Asphalt Contractor March/April 2021

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MARCH/APRIL 2021

THE LATEST PRODUCT INNOVATIONS FOR THE

ASPHALT INDUSTRY

RAP

Management Uses Education to

DRIVE SUCCESS

www.ForConstructionPros.com/Asphalt

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➲ HOW

ASPHALT PAVERS

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GENCOR INDUSTRIES

THE LEADER IN PERFORMANCE AND EFFICIENCY

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TABLE OF CONTENTS |

MARCH/APRIL 2021

COVER STORY Education Key to Success at RAP Management With a focus on producing high-quality and sustainable mix designs, the Ohio-based producer works to overcome the old school mindset surrounding recycled asphalt materials. | 22 TECHNOLOGY MATTERS

PRODUCTION NOTES

PRESERVATION UPDATE

10 When is the Best Time to Implement Fleet Telematics?

28 Production Products

42 How to Use Chip Seals for Pavement Preservation

Many companies turn to telematics when it’s too late, before they realize there’s technology that can solve the issue they’ve run into. Get the system implemented early and avert the crisis in the first place.

SPECIAL REPORT: INDUSTRY INNOVATIONS

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As the work continues, it is more important than ever for contractors to keep their businesses competitive and the latest products from equipment manufacturers can help.

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

JOBSITE INNOVATIONS

32 Operators Move to the Forefront in Paver Designs

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

When a chip seal is applied to a pavement in good condition, pavement life can be extended six to eight years, making this preservation treatment ideal for low volume roadways.

Asphalt pavers have evolved to provide greater controllability and operator comfort.

40 Jobsite Products Pavers, rollers, MTVs & more.

48 City of Phoenix Gives RAP a Test Drive Recycled asphalt had never been used on roadways in the city before a paving contractor presented them with the evidence of its performance.

IN EVERY ISSUE 8

Editor’s Perspective

58 The Last Exit

Blaw

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BACK IN THE MIX

With over a century of innovation to its credit, Blaw-Knox pavers have earned a reputation for quality, durability and performance unmatched in the industry. Today, with its new and improved highway-class designs, Blaw-Knox continues to deliver on its promise with all the performance features you’ve come to expect from an industry leader.

BLAW-KNOX, THE LEGACY LIVES ON. Blaw-Knox Corporation 1280 Superior Avenue Chambersburg, PA 17201 Tel. 717-400-7900 www.blawknox.com

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DIGITAL CONNECTION www.ForConstructionPros.com/Asphalt

Where Does Surface Transportation Funding Stand?

With the latest Coronavirus relief bill to the Senate, experts say infrastructure funding is the next item on the Congressional agenda.

Search: 21307064

[VIDEO] Catch Up on Hops & Highways Hops & Highways is your weekly newscast dedicated to the road building industry.

Join us each week as we share the latest industry news, provide contractors with best practices and share your hard work for Build America Friday.

Search: ForConstructionPros.com/ Videos/Hops-Highways

Turning Face Masks into Pavement An innovative way to reduce pandemic-generated waste by recycling single-use face masks into pavement.

NAPA Honors Asphalt Industry Leaders and Quality Jobs with 2020 Awards

Search: 21259812

Get social with us! Share pictures of what you’re working with over 29,000 other asphalt contractors on our Facebook page: Facebook.com/ Asphalt.Contractor/

The National Asphalt Pavement Association announced winners at their 66th annual meeting.

Search: 21295315

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CONTRACTOR LATEST INNOVATIONS FOR ASPHALT PROFESSIONALS

LATEST INNOVATIONS INNOVATIONS FOR FOR ASPHALT ASPHALT PROFESSIONALS PROFESSIONALS LATEST

ASPHALT ASPHALT

MARCH/APRIL 2021 Vol. 35, No. 3

CONTRACTOR CONTRACTOR LATEST INNOVATIONS FOR ASPHALT PROFESSIONALS

LATEST INNOVATIONS FOR ASPHALT PROFESSIONALS LATEST INNOVATIONS FOR ASPHALT PROFESSIONALS

Published by AC Business Media.

Asphalt

Asphalt CONTRACTOR

CONTRACTOR

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Published and copyrighted 2021 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, Fifth Floor, Fort Atkinson, Wisconsin 53538.

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ASPHALT CONTRACTOR MARCH/APRIL 2021

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CONTRACTOR

EDITOR’S PERSPECTIVE

LATEST INNOVATIONS FOR ASPHALT PROFESSIONALS PROFESSIONALS LATEST LATEST INNOVATIONS INNOVATIONS FOR ASPHALT PROFESSIONALS

MARCH/APRIL 2021 • Vol. 35, No. 3

Jessica Lombardo, Editor-in-Chief

ASPHALT

CONTRACTOR LATEST PROFESSIONALS LATEST INNOVATIONS FOR ASPHALTPROFESSIONALS LATEST INNOVATIONS FOR ASPHALT

jLombardo@ACBusinessMedia.com 920.542.1247

Published by AC Business Media

Adapting to Life Asphalt Without Tradeshows CONTRACTOR

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

It’s more important than ever for the industry to keep moving forward, even without in-person events

S

pring is officially tradeshow season.

We attend many industry events from January-April and always bring back the latest news and equipment introductions for the asphalt industry to showcase to our readers. That is of course not the case in 2021.

While we can't wait to get back out there and travel, the industry has been forced to figure out how to continue moving forward while much of the world stands still.

EDUCATION STILL IMPORTANT While live exhibit hall events aren't taking place, there are more virtual events than ever before. This is a bonus to many in the industry who may have been unable to attend inperson events but can now attend from their home and offices instead of having to travel.

Industry associations were the first to lead the charge with these type of events, stressing the importance of member meet-ups to keep conversations going about adapting to COVID. There have been countless association meetings held virtually with opportunities for members to network with each other to continue to grow their business even during these uncertain times.

In addition to association meetings, national industry events like World of Asphalt and the National Pavement Expo held virtual conference sessions this year. Many speakers who were scheduled to appear in-person agreed to adapt their presentations to a virtual platform allowing attendees to still gain the industry knowledge they need to drive their business in the new year.

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INDUSTRY INNOVATIONS Then there's the iron. Boy do we miss being able to kick some tires. But that doesn't mean companies have stopped innovating.

And because opportunities haven't stopped as a result of the pandemic, many construction companies are still in buying mode, looking to purchase the equipment and technology they need to keep their businesses moving forward.

While nothing will replace an in-person networking event, these online events have given construction equipment manufacturers the opportunity to network with contractors through virtual tradeshow booths. These online tradeshows give contractors a chance to connect with a company that creates a product they need or potentially learn about a new product they weren't aware of. Attendees can speak to someone virtually or just drop a "business card" to be contacted at a later date to learn more.

Did you pick up a new skill during the pandemic because you had time on your hands? Maybe your favorite piece of machinery did too. Equipment manufacturers are continuing to create and unveil new equipment. As they should since contractors still want and need the best technology and iron that's available to them. On page 14 of this issue, we have a list of the latest asphalt industry innovations that equipment manufacturers have been working on during the pandemic.

Be sure to also follow Asphalt Contractor on social media where we'll be highlighting this equipment throughout the month. Don't let this pandemic put your company behind the competition. Continue to learn, grow, innovate and adapt. We'll all come out of this stronger than ever.

Stay safe out there.

