diesel is a very volatile fuel with a flash point around 165° F. Why would you inject it into a 300° F environment such as the mixing chamber of a portable asphalt plant?

To answer this question, we need to understand how the asphalt injection system works on the contemporary asphalt plant. Liquid asphalt is held in a storage tank where it is maintained at an elevated temperature, somewhere around 300° F. If the liquid falls below 270° F, depending on the asphalt, it becomes too viscous/thick to pump.

When this happens, nothing short of

44

heat will lower the viscosity enough to pump.

When we want to make hot-mix, we heat our rocks to the desired temperature, then we use a pump to inject the liquid asphalt into the mixing chamber. This process requires a pump and a series of pipes in which the temperature of the asphalt must be maintained above the 275° F threshold we talked about earlier. To do this, manufacturers ‘jacket’ all the oil lines and the pump, then force a heated liquid, heat transfer oil, through the system. At the end of the mixing session, most plant operators simply reverse the direction of the pump rotation which sucks the asphalt out of the lines and the pump.

With this in mind, the question becomes why were these men injecting diesel rather than simply sucking out the oil by reversing the pump?

To answer this question, I began by examining the asphalt injection system.

The first thing I noticed was where the plant personnel had added a 55 gallon drum onto the pump pallet and plumbed it into the suction side of the pump. This was the device the men used to add diesel to the pump and introduce it into the injection system.

The next thing that I saw was that the factory asphalt metering system had been replaced with a ‘mass flow’ metering system. I also noticed that the new metering unit and the pipes added during its installation had not been jacketed. I talked with the plant operator and was told that the installation of the ‘mass flow’ system was a hurried affair, the men concentrating on getting the plant running again as quickly as possible.

Once the installation was complete, the plant’s personnel discovered that the new metering system had enough internal restriction that the pump could no longer be simply reversed to clean it out.

This plant was the first drum mix plant owned by this particular company. All of their previous plants had been batch plants. It was a common practice to use diesel to clean

out batch plants, so it is not hard to see why the plant personnel would revert to diesel when normal clean out protocols failed.

The causal factors of this accident were now evident. Sometime in the past the asphalt plant had been modified from its factory configuration. During these modifications, a simple oversight led to the necessity to use diesel to clean the asphalt out of the system. This set the stage for the coming tragedy.

LESSONS LEARNED The first and foremost lesson that this incident teaches us is that there is no circumstance that diesel should be pumped through a heated asphalt injection system and into the heated, enclosed environment of a drum mix asphalt plant. It’s not hard to imagine the diesel heating up as it travels through the sections of pipe that were jacketed. As it passed its flash point of 165° F the only thing it needs is room to expand and oxygen to turn it into a vaporous cloud of explosive gas. It got the room it needed as it was injected into the heated atmosphere of the mixing chamber.

The only thing missing was a source of ignition. Perhaps it was a rock caught between a mixing paddle and the floor, or maybe a piece of metal rubbing against another piece of metal.

Whatever the source, the diesel ignited catastrophically and peoples’ lives were irreversibly altered.

Are your men using diesel at your asphalt plant? Time to reconsider.

Cliff Mansfield operates C.M. Consulting, an asphalt repairing, upgrading and operational training company. He has 40 years of experience in the industry.

Visit hotplantconsulting.com for more information.

For more information on asphalt plant safety, visit ForConstructionPros. com/20987267

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES

E.T. Clancy Asphalt Plants E.T. Clancy Co. has specialized in selling asphalt plants and equipment for 40 years.

• Complete inventory of drum plants, batch plants and components • Assist in plant dismantling and set up, as well as trucking www.ForConstructionPros.com/ 10086122

Heatec Barracuda Colloid Mill Heatec emulsion mill skid includes an asphalt meter system, a latex pump, a control panel, and the new Barracuda colloid mill.

• Skid is designed to produce 60 tph of emulsified asphalt • The Barracuda mill allows adjustments to be made while the mill is running www.ForConstructionPros.com/ 11322471

ADM Fuel Meter ADM’s digitized fuel meter linked to the control house provides an easier and safer way to measure fuel consumption than having a worker stand on top of the tank and use a stick and tape measure to read fuel levels • Accurate to a fraction of a gallon, it’s also more reliable and easier to read than a sight gauge • The benefit of being aware of an operation’s exact fuel consumption is quickly realizing whether the plant is consuming too much or too little fuel • Changes in fuel consumption can help determine if there is a problem at hand, such as needed burner maintenance, greater than normal aggregate moisture content and high pollution www.ForConstructionPros.com/ 21026260

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Stansteel Greenline Products Stansteel offers a comprehensive array of Greenline products.

• More fuel efficient hot oil heating systems • Dryers and drum mixers that make low energy asphalt • Can retrofit existing plants to increase recycle percentage that can incorporate shingles and run multiple types of warm mix, foamed chemical or other exotic additives www.ForConstructionPros.com/ 10146938

Stedman Grand Slam Horizontal Shaft Impactor (HSI) The Grand Slam Horizontal Shaft Impactor (HSI) from Stedman uses high-chrome metallurgy to increase the wear life of machine components. The 48 x 60 Grand Slam can process recycled asphalt pavement (RAP) at 300 tons per hour at standard settings.