ASPHALT CONTRACTOR MARCH/APRIL 2021

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Publication Staff Publisher

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TECHNOLOGY MATTERS Edward James

When is the Best Time to Implement

FLEET TELEMATICS? Many companies turn to telematics when it’s too late, before they realize there’s technology that can solve the issue they’ve run into

T

elematics can put the right data in the right hands at the right time to save a company time, labor and stress. But for many managers, knowing when and how to implement telematics technology can be daunting. However, if done correctly, implementing telematics can increase productivity, efficiency and morale.

DOING MORE WITH LESS Telematics shows company representatives where their trucks are at all times. But more than that, it gives managers and foremen the ability to see trends in data and compare different datapoints. Being able to see where one truck is at any given time helps managers plan and oversee their fleets.

But one truck’s data becomes invaluable when you compare it to the rest of the trucks on the job. In order to make the changes that will increase efficiency at the job site, managers have to see the whole forest—not just a single tree.

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An asphalt trucking company in Florida installed Earthwave Technologies’ FleetWatcher Materials Management Solution. The system showed them data on all their trucks across several job sites. By looking at the bigger picture, they were able to see that they were averaging eight trucks waiting to be loaded at any given time throughout the day. That added up to an hour wait time per cycle, and three and a half hours of idle time per day.

The company was paying $350 a day for a truck to wait in line.

They were over-trucked and could see it when they looked at the bigger picture—the data trend over time. The company quickly shared the information with the plant, sent out fewer trucks at a time, and shaved 75% off the idle time.

That’s what telematics is all about: getting that data to the right people in the right amount of time so that they can proactively make business decisions before it’s too late.

GO BIG Rather than starting a telematics system at the start of the season, implement it at the start of a high-impact job. Often companies are trying to do a lot of different projects at the start of the season, and some projects, like implementing a telematics system, fall by the wayside when the company gets busy.

Big, make-or-break-the-year projects get the most amount of resources, and provide the largest possible data-set.

The more trucks are out, the more datapoints a company will be able to collect.

With more datapoints, trends will be clearer, comparisons will be sharper, and managers will be able to see the bigger picture. When a manager notices a job is over-trucked and makes an adjustment, the result will be clearer too: more productivity, less downtime.

Whenever you can devote the right amount of resources to it, that’s the best time to implement telematics.

Many companies turn to telematics when it’s too late. Many a manager has turned to ask for help after spending the trucking budget for the year or a crisis has occurred on a high-impact project. Only then do they realize there’s technology that can solve the issue they’ve run into. Get the system implemented early and avert the crisis.

THE BIG BROTHER FACTOR With managers receiving real-time data on routes and drive time from their drivers, many companies are nervous that employees will feel like they’re being micromanaged. However, with transparent and proactive communication, managers can dispel the Big Brother Factor before it is even established.

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BestVectorStock/AdobeStock Edward James

Drivers buy in to telematics systems when they understand why and how the system is being implemented. Show the drivers that telematics is a win-win situation: the company gets real-time data that allows them to strategize how to use the drivers to increase productivity. Meanwhile, the drivers get to drive, rather than wait in lines. In some cases, companies have even forwarded the influx of cash from increased productivity to drivers in the form of a pay raise.

Transparency is another tool to earn employee support. Managers should show drivers how the data looks from their perspective, including what they see and how they intend to use it. It shouldn’t be a behind the curtains thing.

NO TIME LIKE NOW With companies relaxing quarantine restrictions, many are looking for ways to implement the “new normal” of social distancing and working from home. Of course, working from home isn’t possible for many industries, such as trucking or asphalt paving.

Telematics can help companies adjust to these changing times. A construction or materials management solution can track and transfer data from the jobsite or plant to a foreman, manager or executive without that person having to go knock on the door at the site. Managers can access and analyze information while working from home, reducing the need for contact and exposure.

E-ticketing is another way telematics can reduce exposure.

E-ticketing tracks and transports data without paper printouts or physical contact. With more and more states tracking contact, e-ticketing has become a high priority.

On top of that, with uncertain markets and budget cuts looming, many companies are looking at how to do the job with less people. Some are trying to reduce the cost of a job while others are trying to free up employees for other projects. With real-time data delivered into the right hands, companies can

begin to re-strategize how to use their employees more effectively.

By being proactive about implementing telematics, companies can introduce the system in a way that increases buy-in from employees across the board. Getting a jump start on introducing telematics early in a season helps companies see the bigger picture faster.

More data means a clearer picture, and a manager can adjust productivity before it’s too late. Being proactive allows companies to start saving time and labor on projects now, rather than waiting for a crisis or budget shortage to start looking for ways to save.

Jim Wahl is owner of Wahl Marketing Communications and can be reached at jim@wahlmarketing.com

For more information on fleet telematics, visit ForConstructionPros. com/21135710

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SPECIAL REPORT | INDUSTRY INNOVATIONS JESSICA LOMBARDO, EDITOR-IN-CHIEF

The Coronavirus pandemic has forced the asphalt industry to figure out how to move forward while much of the world stood still. As the work continues, it is more important than ever for contractors to keep their businesses competitive and manufacturers have been essential to this. The next few pages of Asphalt Industry Innovations provide construction companies with the latest equipment and technologies that will help them compete in 2021.

Libra Sentinel GPS Truck/Asset Management Solution The Libra Sentinel Asset Management Solution is a cloud-based GPS system that helps you gain more visibility into high-value trucking and hauling assets through one integrated solution.

• Streamline your asset management tasks—saving time and money while improving utilization • Visual displays of truck statuses across all orders so that you’re always in the know • Options for simplistic vehicle mounted hardware or driver app - choose what works for you or mix and match based on internal/external fleet • Asset tracking available via smart device includes mobile tickets with signature capture • Exchange eTickets that meets DOT specifications • Auto or manual status via Geofences or Driver Selection • Performance dashboards to ensure you’re making informed decisions each and every day ForConstructionPros.com/21108646

Caterpillar RM400 Rotary Mixer The 51,809-lb. RM400 rotary mixer features an 8-ft. cutting width and is powered by a 417-hp C9.3 Tier 4 Final engine.

• Standard all-wheel drive utilizes four independent drive pumps for maximum torque, traction and speed • Three different rotor speeds help deliver the desired material gradation and the electronic controller keeps the rotor at the proper depth and machine at a consistent speed to ensure optimal blending performance • Four rotor options are available for a variety of applications and a universal rotor with 200 point-attack carbide-tipped tools can be used for fulldepth reclamation or soil stabilization ForConstructionPros.com/21086837

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ADM EX120 Asphalt Plant Asphalt Drum Mixers (ADM) redesigned the EX 120 asphalt plant as a solution for producers who need a portable counterflow plant that can process high percentages of RAP. • ADM’s EX Series plants are available in a variety of prices and configurations to meet production capacity for a wide range of applications • Designed for smaller output and optimal transport, the EX120 is the ideal asphalt plant for remote and demanding locations worldwide • Like all EX Series plants, the EX120 uses single-drum counterflow technology and meets all federal and state specifications ForConstructionPros. com/12317992

Ammann Releases Dynamic RAP Addition Module A unique product for effectively handling RAP content in various proportions and in varying conditions is the Ammann Dynamic RAP Addition.

• This module is part of Ammann’s proprietary as1 Control System • Dynamic RAP Addition allows modification of the RAP ratio – even during production runs • System helps plant operation and quality assurance staff compensate for the qualitative and quantitative attributes of the RAP being used ForConstructionPros. com/21259495

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SPECIAL REPORT | INDUSTRY INNOVATIONS

VT LeeBoy Raised on Blacktop 8520B Paver

WEM Analytics WEM Analytics is a manager’s go-to tool to help identify the operational opportunities that have the greatest impact to production.

• Web-based software that can be accessed by a desktop, laptop, tablet or smartphones’ web browser • Easy drag n’ drop interface lets you create additional dashboards for monitoring various functional areas of your plant, across any time span • Data is accessed from your automation control system, both PLC and transactional data, stored on the WEM SQL database.

• Most dashboards have multi-tiered data – high level data that can be viewed with the option to dive deeper into additional details • Dashboards can be exported as images in various file formats, such as JPG, PNG, TIFF, etc.

• Tabular data reports for the dashboard images can be created, viewed, or exported as PDF or CSV files ForConstructionPros. com/21135693

Get social with us!

Share pictures of what you’re working with over 29,000 other asphalt contractors on our Facebook page: Facebook.com/ Asphalt.Contractor/

Raised on Blacktop was created as a way to tap into the pride and passion of those in the asphalt industry. To honor this passion for the industry, LeeBoy engineers have unveiled a new Raised on Blacktop special edition 8520B heavy-commercial asphalt paver that pays homage to the Raised on Blacktop crowd including: • An exclusive gray paint scheme • Red operators’ seats embroidered with the Raised on Blacktop logo • Stylized Raised on Blacktop decal • Carbon-fiber embellished wing decal • A larger American flag decal • A weather-proof ticket/phone box • Various shovel/rake carrier options • Engraved serialized badge • An optional custom lighting package ForConstructionPros.com/21259413

Astec Inc. Versa Jet Burner

• • • • • •

The Astec Versa Jet burner is an evolutionary leap forward. Ideal for retrofit applications, the Versa Jet burner fits nearly any drum configuration.

• One versatile platform can be quickly configured to fire at 25, 35, 50, 65, 75 or 100MM BTU/hr Highly adaptable burner combines three burner packages in one platform which can be easily adapted for the system at the install site The unique platform of the Astec Versa Jet burner permits quick delivery and setup which minimizes downtime while maximizing profitability Streamlined design ensures that these burners are ready to ship to your site quickly and can be installed with minimal modifications needed Base burner does not include the fuel train, ideal when a functional fuel train is already on-site and available to be used Fuel options: Heavy oil, light oil, natural gas and vaporized propane Patent US2021/0025587

ForConstructionPros.com/21121730

Case E Series Compact Vibratory Rollers Seven compact vibratory rollers range from 33.5 to 43.9 hp and from 4,920 to 9,520 lbs. and come in double-drum and combination configurations with drum widths from 39 to 54 in.

• Redesigned operator interface includes an electronic travel lever and rpm settings, drive settings, sprinkler system controls and more at the operator's fingertips • Operation mode selector allows selection between loading, working and transport modes • Soft drive setting provides a smooth ride during asphalt compaction, while the optional hard drive setting enables swift turns • Deliver high centrifugal forces and frequencies at lower rpms with selectable dual vibration frequencies ForConstructionPros.com/21120047

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SPECIAL REPORT | INDUSTRY INNOVATIONS

Topcon Thermal Mapping System for Asphalt Paving The Thermal Mapper for asphalt paving is designed to monitor temperature segregation and easily provide accurate compliance reporting, all with real-time kinematic (RTK) positioning accuracy.

• Provides a visualization to operators in real time of whether the mix falls within a pre-defined temperature range • Quickly tells operators if mix is stable or if moderate or severe temperature variation is occurring • Creates data reporting files to download for applications such as DOT compliance via an interactive Pavelink module ForConstructionPros.com/21121074

ALmix Insignia Control System The ALmix Insignia Control System (ICS) is where powerful tools meet a simple user-experience. ICS features the very latest in asphalt plant automation technology within the framework of an easy-to-navigate, point-and-click design. A comprehensive main screen is paired with a series of informationinfused, operator-focused screens available at the click of a mouse. The optional ALmix mobile application allows management real-time remote viewing of plant data and information.

Trimble Roadworks 3D Paving Control for Asphalt Pavers Trimble Roadworks is an automatic 3D screed control system that can significantly improve paving productivity and rideability by directly referencing the design rather than a surface or stringline to minimize asphalt usage, reduce waste and overruns and finish projects on time and under budget.

• Android-based application runs on the 10-in. touch-screen Trimble TD520 Display and colorful graphics, natural interactions and gestures, and self-discovery features make the software intuitive and easy to learn • Using a Trimble SNM941 Connected Site Gateway, Trimble Roadworks allows the transfer of 3D designs from the office to the machine via the cloud so that the operator is always using the latest design. Productivity data collected from the machine is automatically synced back to the office ForConstructionPros.com/21259603

Stansteel T-Trac System • Automatic plant start-up and shutdown with sequence interlock • Multi-point capability for all calibrations • Burner ignition sequence and fault display • Automatic burner control with start-up and firing percentage • VFD exhauster control with speed percentage and drum negative pressure status • Automatic baghouse cleaning control with baghouse differential pressure status • Automatic batcher and silo selection control • Interlocks, warnings, settable limits and logs for added safety ForConstructionPros. com/21259498

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Correctly adjusted trunnions reduce maintenance cost and plant downtime with the T-Trac Trunnion Alignment Tool by Stanstee and Hotmix Parts & Service can help accomplish this task.

• The T-Trac allows you to square the trunnions and tires within 100/1000th of an inch in precision • In order to use the T-Trac correctly, lockout procedures need to be observed while working in contact with the equipment • The T-Trac consists of a magnetic base with dial indicators attached on each end facing the tire. Calibrate the dial indicators to the base with the included calibration blocks and the T-Trac is ready for use. Place the T-Trac on the side of the trunnion with both dial indicators on the side of the tire. Each of the four trunnions must be adjusted to the neutral position, meaning there is no longer uphill- or downhillthrust. Adjust the trunnions to achieve a neutral (zero) delta between the two indicators, meaning that the trunnion is perfectly parallel with the tire. The same method is performed for all four trunnions • Once all four trunnions are in a neutral thrust, the T-Trac can be used to skew each trunnion for the correct skew and thrust • The trunnion adjustment methods of using a laser can take up to four to five hours to properly adjust your systems ForConstructionPros.com/10146976

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SPECIAL REPORT | INDUSTRY INNOVATIONS

Etnyre New Era Live Bottom Belt Trailer The re-designed Etnyre Live Bottom now has all the features that you asked for in a belt trailer and includes the proven Etnyre standard features as well as many improvements.

• Aluminum huck bolted bogie to reduce weight, fatigue and corrosion • New polymer belt flashing that is easy to adjust and replace • Hardox interior bin walls to resist wear and extend the life of your trailer (optional stainless-steel bin walls are available) • Etnyre exclusive eight-chain drive system with a one-piece asphalt rated belt high-temp belt

Dynapac CC1300VI and CC1400VI Asphalt Rollers The double drum and combi versions of CC1300VI & CC1400VI were designed to meet the commercial and highway paving industry’s tough conditions. By keeping the operator in mind, it results in a robust, comfortable and modern machine producing the best compaction result.