• Capable of high size reduction ratios up to 30 to 1 • All types of material sizes and hardnesses can be crushed producing a cubical particle shape • Series consists of 11 high-production models with capacities ranging from 1,200 to 1,600 tph • Design incorporates both primary and secondary aprons for maximum product control • Two-stage crushing action • Full-length rotor shaft with two, double-row spherical-type bearing assemblies • Rotor features either a 2-, 3- or 4-row breaker bar design, depending on machine model size • Wedge locking design secures the breaker bars in place and simplifies breaker bar servicing www.ForConstructionPros.com/ 10283986

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PRODUCTION NOTES CMI E3 RAP-STAR Series Drum Mixer The E3 line of continuous counter-flow drum mixers marks the newest technology in drum design, combining high productivity and high RAP percentage capabilities with simplicity and reliability.

• Available as portable drums in capacities from 200 to 500 tph and as relocatable and stationary drums in capacities from 200 to 600 tph • Continuous full-length main shell is surrounded by an outer RAP drum that fully heats RAP before mixing it with virgin aggregate and AC • Capable of handling high percentage RAP mixes • Available with trunnion drive or chain drive • Abrasion resistant materials throughout to increase working life www.ForConstructionPros.com/ 12320479

ADM EX 8844 Asphalt Plant The Asphalt Drum Mixers EX Series Model EX 8844 asphalt plant allows contractors to increase capacity with up to 50% RAP in a compact package.

• Counterflow technology allows for maximum heat transfer and fuel efficiency via separate drying and mixing zones • Clean operation for virtual elimination of blue smoke and hydrocarbon emissions and efficient design for single-operator capability, easy troubleshooting and simple on-site maintenance www.ForConstructionPros.com/ 21039896

Astec Phoenix Talon II Burner The Astec Phoenix Talon II utilizes the latest burner technology to deliver very low emissions combined with energy efficiency.

• Precisely and completely mixes the air and gaseous fuel to achieve an advanced low NOx and CO method called lean burn premix • Variable speed main combustion blower drive helps provide precise firing rate control and uses significantly less electrical energy and eliminates the need for an air damper and for drive motor adjustments and maintenance • Optional silencing package www.ForConstructionPros.com/ 12231117

Bed-down material delivery is a safer way to pave!

Built by a Paving Contractor for Paving Contractors The Pegasus exclusive patented extruded aluminum interlocking components create a fully unitized structure that is strong, light, and durable. The all-aluminum body allows for increased payload, and the ultra wide belt gives a low center of gravity and fast-controlled discharge of material.

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Meeker Transfer Conveyor

Troxler Moisture Measurement System

The Meeker 500-TPH transfer conveyor features bolt in Ni-Hard cast floor liners, removable flop gate system, electric heat on floor, Rex planetary gearbox, bin indicator on headshaft and split return rollers.

The Troxler online Moisture Measurement System (MMS) measures the moisture content of the aggregate component of a concrete or asphalt mix.

• The moisture measurement occurs as the mix is moving through the plant on the conveyor belt • The moisture system is mounted on the conveyor closest to the area where moisture determination is most critical • The moisture content, combined with the knowledge of the mass proportions of the other components in the mix can be used to give a precise and reliable moisture content of the aggregate

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Command Alkon APEX Asphalt Software APEX Asphalt software enables trucks to check-in, load and ticket without interruption as well as controlling all of your asphalt batch operations with ease. Combined with a full range of tools for quoting, billing, reporting, performance analysis and transportation management, Apex Asphalt delivers a comprehensive solution for the asphalt supply chain.

• Asphalt Batching: A single screen operator interface ensures simplified yet powerful control of your batching process that is fully integrated with the downstream processes for loadout, ticketing, logistics and back office operations • Asphalt Loadout & Ticketing: Fast, accurate truck or rail car loadout is combined with advanced ticketing software that allows for unattended loadout and ticketing

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JOBSITE INNOVATIONS |

BY CURT BENNINK, CONTRIBUTING EDITOR

Ergonomic Advances Position Paving Equipment Operators for

SUCCESS

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ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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Safety, productivity and ease of use have been enhanced through ergonomic advancements in asphalt paver design.

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Speed limiters, grade and slope control, auto vibration and material-flow sensors on the screed are all perfect examples of technologies on Volvo asphalt pavers that help automate tasks that could cause mat quality problems, and really help to make paver functions more efficient for the operator.

www.ForConstructionPros.com/Asphalt

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implified controls, operator stations that can be configured for the job and comfort enhancements help paver operators concentrate on producing a quality product. To get the inside scoop, we asked several leaders in the asphalt paving industry to address advancements made in the operating stations and controls of their latest pavers.

What are the most significant advancements made in the operating environment/operator stations of your company’s asphalt pavers and what are the potential benefits in terms of operator comfort and performance?

Jon Anderson, global sales consultant, Caterpillar: A lot of thought has gone into design enhancements that affect the operator and crew.

The fume extraction system improves the work environment for the crew dramatically by removing a large portion of the asphalt fumes that accumulate in the auger chamber and in front of the screed and discharging them up the stack with the engine exhaust.

The cooling system is designed to draw air in from both sides of the paver and discharge it out the front, away from the operator and crew. This cools down the operator environment on the paver, eliminates the hot air discharged out the side of the paver, and creates a barrier to fumes. In addition, it also directs the noise of the fan away from the crew.

For cooler days, optional air-ride heated seats are available on the tractor.

Operators enjoy the benefits of faster heat-up and more daily production from the exclusive Cat generator design, as well as experience less ambient noise around the machine, helping them focus on the work and improving verbal communications around the machine.

Grade Control systems that share information with multiple operators

(screed to screed, tractor) ensure everyone has information to do their jobs.

The operator station is designed to position the operator so that he has a clear line of sight outside of the hopper without having to lean to the outside, eliminating strain. It also allows the operator to only turn his head about 45° in each direction between looking forward and looking at the auger chamber.