• 37 kW/50 hp T4f Kubota engine with ECO mode • Features high frequency compaction with the possibility to choose between dual frequencies (3,240/2,940 vpm’s) depending on different conditions and applications.

• Dual amplitude (0.02”/0.007”) function is also available as an option for even more flexibility to compact different layer thickness • Optional dual amplitudes and dual edge pressers • Optional asphalt temperature meter to ensure compaction is done at the right temperature interval • Available in a combi-version with four static rubber wheels at the rear ForConstructionPros.com/21259834

Weiler E1650A Remixing Transfer Vehicle

ForConstructionPros. com/21259916

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The Weiler E1650A Remixing Transfer Vehicle builds upon the success of previous Weiler MTVs with innovative new features engineered to maximize productivity while providing low operating costs.

E1650A has a larger, 18 tons of onboard storage, enhanced elevator motors and triple-pitch remix augers to provide 600 tons per hour discharge capacity for nonstop, non-contact paving with reduced particulate and thermal segregation Front-mounted control station layout features increased visibility with a 10-in. color, touch screen display with integrated camera along with proportional conveyor swing joystick control. The crab and coordinated rear steer with auto-center is standard for a 17-ft. inside turning radius Storage hopper management system, paver hopper management system with distance to paver control and auto-center options allow the operator to focus on truck exchanges while maintaining proper material feed to the paver Full-width, hydraulic drop-down floors along with four clam-shell doors for ground level access to the storage hopper and remix augers provide access for cleanout and machine inspection

ForConstructionPros.com/21259585

BOMAG ION Dust Shield The ION Dust Shield was specially developed for cold milling machines to transfer dust away from the operator and eliminate fine particles (PM 2.5, PM 10) by up to 80%.

• In addition to visible dust, a considerable amount of particulate matter is also produced when removing an asphalt surface and the ION Dust Shield binds the fine particulate matter by electrically charging the particles • The particles clump permanently to harmless coarse dust and can be easily removed which leads to a reduction in particulate matter of over 80% - as confirmed by the IGF Institute for Hazardous Substances Research at the Ruhr University

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En g i n e e r e d In n o v a t i o n .

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.

w e ile r p r o d u c ts .c o m

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PRODUCTION NOTES |

JESSICA LOMBARDO, EDITOR-IN-CHIEF

EDUCATION KEY TO SUCCESS AT

RAP MANAGEMENT

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RAP Management, LLC consistently produces pavement averaging 55% RAP and is producing over 200,000 tons of material per year.

With a focus on producing high-quality and sustainable mix designs, the Ohiobased producer works to overcome the old school mindset surrounding recycled asphalt materials

P

rofit reigns supreme in the asphalt industry and it's getting harder and harder to compete. Unless of course you find a way to separate yourself from your competition as RAP Management has.

Since 2016 the company has worked to produce high-quality, sustainable pavement materials that perform well and best fit their customers' needs, and those needs don't include creating virgin hot mix asphalt.

"Utilizing our high-RAP mixes we gain leverage to compete in our market by lowering our cost to manufacture materials," owner Ryan Smith says.

"That, along with the level of quality material we are able to achieve even at 60 and 70 percent recycled content, makes producing virgin materials unfavorable for us."

www.ForConstructionPros.com/Asphalt

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Located in Columbus, OH, RAP Management serves Columbus and the surrounding towns, cities and municipalities with mix produced from their Ammann High Recycling Technology Asphalt Mixing Plant. The first mix they produced to pave the plant site consisted of 60 percent recycled aggregate and 2.8 percent binder displacement, for a total of 62.8 percent recycled materials.

Since then, the company has achieved a 92 percent recycled content cold mix product and a 70 percent recycled asphalt pavement (RAP) hot mix asphalt (HMA) product. The plant consistently produces pavement averaging more than 55% and is producing over 200,000 tons a year.

FIRST IN THE COUNTRY If you took all the newspapers, aluminum cans, glass and plastic bottles the U.S. recycles annually and put them on a scale, they would still weigh less than three-fourths that of all the RAP in our country. This makes asphalt America’s most recycled product.

According to a 2019 survey by the National Asphalt Pavement Association (NAPA) in partnership with the Federal Highway Administration (FHWA), our industry reclaimed 97 million tons of RAP for future use, saving enough landfill space to fill up the dome of the U.S. Capitol 1,223 times.

Smith believes using that product is a smart business move, and RAP Management is on its way to proving it.

While the industry has long recycled, RAP is used in small quantities in most batches produced in the U.S. Smith wanted to use dramatically more, but he couldn’t find the equipment he needed. “No one in the United States was recycling to the degree I wanted to,” he said.

Eventually he found the Ammann Group, a Swiss company whose asphalt plants can handle a large ratio of RAP. Recycling is common in Switzerland, which has an aging infrastructure and limited natural resources. Smith brought the first Ammann asphalt plant to North America and produced his first batches near the end of 2017.

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PRODUCTION NOTES

RAP Management owns the first Ammann ABT HRP in the United States.

For 2018, RAP Management produced more than 130,000 tons of asphalt with an average of 60 percent recycled material, three times more RAP than the average nationally.

The production total is double what the company had forecast, and revenues are also beyond projections.

The Ammann plant can run 175 tons per hour with 60 percent recycle materials.

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Smith credits several factors for RAP Management’s early success. The most important factor is the quality of the asphalt products the company produces.

The company uses a proprietary chemical formula to overcome one of the problems with using a higher percentage of recycled RAP binders.

“Over time, asphalt deteriorates on the road. It gets stiffer or more brittle,” Smith explained. “You need to incorporate chemistry to counteract that.”

RAP Management’s formula expands the usable temperature range for asphalt performance. Because it uses recycled material, the manufacturing process is more cost efficient, a savings Smith passes on to customers.

RAP Management says their primary source of RAP is from their customers.

A lot of the jobs RAP Management supplies are reconstruction projects, meaning there is asphalt being removed.

They incentivize their customers to bring those materials back to them to be recycled. The company also has formed relationships with various other contractors in town that generate RAP. They allow these contractors to bring that material to them rather than pay to dump at a landfill.

However, with the industry not adopting RAP mixtures as fast as the materials are being collected, RAP

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3/9/21 9:47 AM

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PRODUCTION NOTES

Material Processing is Key Having the right equipment is instrumental in producing quality asphalt. In addition to the Ammann asphalt plant, one of the most important pieces of equipment RAP Management LLC has purchased has been a KPI-JCI and Astec Mobile Screens Prosizer 3600 crushing and screening plant.

“Good crushing and screening equipment is essential to control the recipes we sell,” company owner Ryan Smith said. “The challenge is to separate and liberate the asphalt.”

Because the stones and aggregate in RAP are already the right size, the impactor simply has to help separate them. The Prosizer’s high-frequency screen helps separate out the fine materials that are needed in the mix.

While the leased Prosizer worked well, the company recently purchased a KPI-JCI and Astec Mobile Screens crushing/screening plant with similar components, but it will have a larger screening deck and three decks, rather than two, so the company can process three kinds of materials. stockpiles are piling up and the industry needs to work to change the perception behind these mixtures.

“We’re never going to be the replacement of what’s currently being done, but I think this business model is going to be represented in every urban asphalt manufacturing infrastructure across the U.S.,” Smith says. “It’s essential.

Why would we throw RAP away when we can make better quality material at a lower price and recycle in the process?”

EDUCATION IS KEY The company is fairly new to the industry and working hard to break through barriers associated with high RAP mixtures.

"RAP Management operates the first plant of its kind on this continent and we are the only in our region able to achieve the level of quality proven by our Sustainable Pavement Materials.

We are the first to push specifying entities to rethink their current way of evaluating quality," Smith says.

"Educating the market and specifying bodies that sustainable pavement materials can equal high-quality is our biggest challenge. We are able to develop high RAP Marshall and Superpave mix designs that perform excellent."

Still, the company has to consistently work to remind their customers that these types of mixtures are not only good for the environment, but also good for profitability and the life of the roadway.

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"Trying to get anyone to change the way things have ‘always been done’ is a challenging task no matter what the topic is," Smith says. "We find open minded groups and individuals who are willing to look at the data and think outside the box. This allows us to consider a new way to define what quality is and utilize performance based testing to validate what we are producing. So far, we have worked alongside the City of Upper Arlington, The Ohio State University, Franklin County and the City of Columbus in completing demonstration projects to test and evaluate high-RAP against what is currently specified. We delivered industry leading material quality to each project, proving sustainable pavement materials and performance based testing are the future of the industry."

The company uses these test results to speak for themselves on the performance of their mixes.

"We have a rigorous testing protocol," Smith adds. "On top of standard volumetric testing, we are conducting performance based testing daily. We closely monitor our RAP piles by checking gradation and binder performance grade. It is essential we understand the composition of all the materials used in our process. This helps ensure a consistent and high-quality product."

The team also keeps an eye on the paving process for these mixtures to ensure the mixture is being set up, or

put down rather, for success.

"On every day of production, we have a member of our team visit the jobs being paved with our materials to check in with the crew and see how it's going down," Smith says. "A lot of these crew members have been doing this for decades and they know good material when they see it. The feedback we receive is overwhelmingly positive. From comments on how great the mix looks to its improved workability, they notice the quality and we take pride in that."

Finally, the Ohio climate provides the harshest testing ground for their materials that they would possibly endure, proving that if they can produce high quality RAP mixtures that perform there, in the freezing cold winters and stifling hot summers, these mixtures will last anywhere.

"We have produced close to half a million tons of asphalt, that is over 30,000 loaded dump trucks going across the material we installed around our plant," Smith says. "Not to mention three 80,000-lb. loaders, various other heavy machinery and the stock trucks hauling material to the site. After all of that, the pavement still looks excellent.

If it can hold up to that abuse, it will hold up to any standard application without a doubt."

For more information on RAP, visit ForConstructionPros. com/21089290

www.ForConstructionPros.com/Asphalt

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PRODUCTION NOTES Astec Double Barrel Drum Mixer The Double Barrel dryer/mixer is a combination aggregate dryer and HMA mixer that can keep RAP and virgin aggregate separate until the mixing phase of production.

• Minimizes emissions • Ensures mix quality • With the RAP and virgin aggregate meeting in the outer mixing chamber, excess moisture is removed from the RAP and the reclaimed liquid asphalt partially coats the virgin aggregate ForConstructionPros. com/10077061

ALmix Compact Series Asphalt Plants The ALmix Compact Series is designed for portability and a small footprint, this simple yet rugged design meets the needs of the small to mid-size contractor.

• Judicious control of plant frills versus plant cost has yielded a series of asphalt plants which allow the long time asphalt paver to become a first time asphalt producer ForConstructionPros. com/20866312

Meeker AC Storage Tanks Meeker AC Storage Tanks are available in vertical or horizontal configurations • Up to 35,000-gal. capacity • Hot oil, electric, or direct fired systems • Pipe fitting locations built to customer's specifications ForConstructionPros. com/10086117

Reliable Asphalt Plants Reliable Asphalt Products offers a complete line of new, used and reconditioned equipment for the HMA producers looking to improve their operations.

• Supplier can visit your site and evaluate your needs, then make recommendations to improve your plant • Can supply new batch and drum plants; stationary and portable arrangements are also available • Large database of used plants and components; all listings have been pre-qualified for quality • Used equipment can be purchased on an as-is basis or reconditioned for exact specifications

T

ForConstructionPros.com/10084582

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CMI Impulse III Control System

The Rotary Recycle Mixer is one major functioning component and extensive application of custom retrofitting of an existing plant.

• Unit can be used for combining heated aggregates, recycle, fines, liquid asphalt and other components outside the gas stream and avoiding blue smoke or RAP explosions that are common on many plants • Can be added to a batch plant to dramatically increase the RAP percentage or can be utilized in conjunction with a converted parallel flow drum mix

The CMI Impulse series of total asphalt plant control systems utilizes Programmable Logic Controller (PLC) technology and Windows based operator interface software to precisely control and monitor asphalt plant operations, on-site or remotely.

• Total plant control featuring plant diagnostics, remote plant monitoring, step by step instructions to guide the operator through the calibration procedure, data recordation, alarm log, activity log, mix cost analysis

•

ForConstructionPros. com/12320536

ADM SPL Asphalt Plants Asphalt Drum Mixers Inc. offers its line of SPL hot-mix asphalt plants as an affordable option for contractors with low production requirements.

• Includes all necessary components for drummixing asphalt production yet fits on a single trailer frame • Available in 60-, 100- and 160-tph production rates and come standard with a drying/mixing drum, wet wash, cold feed bin and surge system • Portable or stationary configurations with the option of automated or manual operation • Customized components include cold feed bins, hot oil asphalt cement tanks (both horizontal and vertical), direct-fired horizontal cement tanks, portable and stationary bag houses, mineral filler systems, RAP systems, self-erect and stationary silos, weigh and drag conveyors, weigh batchers and fuel oil tanks ForConstructionPros.com/12315127

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Stansteel Rotary Recycle Mixer

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Maxam Accu-Level Tank Level System The Maxam Tank Level System allows for accurate tank leveling with no moving parts.

• Pressure type sensor, more reliable than radar • Easy installation and set up

Ammann ACM 140 Prime Asphalt Plant The ACM Prime Asphalt-Mixing Plant is perfect for those who have a number of small jobs in varied locations and where frequent transport is required, and for paving contractors looking to introduce asphalt production into their businesses.

• The plant excels at specialty mixes, such as those used for paving tennis courts and running tracks • The ACM 140 Prime offers output of up to 154 tons per hour • Engineered for smaller volumes and therefore produces them efficiently, delivering cost savings in fuel and electrical energy consumption • Recycled asphalt can be utilized with this plant ForConstructionPros.com/20988244

• Alarm/interlock for automatic unload pump shutoff • Digital display in inches, feet (or tons on vertical tanks) • High intensity readout - clearly visible in sunlight • Weatherproof display mounts at tank or unload pump station • Includes 100-ft. of signal cable ForConstructionPros. com/21083733

Gencor G Series Asphalt Plant The Gencor G Series is the latest innovation in small portable hot mix plants providing asphalt producers and contractors with all the features of Gencor’s award winning Ultraplant in a smaller compact highly mobile plant that can be erected and operational virtually anywhere.

• The G Series is a rugged designed plant built with all the same premium features you’ve come to expect from Gencor for years of dependable service • The firing end of the burner extends into the dryer beyond the mix section so as not to overheat the aggregates and liquid asphalt as they are mixed together ForConstructionPros.com/21108631

RIGHTValve RIGHTPrice RIGHTNow! Dependable, Economical, Available …

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With cast iron and ductile iron material options, we offer a complete source of valves for any liquid asphalt application.