ECO-mode, while reducing fuel consumption, also reduces the environmental noise, allowing operators to talk to each other in a normal speaking voice.

Kyle Neisen, product manager Pavers and MTVs, Roadtec: Our rubber track pavers use an electronic joystick, which promotes operator comfort and ergonomics. Operators can use the joystick with their hands resting at their sides. The joystick does a very good job of holding a straight line. Operators can have confidence in letting go of the joystick when traveling straight and using their right hand for other machine controls.

Additionally, Roadtec operator platforms use hydraulic swing-out stations, which improve the operator’s sightline. Seats of the dual operator stations move out beyond the sides of the machine, providing increased visibility.

Infinitely variable movement allows the operator to be in the best position while paving, but also allows the operator to move when approaching obstacles. Also, operators sit higher than they do on other pavers, which allows them to see more of their surroundings, improving efficiency, productivity and safety.

The machine’s controls and display screen are conveniently arranged and move with the seat to allow for safe and convenient operation.

In addition to the increased visibility, operator efficiency and productivity are increased through an airflow system that creates a barrier near the back wall of the hopper. This air curtain pushes fumes and heat up and away from the operator platform, enabling the operator to be more productive.

Bill Laing, paving product manager, Volvo Construction Equipment: Safety, productivity and ease of use are some of

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JOBSITE INNOVATIONS On Caterpillar paving machines, the fume extraction system improves the work environment for the crew dramatically by removing a large portion of the asphalt fumes that accumulate in the auger chamber and in front of the screed and discharging them up the stack with the engine exhaust.

the benefits of the operator environment design in the latest generation of our pavers. For instance, a low-profile deck on our B-series asphalt paver — including the P4410B, P7110B and P7170B — provides the operator with 360° visibility and an unobstructed view into the hopper and auger tunnel.

Operators can run the machine from either side of the paver thanks to the swing console with grouped controls.

Plus, when the operator does need to move throughout the machine, the pavers feature wide non-slip walkways, plentiful handrails, a flat deck surface and a glare-resistant hood.

Matt Graves, director of marketing, Wirtgen America: Giving operators luxury heated seats and a glass windbreaker as a standard in North America was necessary. If you ever had to operate a machine at 2 a.m. with a tight deadline then you know.

How could we forget the screed operator on that same 2 a.m. shift who needs to move around the screed and maintain that consistent pile height? We have installed high-power LEDs in the bottom of the screed consoles for better visibility on the walkway. Visibility in the auger box could always be better, and that is why we put the same LEDs on the auger sensor, allowing the screed operator to see the material height in that auger box.

Travis Colwell, marketing and communications coordinator, Carlson Paving Products: The largest advancement

Wirtgen provides operators luxury heated seats and a glass windbreaker as standard in North America.

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ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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JOBSITE INNOVATIONS when it comes to controls and the operator environment is that a lot of machines are going to a full CANbus system. This allows the pavers to incorporate a lot more technology into the machine along with the emergence of touchscreen displays. The result of this is a separation from manual operation for things like screed heating and material control. This means contractors have more information and more ability to adjust the platform.

In moving away from manual functions like toggle controls, the operator station is becoming smaller allowing for better visibility, better ergonomics and creating more control at the fingertips of the operator rather than having a full bank of controls in front of them.

Specifically, how are changes in the control systems of today’s pavers helping to promote enhanced operating efficiency and productivity?

Anderson: One example is 3D grade control systems, which can take a lot of the responsibility for adjustment away from the operators, allowing them to focus on tasks that ensure continuous paving. This can maximize quality in terms of things you can see, such as matching the virtual design, as well as things you can’t see like optimizing smoothness by minimizing paver stops.

We also have ECO mode, which enhances operating efficiency by getting the engine closer to peak torque. Often, operators think ECO mode reduces productivity to save fuel, but the reality is we are just getting the engine speed to where it makes power more efficiently.

Some ECO modes can reduce productivity, but with our oversized feeder pumps and auxiliary system pump, we believe we have the ability to work in ECO mode close to 95% of the time.

Neisen: Operators have an abundance of data at their fingertips, thanks to Guardian Telematics. Roadtec’s Guardian Telematics is the only telematics system that allows live twoway wireless communication. This data enables troubleshooting and diagnostics in real time, increasing efficiency and productivity exponentially. Operators and those at the office or other locations

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Speed limiters, grade and slope control, auto vibration and material flow sensors on the screed are all perfect examples of technologies on Volvo asphalt pavers that help automate tasks that could cause mat quality problems, and really help to make paver functions more efficient for the operator.

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JOBSITE INNOVATIONS

In moving away from manual functions like toggle controls, the operator station on machines like the new Carlson CP 65 is becoming smaller, allowing for better visibility, better ergonomics and creating more control at the fingertips of the operator rather than having a full bank of controls in front of them.

share the same data at the same time.

Modifications are made in real time to prevent machine issues and maintain productivity, reduce in-person service calls and downtime and lower overtime and labor costs.

Laing: Seemingly small mistakes by the operator can have an enormous impact on mat quality. That’s why so many of the new features help automate paver functions. Speed limiters, grade and slope control, auto vibration and material flow sensors on the screed are all perfect examples of technologies on Volvo asphalt pavers that help automate tasks that could cause mat quality problems, and really help to make paver functions more efficient for the operator.

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Another area used to increase efficiency, uptime and productivity is telematics. Traditional telematics systems such as CareTrack can let contractors see where their machine is, how much fuel it’s consuming, and get basic fault codes to help diagnose issues before they result in downtime.

One major differentiator... is ActiveCare Direct, a 24/7/365 machine monitoring and reporting service managed directly by Volvo. Right now, ActiveCare Direct is available on other earthmoving equipment, but it will be available on select pavers by the second quarter of 2019. This service allows dealers to shorten the reaction time if there is a problem with the machine. If a fault code comes through, Volvo does the legwork of providing the probable cause and recommended solution, so that the dealer and customer will know about it in near real time and can take action.

Graves: We have added operating range LEDs on all of our sensors, making it faster to set up and reducing the

potential for errors. When setting up the sensor over the reference, it is as simple as moving it up or down until you have two LEDs letting you know you are in the correct operation range; there is no need for a tape measure or a yardstick.

When adjusting the material height, you can now control it from the sensor hand remote and the screed console.

No longer will you need to look for the screen in the display because when you make the adjustment, it automatically pulls that auger page up in the display.

Lastly, with our two-speed smart wheel, the screed operator has the choice of slow for matching a joint or fast for catching a driveway.

Colwell: Advancements in control systems allow contractors the ability to tailor the machine to the specific operator’s preference whereas before it was more of a one size fits all approach.

The new systems allow controls right down to steering sensitivity to be dialed in to whatever is most comfortable for that operator.

This is only going to enhance their performance and efficiency on the jobsite, boosting general morale.

How have the advancements improved the overall operating experience with these machines? How might they help in attracting, training and retaining paver operators?

Anderson: Our systems can enhance the performance of both experienced and inexperienced personnel by making day to day operation easier and more consistent. Cat pavers are designed to simplify a complex process by providing controls and interfaces that are easy to learn, use and understand. This reduces the need for human interpretation and enhances performance by automating some processes. The result is smoother, more accurate and more consistent pavements.

The control interface has great appeal to future hires that find comfort in video screens. The modern controls make it easier to onboard inexperienced operators when you compare a modern paver and screed control system to a few generations previous, with manual levers and screws. Operators who feel

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JOBSITE INNOVATIONS

Modern controls make it easier to onboard inexperienced operators . Even very experienced operators have quickly learned to use new systems and have found the additional features and information beneficial in day to day operation.

safe and comfortable with the tools they use are typically easier to retain. Even very experienced operators have quickly learned to use the system and have found the additional features and information beneficial in day to day operation.

Neisen: Advancements in operator stations help equipment operators feel comfortable and safe, which leads to increased confidence. Confident operators are able to focus on the work, and create a better result. When employers and manufacturers make investments that contribute to operator stations that are ergonomic, easy to use and safe, they demonstrate a commitment to their employees.

Laing: Advancements in the Volvo asphalt pavers have improved the operating experience by making the equipment easier to use, safer and more productive, while still focusing on the operator’s comfort. Valuing the operator

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and giving them a comfortable, safe working environment increases the likelihood contractors will retain their experienced operators.

Making these machines more accurate and easier [to operate] with technology features like material flow sensors, auto vibration and grade and slope control expands the potential labor pool and shortens the training cycle for less experienced operators.

At the same time, these machines are automating certain parts of the job, which also makes the lives of experienced operators easier and could lead to improved retention.

Graves: We have simplified operation for operators who have been paving for years, making their life more conformable. In addition, we created a control system that the younger generation has access to from birth — push buttons and joysticks.

Colwell: Finding controls that achieve a balance between the old and familiar and the new and improved will help keep existing crew members happy along with attracting the younger generation and a lot of manufacturers are doing that well.

You have controls that are very easily accessible to those operators that are a little older or not as proficient in technology and they don’t feel shunned from the technology, they still feel comfortable with it and the technology is approachable. And then you have younger operators who will be attracted to these newer platforms because they know they can do more with it and will be able to get the most out of that technology and that will pay dividends in productivity on the jobsite.

With the upgraded systems, you are bringing more of the highway class style controls down to the commercial class. If you are running a bigger group of pavers with large and small machines, these upgrades are going to improve efficiencies for operators because controls are becoming more in line with each other so operators are familiar with upgraded controls across all systems.

For more information on asphalt pavers, visit ForConstructionPros. com/21026879

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JOBSITE INNOVATIONS Dynapac FC1600C Paver

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• Operator’s platform offers a spacious working area with optimal all-around views of the roller drums, asphalt mat and surrounding areas • Adjustable, multi-position seat rotates and slides laterally to both side positions • 73.2-hp Kubota water-cooled, Tier 4-compliant diesel engines, www.ForConstructionPros. com/11176441

The 4,500-lb. FC1600C highway class paver includes extreme-grade poly pad tracks, rebuildable wearresistant conveyor floor plates and segmented highwear augers.

• 99-hp Cummins diesel engine with double pump drive system • Offers a hydraulic tow point, power crown and power match height.

• Feed system uses a 24-in.-wide wear-resistant dual slat conveyor and a 9-in.-diameter segmented high-wear auger • Equipped with a VF0816C screed with a 16-kW generator for high-precision electric heat • Ultrasonic sensors automatically control auger and conveyor speeds www.ForConstructionPros.com/12314994

GSSI PaveScan RDM Asphalt Density Assessment Tool The PaveScan RDM asphalt density assessment tool is an easy and affordable tool to nondestructively determine asphalt density during application.

• Offering real-time critical data for new pavement QA/QC, it uncovers poor uniformity and density variations that can lead to premature failures such as raveling, cracking and deterioration along joints • Seamlessly integrates with GPS systems www.ForConstructionPros.com/12273430

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Rosco Max 3 Asphalt Distributor With a larger fully circulating extending spray bar, the Rosco Maximizer 3B Distributor is a highly versatile piece of equipment designed with the end user in mind and has the ability to cover a wide area in an extremely efficient manner.