Our full line of hot-jacketed 2-way shutoff & 3-way diverter valves provide a ready solution to meet your flow requirements.

Homestead’s cutting-edge actuation design allows you to easily add actuators to your existing Homestead valves, in-line, without modification.

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NO ONE OFFERS MORE THAN ASTEC Our commitment to serving our customers in the asphalt pavement industry drives us to be our best, from our full-service engineering department eager work with you to configure a plant to meet your needs, to our logistics and construction crews ready to get your plant delivered and operational. Astec plants are all backed by after the sale parts and service support. You can count on us as your single source for complete plants, component equipment, parts and service.

SALES: 423.867.4210

All specifications subject to change with or without notice. | Products shown are representative, details may vary. | Equipment shown with options at additional cost.

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3/9/21 9:54 AM

JOBSITE INNOVATIONS BECKY SHULTZ, CONTRIBUTING EDITOR & JESSICA LOMBARDO, EDITOR-IN-CHIEF

OPERATO Move to the Forefront in Paver Designs

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Wirtgen Group / Vogele

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crews," Vijay Palanisamy, director of product marketing & communications, Dynapac North America LLC says.

"They are looking for ways to improve efficiency and also working conditions.

Technology advancement in this area not only helps tremendously on operators’ efficiency, it also helps getting real time feedback about the paving process."

These advancements are also being developed to help a struggling industry attract new workers.

"Operator stations need to appeal to younger workforce. Most of the people getting hired are new to the industry and younger," Kyle Neisen, product director, Construction Machinery Solutions at Astec Industries, Inc. says.

“We recognize there is constantly a new generation joining the industry, and we need to make sure as an industry that we are making equipment that will appeal to the younger people who will run it.”

The goal of paver manufacturers is to use technology to enhance the performance of the equipment, make operators more productive and make the equipment operate more efficiently.

Asphalt pavers have evolved to provide greater controllability and operator comfort

P

aving equipment has come a long way in the past decade as manufacturers continue to

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improve their products’ features and capabilities in order to ensure optimal production speed and pavement quality.

But changes have also targeted the paver operator and improved operations.

“Operator control systems on highway class pavers have been evolving very rapidly in the past decade and the primary reason behind this is adaptation of advanced technology by the paving

COOL OPERATOR As with other equipment, operator comfort goes a long way in keeping paver operators content. Vögele asphalt pavers from the Wirtgen Group include ergonomically efficient operator stations.

“This keeps the operator in a comfortable position so they are more alert and productive,” says Jim Holland, vice president of sales, Vögele. “It was important for us, as well, to prevent the paver operator from sitting over the tunnel where the heat of the asphalt can cause more fatigue. In addition, our swingout dual operator seat has glass shields protecting the operator from elements of wind, heat and noise, providing the most comfortable workspace in the industry.”

“Comfort and simplification have been big drivers in the highway-class paver development,” adds Jon Anderson, asphalt paver sales support consultant at Caterpillar. “Long days and high employee turnover have led to the development of cooler operating environments, fumes ventilation systems and enhanced visibility. Also, automated machine functions and interactive operating displays have evolved to help limit operator fatigue and enhance efficiency.”

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JOBSITE INNOVATIONS

Caterpillar’s top deck, frontmounted cooling system helps keep the operating environment cooler by redirecting exhaust air away from the operator and crew.

Consider features such as Caterpillar’s top deck, front-mounted cooling system, which can help keep the operating environment cooler by redirecting exhaust air away from the operator and crew. “Cooler operating stations and fumes mitigation help operators stay more attentive,” says Anderson. “Cat highway-class pavers are equipped with a ventilation system that collects fumes from the auger chamber and redirects them with the engine and cooling system exhaust out over the hopper, away from the crew for a more user-friendly operating environment.”

Cooling isn’t the only benefit of such design enhancements. “The top deck cooling system combined with the integrated generator have dramatically reduced the sound levels around the [Cat asphalt] paver, helping to improve crew communication and efficiency,” says Anderson.

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SIMPLIFICATION AIDS CONTROLLABILITY The ability to easily perform and monitor paver operations, along with simplified use, has been another key focus.

“Consistent controls and user friendly interface result in a better user experience," Neisen says. "The development team continually works to review controls and implement improvements. We look at what people like and don’t like in heavy equipment, automotive, etc. and apply those principles where they make sense."

Controllability is critical given the broad range of skill levels among today’s workforce. “The operator stations have become more intuitive to control and monitor the functions of a paver,” says Holland. “The Vögele paver can be placed into Pave Mode with the press of a single button. All settings for that job, including auger speed, conveyor speed, grade settings and paving speed, automatically resume to the previous settings. This allows for the operator to be more productive and maintain positive control of the performance of the paver. With the simplified controls, it allows the operators to be more conscious of safe practices and productivity.”

“The goal of equipment manufacturers is to use technology to enhance the performance of the equipment, make the operators more productive

and make the equipment operate more efficiently,” he adds, noting that Vögele’s operations concept is centered around ease of use. “This provides the best platform for a new operator to learn from and the experienced operator to better their productivity.”

Operator stations now include carefully positioned switches/buttons based on frequency of use, says Palanisamy, making them easy to remember with minimal training.

“Also, most manufacturers are going with symbols so that regardless of the operator region/language preferences, the operator can easily understand the functions,” he points out.

“By consolidating these functions, it is easier on the operator to locate and monitor the performance of the asphalt paver,” Holland comments.

“In addition, this enhances the ability to train new operators since it takes fewer steps to put the machine into the paving mode.

“Control of the paver is much more accurate with the use of sensors, which give feedback to the operator, as well.

This will enhance our ability to allow the use of 3D control systems, as the use of these in paving applications is expanding,” he adds.

Switches/buttons with lights for activated function on the control panel make it even easier to monitor paver operation at a glance.

Operators are benefiting from increased automation, which enables them to get the job done accurately with repeatable results.

Dynapac

www.ForConstructionPros.com/Asphalt

3/9/21 10:02 AM

The Most Innovative Paver Technology!

VÖGELE SUPER 1700-3i / SUPER 1703-3i VÖGELE SUPER 2000-3i / SUPER 2003-3i

The number one on the global market presents the “Dash 3” paver generation for the North American market. The 8-foot SUPER 1700-3i track and SUPER 1703-3i wheel and the 10-foot SUPER 2000-3i track and SUPER 2003-3i wheel pavers are available with an unparalleled range of screed offerings including front and rear-mounted vibratory screeds to high-compaction screeds. The new pavers include the intuitive ErgoPlus 3 operating system along with a few enhancements including VÖGELE EcoPlus and PaveDock Assistant. www.wirtgen-group.com

WIRTGEN AMERICA, INC. · 6030 Dana Way · Antioch, TN 37013 · Telephone: (615) 501-0600

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JOBSITE INNOVATIONS

“Simplified controls with interactive operating displays help operators visualize machine conditions and simplify setup for more efficient performance,” says Anderson. “Being able to optimize machine functions not only helps reduce fatigue, it also helps crews produce better asphalt mats.”

ADVANCES IN AUTOMATION A number of manufacturers have invested in “smart” control systems designed to enhance and/or automate key functions.

“Easy and reliable operation is one of the main focuses of control system advancements. Another area is capturing and showing in real time the key paving parameters so the paving crew consistently knows the mat they are putting down is within specification,” says Palanisamy.