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Caterpillar F-Series Pavers The AP500F and AP600F have wheeled undercarriages while the AP555F, AP655F and AP1055F come with the Mobil-Trac undercarriage.

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JOBSITE INNOVATIONS Wacker Neuson Restyled RD12 Series Rollers Live Bottom Trailers

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E RECYCLING Fills the d on Rural Florida Road A combination of Wirtgen machines was used to widen and in-place recycle a failing road in Seminole Count, FL

I

n February 2018, a failing rural road in a rapidly growing area of Seminole County, FL, just north of Orlando, was widened using in-place recycled and asphalt emulsion stabilized materials.

The project was executed swiftly and with minimal impact to traffic, saving taxpayers both time and money.

Asphalt Paving Systems, Inc. (APS) began by widening and recycling the 10-ft. southbound lane of Lake Markham Road to 12 ft. The 12-ft. northbound lane was in-place recycled days earlier.

"We're taking a 20-ft. roadway and widening it out 2 ft. in each lane to produce a 24-ft. finished roadway," Tommy Donald, regional manager for APS based in Zephyrhills, FL says.

“They first used a a smaller Wirtgen W 1000 cold mill to make the 2-ft. widening cut, boxing it out. Now, we are following with our recycling train on the main lanes, recycling down 8 in.”

DOWN VS. UP CUT A distributor truck placed cement on the disintegrating pavement at 22 lbs. per sq. yd. "That's about 2.5% by weight of the existing material," Donald says.

This was followed Wirtgen 3200 CR cold recycler with a 10.5-ft. cutter drum offering a working width of 10 ft. 6 in.

"Because we are widening a 20-ft. roadway, the 10.5-ft. width is optimum

www.ForConstructionPros.com/Asphalt

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for this particular scenario," Donald adds.

In addition to the conventional up-cut method, the 3200 CR (as well as the larger 3800 CR) can perform what is known as down-cut milling, a recent development by Wirtgen designed to optimize the cold recycling process. The down-cut process allows the particle size to be precisely controlled during material processing, especially when milling very old and brittle asphalt roads. This enabled the recycled material to be rear loaded directly onto the paver.

FILLING THE VOID "We're running 2.25 gal. per sq. yd. of cationic slow-set [CSS-1h] asphalt emulsion, with about 65% residual asphalt content,” David pointed out.

Water in the emulsion (35%) serves to hydrate the cement, resulting in a Marshall Stability value of 3500 for the stabilized product.

The 3200 CR fed the asphalt emulsion-stabilized recycled asphalt pavement directly to a Vögele Super 2100-3i paver, where it was used to fill the full 12-ft. width in one pass southbound.

"Because we're dropping the surface an inch and a half, we're able to generate enough recycle material off the main lane to fill in the void where it was widened," Donald said. "The Wirtgen equipment gives us the ability to widen and recycle all at the same time."

The paver’s AB 600-3 TV tampingvibrating screed averaged 60% to 65% of target density coming right out of the screed.

"We have an older 2100 with pressure bar/tamper bar screed, and the compaction results we were getting

from it in the recycling train were really good," Donald says. "That heavy screed controls this kind of stiff material, especially in heavier lifts. Previously, we used a different paver and screed, and the material would push that screed around, controlling the screed so to speak. The Vögele screed gives us more control over the material."

Following the paver, a Hamm HD+ 120 VV HF tandem steel drum roller provided breakdown compaction in vibratory then static modes over six cycles. It was followed by a 22-ton GRW 180i pneumatic roller. "[The roller operators] continuously roll that until we achieve our density number of 96% to 98%," Donald says.

"The pavement then will receive 2 in. of hot mix asphalt surface course placed in two 1-in. lifts by us with the Super 2100-3i.”

TONS OF RESULTS Once completed, a total area of 42,240 sq. yds. and 19,008 short tons of material was recycled along the 3-mile stretch of road.

"The beauty of doing it this way with the in-line, in-place train is that you are boxing out your widening as a 2-ft. wide, 8-in. deep trench in front of the train, then filling it right back in with the recycled material," Donald says. "Doing it this way eliminates the longitudinal cold joint that you get with conventional widenings. It's eliminated as you have the same type material from shoulder to the crown."

For more information on in-place recycling, visit ForConstructionPros.com/20984416

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PRESERVATION UPDATE

Chicago Suburb Invests in Pavement Repair This Off-Season Village of Winnetka uses 6-ton hot box to move away from cold mix, keeping crews busy year-round to perform long-lasting repairs

W

innetka, IL is one of the most affluent communities in Illinois, and one of the wealthiest in the United States, with a median household income above $250,000. Residents have very high expectations for the quality of services in the historic village, which has been the setting for many Hollywood feature films, including Home Alone, Risky Business and Ferris Bueller’s Day Off. Illinois Governor Bruce Rauner and his family were residents of Winnetka prior to moving to the Governor’s mansion in 2015, keeping the Village – and its roads – in the public spotlight.

When Mike Mahoney, street supervisor for the Village of Winnetka,

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first began looking at asphalt repair equipment, he thought a 2-ton unit would fit the needs of 12,000 residents living the in Chicago suburb. But with more than 50 miles of roadway within the Village’s jurisdiction, and the nearest asphalt plant located 12 miles away, he determined they needed a second solution that could keep asphalt hot all day and reheat cookies for the occasional larger patching jobs.

“We looked at equipment for several years,” Mahoney says. “Volume was an issue, so having the 6-ton capacity was key. Being able to put it on a truck was huge, and the heat management system in the unit we purchased was superior to anything else we looked at.”

With traffic, a round trip to the asphalt plant can take up to three hours, so a large capacity was a determining factor in keeping crews productive all day. The village eventually chose the Falcon 6-ton Hot Box due to the unique grid design of the Falcon EvenTemp heat management system. The system uses a series of engineered baffles to heat the asphalt evenly throughout a massive 6-ton hopper.

“The Falcon unit provides a crisper patch with better appearance,” Matt Deutsch, vice president at Midwest Paving Equipment, the local dealer in Glen Ellyn, Il that supports Winnetka’s equipment needs says. "By keeping asphalt hot all day at a consistent temperature, the Falcon hot box makes it easier to work

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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The Public Works Department team using its Falcon hot box and recycler to make repairs outside New Trier High School in Winnetka, IL. Built to be slid into the bed of a truck, the Falcon unit is available in 2-, 3-, 4-, 5-, 6-, 8- or 10-ton capacities.

with the material, providing time for proper site and pavement preparation to achieve a superior repair."

VERSATILITY MATTERS The Village of Winnetka uses its hot box unit year-round, including daily use in the summer months when crews are primarily focused on street maintenance. Much of the focus is on repairing and maintaining Green Bay Road, a high-traffic thoroughfare that connects the wealthy North Shore communities of Chicago.

Winnetka is also unique in the process that it uses to fill potholes. A dump truck is used to apply the base and then the Falcon unit is used to provide a 1-1.5-in. finish coat for a stronger patch with a better appearance. “I love it for that,” Mahoney says.

Another of the key advantages of the hot box is the ability to load it on any of the three Village trucks via a hook

lift system. This provides the flexibility Winnetka’s Public Works Department needs for its team of eight maintenance workers. In addition to routine and preventative maintenance of the Village’s roadways, Public Works is also responsible for refuse collection, street sweeping, leaf collection, spring cleanup, snow and ice control and forestry services.

“Unfortunately, every truck has a different voltage output,” Steve Konstanty, central region sales Manager at Falcon Asphalt Repair Equipmen says. "As a result, Winnetka was one of the first Falcon customers to pilot the patent-pending Voltage Indicator and Protector (VIP) technology, which prevents the burner from operating below required voltage, protecting critical components from failure."

“This was a huge improvement over previous systems. We like everything Falcon has shown us so far,” Mahoney adds.

The company will continue to partner

with the municipality on new products and upgrades for its existing unit. With its 6-ton Falcon unit providing hot asphalt whenever and wherever needed, the Village of Winnetka is paving the way to smoother roads for years to come.

For more information on pothole patching, visit ForConstructionPros. com/11486037

Residents of Winnetka, have very high expectations for the quality of services in the historic village, which has been the setting for many Hollywood feature films, including Home Alone, Risky Business and Ferris Bueller’s Day Off. Photo Credit: craiguglinica/ iStock / Getty Images Plus

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PRESERVATION UPDATE Dynapac PL2000 Cold Planer The Dynapac PL2000 hydraulically powered, high-capacity cold planer features four-track steering, a front loading system and a mechanical belt-driven cutting drum.

• For removing both asphalt and concrete pavements • Working width of 79 in. and a 13-in. cutting depth • Operated by two joysticks (driving and conveyor belt functions) • Automated sequential processes for conveyor belts and water spraying system • 600-hp Cummins QSX 15 diesel engine • 977-gal. water tank www.ForConstructionPros.com/10078174

Neal Manufacturing Asphalt Road Preservation Package

Cimline P-5 Pothole Patcher Municipalities can now attack the pothole epidemic with one man behind the wheel of the new P-5 Pothole Patcher.

• In-cab operation is the safest most efficient way to repair potholes using the proven DuraPatcher sprayinjection method • Four easy steps remove the pothole by: 1. Cleaning with high-pressure air 2.

Applying a tack coat 3. Filling the patch with sufficient velocity to compact the emulsion-coated aggregate 4.

Applying a final coat. The result is a permanently repaired pothole that can be driven over immediately.

• The P-5 capitalizes on the effectiveness of the spray-injection method by applying state-of-the-art controls for in-cab operation • Single joystick has color-coded buttons corresponding to the four steps to pothole patching • Display informs driver of their sequence in the patching operation www.ForConstructionPros. com/12321744

The Asphalt Road Preservation Package was designed for optimal efficiency and highquality results on both detail and high-volume sealcoating applications.

• The package includes Neal Manufacturing’s drivable DA 350 dual applicator for quick prep work and sealcoating around curbs and gutters and its High-Volume Road Maintenance Vehicle that delivers high material output for efficiency on large projects • The DA 350 is a three-wheeled self-propelled sealcoating machine that features a built-in, high-powered blower and AutoTrim, an automatic cutting-in attachment. These features allow contractors to complete prep work along curb-and-gutter streets as much as seven times faster than manual www.ForConstructionPros.com/21010006

Wirtgen W 150 CFi Compact Milling Machine The Wirtgen W 150 CFi with new 1,800 mm milling drum can take on surfacecourse rehabilitation for medium to large job sites.

• Powered by the Cummins QSL9 diesel engine rated at 380 hp www.ForConstructionPros. com/21040111

Caterpillar K System Milling Drum After four years of research, Caterpillar Inc. has unveiled the K System standard milling drums with advanced features for surface removal or complete removal of road surfaces.