Such capabilities are referred to as operator assist functions on Dynapac Highway Class SD asphalt pavers. One example is Set Assist, which enables the paver to “memorize” the paving parameters of different layers of the job — paving width, thickness, head of material, etc. — and replicate those parameters consistently across different areas and days during a paving project. Another is Paving Manager, which controls all functions and displays real-time paving parameters, such as paving width and thickness and material throughput, so the jobsite foreman can monitor production in real time. Other assist functions include Truck Assist, Mat Tracker and more.

“These advancements help the paver operators quickly set the paver for the particular job and start paving rather than waiting for time-consuming setups and trials before full production can begin,” says Palanisamy. “Another area where the operator is benefiting is the level of automation, which makes their life very easy and gets the job done accurately [with] repeatability of results.”

Automated functions simplify and speed operation from setup to cleanup. “Cat F-Series [asphalt] pavers

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By consolidating functions, it is easier for an operator to locate, control and monitor paver performance. Shown is the current generation operating concept on a Vogele asphalt paver.

Roadtec operator stations appeal to the younger workforce. This means they designed a user-friendly interface with consistent controls for a better user experience.

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JOBSITE INNOVATIONS

are equipped with auto-fill that helps simplify paving starts by filling the auger chamber until the mix reaches the material feed sensor set point,” says Anderson. “A single-touch material delivery function automatically activates the augers and conveyors with the touch of a button. One-touch hopper control allows the hopper wings and the optional front hydraulic apron to be folded with a single touch and release.

“Cleanout/warmup mode activates the augers, conveyors and tamper bars (if equipped) in slow speed, allowing for the application of release agents to prevent material buildup,” he continues.

“Machine-integrated grade controls help provide paving accuracy and ensure that the system always stays with the machine.” These features enable the operator to focus on other critical tasks, such as haul truck management and crew safety.

IMPACT ON PAVEMENT QUALITY While designed to aid the operator, these and other advancements ultimately improve overall paving operations.

"The machines need to be intuitive," Niesen says. "If a control is not working or is too confusing, it could result in laying a poor quality mat.

That’s where that intuitive feature set comes into play."

Anderson agrees, noting, “Ease of use, comfort and machine automation all play an important role in producing quality pavements. Simplified machine functions that operators easily understand can help operators monitor other jobsite functions. Comfort features help alleviate operator fatigue and can lead to a continuation of proper paving techniques. Machine automation can help ensure consistent asphalt placement, leading to better quality surfaces and longer lasting roads.”

Such end results make not just paver operators but all parties, particularly

Most manufacturers are beginning to use symbols so that regardless of the operator region/ language preferences, the operator can easily understand the functions

project owners, much happier at the end of the day and at the end of a project.

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The seats and controls mounted to the seat station slide out past the side of the machine for increased visibilty.

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JOBSITE INNOVATIONS Case DV Series Highway Rollers The DV207, DV210 and DV213 double-drum, large asphalt compactors deliver dual amplitudes, dual frequencies and centrifugal forces to meet the needs of various paving applications.

• Independent drum vibration control combined with two operating frequencies • Automatic vibration control ensures smooth starting and stopping ForConstructionPros. com/10244808

Dynapac F800W Asphalt Paver The Dynapac F800W wheeled paver offers a paving capacity of up to 1,000 tph and 8- to 19-ft. paving widths.

• Carlson EZIV08-15 vibratory front extension screed • 34-kW, hydraulically driven, oversized generator heats the full width of the screed at all times • Smart controls automatically lock screed, halting leveling, feed and vibration when the paver comes to a stop • Dual, swing-out operator platforms • Two-speed hydraulic motor and heavy-duty torque hub provide ample tractive force for paving and enable transport speeds up to 11 mph • 173-hp Cummins QSB 6.7 Tier 4 Final engine ForConstructionPros. com/12214773

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Vögele MT 3000-2i Material Transfer Vehicle The MT 3000-2i material transfer vehicle from Vögele offers optimal performance in a new-design MTV for asphalt paving.

• The unit weighs 56,000 lbs. and has an 18-ton storage capacity, making it heavy enough to get the job done but portable enough to haul with minimal hassles.

• Low profile gives it a low center of gravity, and it can move 1,300 tph • Active remixing is achieved by two 16-in.-diameter conical augers in the receiving hopper ForConstructionPros.com/12113037

BOMAG BW138AD-5 Economizer

Carlson CP130 Commercial Paver

The BOMAG BW 138 AD-5 tandem vibratory roller is the perfect all-round roller for paving contractors and municipalities.

• 54.3-in. rolling width, 35.4-in. drum diameter • Dual vibration frequencies of 3,000 and 3,360 vpm offer rolling speeds reaching 3.8 mph while maintaining proper impact spacing on asphalt projects

The CP130 commercial-class paver offers a single-slide EZCSS 8-ft. to 15-ft. electrically heated screed with power extension height, power slope and power crown.

• 130-hp Cummins QSF3.8 Tier 4 Final engine • One-piece forward tilting hood, large side doors and access panel in the hopper for service and accessibility to engine compartment

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Caterpillar Grade & Slope System for Asphalt Pavers This 2D system allows paver operators to place the exact amount of mix on the surface for better compaction performance, optimal material usage and improved mat quality.

• Can be equipped with single or dual LCD displays with text-based menus offering multiple language options • Can be configured to control elevation to one or both sides of the screed, crossslope and elevation plus cross-slope • Can be equipped with sonic or contacting grade sensors ForConstructionPros.com/10983751

Roadtec MTV-1105e The rubber track MTV-1105e transfers asphalt material from a truck to a paver for non-contact paving.

• With tracks made for any environment, you never have to worry about the jobsite base. If the ground is solid enough for paving, the MTV-1105e smoothly and effortlessly carries material anywhere you need • Operator station gives exceptional visibility from the dump hopper across the low-profile design back to the paver. This position allows the option of the main operator signaling truck dumps while leading the pave • Innovative staircase entrance instead of ladder allows the crew to cross over the machine, and over the paving line, instead of moving between equipment • Sized for mass discharge from standard haul trucks, the front hopper allows trucks to unload fast

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PRESERVATION UPDATE |

JESSICA LOMBARDO, EDITOR-IN-CHIEF

How to Use Chip Seals for Pavement Preservation When a chip seal is applied to a pavement in good condition, pavement life can be extended six to eight years, making this preservation treatment ideal for low volume roadways

A

ny asset owner knows that preserving their pavement is the most important thing they can do to protect their investment. Pavement preservation methods, like chip seals, helps pavements in good condition last longer and are more cost effective than remove and replace.

A chip seal is designed to seal and protect a pavement from oxidation and weathering by sealing minor cracks in a pavement surface and preventing the intrusion of water and air. A chip seal can also be used to address raveling (loss

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of fines), correct bleeding and flushing problems and generally extend the pavement life.

"Chip seals can also add skid resistance," Larry Tomkins, vice president of sales and marketing at Ergon Asphalt & Emulsions says. "If we have a somewhat smooth surface, we can put a chip seal on top of that and it will increase skid resistance immediately."

While chip seals can extend the life of certain pavements six to eight years, they are not suited for all pavements; the existing structure should be sound with only minor surface defects as they are not appropriate for rutted, potholed, or severely distressed surfaces.

"Chip seals consist of spraying a layer of asphalt on a surface and then covering that binder with aggregate," Tomkins says. "However there are different designs to take in to consideration before completing the work."