• Dual retention system feature with taper and cylinderical lock. No need for torqueing bolts • Highly featured tool holder with anti-rotating design to ensure proper holder positioning • System designed as left or right sided pieces to allow for optimized cutting effort and material flow delivering an excellent cutting pattern • Available in multiple space sizing with the same holder system www.ForConstructionPros.com/21047786

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Cargill Anova Asphalt Rejuvenators Anova rejuvenators have demonstrated desirable impact on asphalt pavements containing highly aged RAP and RAS binder (reclaimed asphalt pavement and shingles) in documented results in the laboratory and in the field.

• Successfully used in pavements with up to 100% RAP usage • In addition to shifting the PG grade of virgin bitumen, Anova modifiers also rejuvenate RAP and RAS restoring properties of the aged bitumen, allowing for more versatility in mix designs • Has been shown to reduce required compaction temperature by as much as 20C in high RAP pavements • Does not negatively impact rutting resistance of rejuvenated RAP mixture • Enhances low temperature cracking resistance of asphalt mixture, even at high RAP content www.ForConstructionPros. com/21019697

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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CLASSIFIEDS THE RELIABLE WORLD OF ASPHALT PLANT PRODUCTS

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Reliable Asphalt Products builds custom Stationary Split or Single Level Control Houses!

• 360 degree viewing available • Tube frame construction with wood studs and steel siding • Steel roof with cool seal roof coating applied • Floors are I beam construction with ¾” tongue and groove and black coin rubber • Walls have 3” spray foam insulation, roof has 6” spray foam insulation, floor has 4” insulation • Steel doors with crash bars, door closer, insulated safety glass • Countertops for controls available • Heating / AC unit for main room, MCC room, and additional for MCC room

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CLASSIFIEDS Contact Denise Singsime Print and Digital Advertising

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We are offering all of our lightly used asphalt, concrete and soil lab equipment for sale.

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ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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CLASSIFIEDS 



   

       

   







  

                                

                       

       

       

Providing The Highest Quality Replacement Parts & Fabrications

A&A SEALCOATING BUSINESS FOR SALE I am retiring after 27 profitable years. All business assets have been well maintained.

Our team of experienced professionals are dedicated to assisting Asphalt Producers maintain a competitive edge with quality parts and services. Specializing in authentic Ni Hard mixer components and drag liners, flights and custom fabrication, flame hardened trunnions and carbide overlay.

• Biz includes (8) 2003-2004 GMC 5500 trucks

• (1) 26 hp crafco router

• (2) 550 gallon seal units

• 1 Billy Goat crack cleaner

• (1) 1000 gallon seal unit

• (2) 13 HP Billy Goat force blowers

• (1) 1500 gallon transfer unit

• (1) 11 HP Billy Goat Blower

• 1 dump truck

• 3 Graco Stripers

• 1 asphalt tank with 3 ton hot box (infrared patching)

• 1 Whacker compactor

• 2 flat beds

GET IN TOUCH Kelly Steel & Engineering, 26267 Lippert Rd. Cochranton, PA 16314 814-425-1220 | 814-807-5607 www.kellysteel-engineering.com

www.ForConstructionPros.com/Asphalt

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ASKING $740,000

• 1 seal master pro 120 crack melter • 1 ARS infrared trailer unit with 4-4x4 heaters and 1-4x2 pad

• 4 little wonder crack cleaners

• JD 2305 utility tractor with 200 hours has 60 inch power broom • 25 HP Brown standup blower with 60 hours • Many trailers and other items

• 1 Stone asphalt roller

Randy Flick 715-423-9040 aaseal@solarus.net MARCH/APRIL 2019 ASPHALT CONTRACTOR

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CLASSIFIEDS

ASPHALT PLANTS · Gencor 400 tph stationary counterflow plant · BMG 450 TPH Portable Drum Mix Plant · Astec 350 tph Relo Double Barrel plant w/4 silos · Astec 300 TPH Portable Six Pack plant · Astec 150 TPH Portable Drum Mix Plant with SEB & Baghouse · ADM 100 tph stationary drum plant with 1 silo & recycle · 120 tph portable drum mix plant with baghouse · ADM 110 tph portable drum plant · H&B 10,000# tower and dryer · Astec 5000# Asphalt Batch Plant · H&B 4000# asphalt batch plant · Astec 89’X32” slat conveyor · Cedarapids 65,000 CFM Baghouse

· · · · · · · · · ·

Stansteel 44,000 CFM Baghouse Almix 30,000 CFM baghouse Astec 500 tph Double Barrel only Astec 250 TPH Portable Double Barrel drum only Two bin rap system Stansteel 8’X36’ aggregate dryer with burner 7’X30’ portable drum mixer Astec 750 barrel self-erect lime silo 2-200 Ton Asphalt silos and slat conveyor Six bin cold feed system

Please Call For Complete Inventory

Plant for sale? Call Clancy!

Serving the Asphalt Industry for 50 years

E.T. CLANCY COMPANY 219-879-8231 • 800-348-8553 Email: sales@etclancy.com • www.etclancy.com

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ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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CLASSIFIEDS

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YOUR IDEAL

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www.ForConstructionPros.com/Asphalt

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CLASSIFIEDS OIL DISTRIBUTORS OIL DISTRIBUTORS 2019 2019ETNYRE ETNYRE

Etnyre2000 2000Gallon Gallon Centennial Etnyre Centennial • 16' Spray Bar - I' Increments

• Mounted on 2019

Freightlineron& 2019 IHC Trucks • 16’ Spray BarControlled — 1’ Increments • Mounted • Computer Freightliner & IHC Trucks • Diesel Engine • Computer Controlled • 2 Diesel Burners

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• 2• Diesel EU1 yre Burners Centennial

2 Speed Rear Ends

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Rolling Stock Parts

Plant Parts

Shaker Decks

RAPwranglers

 PAVER WEAR PARTS  LIVE BOTTOM TRAILER PARTS

 MATERIAL TRANSFER DEVICE PARTS  PLANT EQUIPMENT & PARTS  WINDROW ELEVATOR CHAINS  PICK UP MACHINE PARTS  SHUTTLEBUGGY ® MTV PARTS

www.asphaltace.com

1-888-878-0898

sales@asphaltace.com

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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Index Advertiser Index

PAGE

Advertiser Index

PAGE

A & A Sealcoating

77

Transtech Systems Inc.

13

Ace Group

80

Troxler

11

Almix

9

Volvo Construction Equipment

59

Ammann Group

47

Weiler

2

Asphalt Drum Mixers

28-29

WEM Automation

21

Astec Inc.

27, 31, 35, 39, 42 – 43

Willow Designs

78

BITCO Insurance Companies

73

Wirtgen America Inc.

5, 48 - 49

Blue Roads Solutions

61

Calculated Industries

64

Carlson Paving Products Inc.

83

Case Construction

7

ClearSpan Fabric Structures

79

C. M. Consulting

81

Dynapac Fayat Group

57

Eager Beaver Trailers

37

E. D. Etnyre & Co.

66

E. T. Clancy Company

78

Evans & Daniels Inc.

76

EZ Road Inc.

77

FastMeasure By KTP Enterprises

77

Gencor Industries Inc.

3

Go Online Asphalt

71

Heatec

53

Homestead Valve Division

51

Hydronix

64

Johnston Sweepers

79

Get fast, relevant product information in the Buyers Guide at

ForConstructionPros.com

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

C.M.Consulting

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www.ForConstructionPros.com/10072464

www.ForConstructionPros.com/Asphalt

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THE LAST EXIT |

BY SARA JENSEN, CONTRIBUTING EDITOR

bauma 2019 Demonstrates a Smarter Heavy Equipment Industry Manufacturers will use this year’s largest tradeshow to demonstrate growing use of digitalization

D

uring the recent bauma Media Dialog—in which journalists and show exhibitors are brought together to discuss products and trends on hand at the show in April—it was clear to see that the continually growing trend of digitalization will be among the highlights at bauma 2019.

Organizers of the show, Messe Munchen, have announced that several companies will have a focus on digitalization. “The digitization of the construction industry is becoming increasingly important. Many construction machines are already equipped with communication interfaces that provide comprehensive data, e.g. on location and consumption. This development is also reflected at bauma 2019,” said Mareile Kästner, Project Manager at bauma in a recent press release about the show.

The media dialog event was kicked off

by Klaus Dittrich, Chairman and CEO of Messe Munchen, discussing a recent survey conducted by the organization. Between June 13 and August 10, 2018, it surveyed 10,000 industry executives from around the world—all in leading, decision-making positions—to gain a perspective on current trends within the industry.

This industry barometer found the level of investment in the construction industry is very high across the globe and expected to continue over the next few years. Fortyfour percent of respondents said they are planning to increase investment levels for

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their company in the future. The survey also found that of the challenges facing the industry, the shortage of skilled labor was the biggest, with 58% of respondents indicating as much. Increasing competitive and price pressures, as well as tightening environmental laws and regulations were also at the top of the list. Digitalization was also noted as a challenge, as well as a megatrend for the industry.

Of those surveyed, 26% said research into the field of digital networking was taking place within their companies.

Over half of respondents said they have already digitized parts of their company or have at least started doing so. Twentytwo percent are still waiting and 20% currently see no need for action. “Only 4% believe they are leading the way in terms of digitalization,” said Dittrich.

He noted that digitalization plays a role in and out of the production process for no more than 34% of respondents.

Only 14% use cloud- or web-based services, and 26% indicated the topic of digital networking is not on their agenda for the future. While digitalization is an important and growing trend, Dittrich said many companies are struggling with its implementation—as evidenced by the survey results—and that there is clearly some incongruency between the importance of research into and actual development of digital products.

Despite the challenges, digitalization is slowly making its way into the industry and will be evident at this year’s show in Munich. “At bauma 2019, visitors can see state-of-the-art excavators, cranes and bulldozers [that] can be equipped with a broad range of sensors and communication interfaces,” Dittrich said. “The data that is produced and analyzed makes it possible to check the machinery on job performance, fuel consumption and locations; to define predictive maintenance to

more precisely determine operating costs; entire fleets can be managed by telematics. Digitalization also facilitates efforts to automate work processes, an increasingly important factor in light of the shortage of skilled workers faced by the industry.”

DIGITALIZATION IN ACTION Today, almost everything from bearings to engines to tires have become smarter and more connected through the use of sensors, CAN communication, telematics and the Internet of Things (IoT). Use of these digital components not only make products smarter, but also enable efficiency improvements.

Another aspect of the industry’s increasing digitalization is the growing use and improvement of safety systems, including lighting, cameras and proximity detection systems. This trend will also be seen during bauma.

Continental, for instance, will introduce the next generation of its ProViu 360 surround view system which will now provide images in HD. In addition, it will be capable of fusing together camera images and sensor information to better analyze the area around a vehicle and alert operators to any potential collisions or objects in the way.

To further increase safety around large equipment, HELLA has introduced its VISIOTECH projection technology of which four models have been released and will be on display at bauma. The LED Projection Module projects an exclamation mark on the ground to provide an optical warning to prevent them from entering the vehicle’s path.

Look for more bauma coverage in the May issue of Asphalt Contractor.

For more information, visit ForConstructionPros. com/21034572

ASPHALT CONTRACTOR MARCH/APRIL 2019 www.ForConstructionPros.com/Asphalt

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