Because of the importance of chip seals as a preservation technique, a great deal of work has been done recently to move to a more engineered, technical approach. Advancements have been

made in materials, design and testing procedures and application equipment.

Material improvements include the use of polymer modified emulsions, tighter specifications on the use of one-size chips, using fibers, crumb rubber additives, etc. Computerized equipment has also been developed that makes placing a uniform application of materials easier and allows for simpler adjustments in progress.

THE IMPORTANCE OF AGGREGATE SELECTION Binder and aggregate need to come together at the correct rate in order for a chip seal to be successful so it's important to make sure you're not only selecting the right materials, but that they are also being distributed in the proper amounts.

Aggregates in a chip seal are used to resist traffic abrasion, transmit wheel loads, improve surface friction and safety. Therefore, several factors need to be taken in to consideration when choosing an aggregate for your chip seal application. Tomkins says there are

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PRESERVATION UPDATE

4. CLEANLINESS

six factors to consider when choosing an aggregate; Type, Gradation, Particle Shape, Cleanliness, Toughness & Soundness and Absorption.

You want to make sure you have as clean of a rock as you can get with 1% or less passing the #200 sieve.

"Dusty aggregates will prevent bonding with the binder," Tomkins says.

"Any time you can limit the amount of dust you have in your aggregates, the better. If you can't limit the amount of dust, then you need to take that in to consideration when selecting your emulsion."

1. TYPE There are two main types of aggregate; natural and synthetic. Natural aggregates are limestone, granite, gravel, etc. Slag, quartzite, expanded clay and bauxite are a few examples of synthetic materials. What type you choose will depend on cost and what materials are available in your area.

2. GRADATION When it comes to gradation, the ideal situation would be to have aggregates all one size as that will provide maximum friction and will be less sensitive to variations in binder application rates.

Single size aggregates will provide uniformity when placing the binder and better drainage.

3. PARTICLE SHAPE We want to limit flat or elongated particle shapes as they are susceptible to bleeding or excessive chip loss.

Aggregates that are too round should also be avoided as they are susceptible to rolling and displacement by traffic.

Angular aggregates on the other hand are not as susceptible to rolling displacement by traffic and they also lock together better.

5. AGGREGATE TOUGHNESS & SOUNDNESS The aggregates you select for your chip seal should be abrasion, degradation and polishing resistant. They should also be selected to weather freeze-thaw cycles.

"You want to consider having a Los Angeles abrasion, British Wheel or other requirement in your specification that helps you make sure you have a nice tough aggregate," Tomkins says.

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6. AGGREGATE ABSORPTION The final consideration when choosing an aggregate is absorption. The more absorptive the aggregate you have, the more binder that will need to be applied. Tomkins says that pre-coated aggregates may also be used to address the absorption of the aggregate.

"If aggregates are absorptive, like limestone, and I place them on top of the emulsion and it sucks up some of the binder into the aggregate, I might not have enough to keep the aggregate in place and I want to take that in to account in my design," Tomkins says.

"Hot-applied chip seals usually do have pre-coated aggregates which adds a little more cost however it definitely helps out."

CHOOSE THE RIGHT BINDER The binder or emulsion that you select will need to have good coverage, adhere to the aggregate and stay in place, and seal minor cracks. The material should be fluid yet viscous, develop adhesion quickly and not bleed when applied.

"You do not want the binder to run off the roadway when applied and you want to be able to get traffic back on it quickly," Tomkins says. "There are a few different types available and you want to select the one that will work best for your application based on these advantages and disadvantages."

No matter what type of binder you choose, you need to make sure you are putting the material down in ideal conditions. Before beginning the sealing work, prepare and clean the existing surface. Fill any potholes, level the ruts and seal large cracks. Weather conditions during construction also have a direct influence on performance so the

weather should be warm and dry to promote proper binder setting and curing.

Make sure the surface temperature is also warm enough to accept the material. Monitor the weather forecast to avoid potential weather problems and avoid possible chip loss.

Traffic volume needs special attention once the material is placed.

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PRESERVATION UPDATE

If your specification doesn't have a chip seal design requirement, Tomkins says it's a best practice these days to add one.

"Just because you specify a type of aggregate or a size, if you have a range built in and they go with the smallest or largest size, that will impact the project significantly," he says.

There are two common methods for chip seal design:

1. MCLEOD METHOD

Chip Seal Limitations While these pavement preservation techniques are great for certain pavements, it’s important to note where chip seals are not recommended.

Chip seals are not intended to add any structural life to an asphalt pavement as they do strengthen the surface them or increase the load-bearing capacity.

Chip seals are also not designed to smooth rough pavement, bridge cracks winder that ¼-in. or address ruts great than ½-in.

The traffic speed should be reduced/ controlled until the binder sets, the rolling has been completed and the first brooming has occurred. Take particular care to avoid scuffing and hard braking on the new surface.

CHIP SEAL DESIGN Now that you have the proper aggregates and the right binder, it's time to put them together in a system that works.

"In years past, there have been a lot of people that have done chip seals for a very long time. They knew what worked and what didn't work," Tomkins says. "As the older generations retire, this information has not been passed down as well as it should be and the new people don't really know where to start. A chip seal design will give you a good start on what you need in terms of application rates."

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The McLeod Method is mainly used with emulsified asphalt and is based on the principles that aggregate will be one-stone thick and that there will be 70% embedment for good performance.

"We're more worried about aggregate staying in place in climates where there is snow and where snowplows could be picking up some stone," Tomkins says.

"We definitely want higher embedment rates in the north whereas we may be able to get away with 50% embedment in the south."

Aggregate application rate in the McLeod Method is dependent on gradation, shape and specific gravity.

"Gradation and shape are huge when deciding how much aggregate you should place on the ground," Tomkins says.

Binder application rate is dependent on aggregate gradation, absorption and shape, traffic volume, the existing pavement condition and the residual asphalt content.

"If traffic volume is really high, you might not put as much binder out," he says. "If you have a real porous surface, you also need to take that into account when putting binder down."

2. MODIFIED KEARBY (AASHTO METHOD) The Modified Kearby Method was designed originally for hot-applied asphalt cements.

Aggregate application rate is calculated based on the dry/loose unit weight, bulk specific gravity and the board test.

"The board test is used to find the quality of aggregate on a board of known size such that full coverage, one stone in depth, is obtained," Tomkins says." A one-half square yard area is typically used and weight of the aggregate applied in this area is obtained and converted to units of pounds per square yard."

Similar to the McLeod Method, the binder application rate on the Kearby Method is calculated based on embedment depth, bulk specific gravity of the aggregate, traffic volume and existing surface condition.

Traditionally, chip seals have provided a quick, reliable and economical surface treatment that seals out water, improves rideability and preserves a pavement for years.

When a chip seal is applied to a pavement in good condition, six to eight additional years of service is a typical expectation when done correctly.

Technological advancements in testing and design procedures, materials and equipment have significantly reduced the dependence on experience and judgment associated with chip seals of the past. Today’s chip seal can be reliably placed on a variety of pavements under a wide variety of conditions and should be considered for your pavement preservation projects.

For more information on surface treatments, visit ForConstructionPros. com/21034462

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3/9/21 10:18 AM

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3/9/21 10:18 AM

PRESERVATION UPDATE

City of Phoenix Gives

RAP

a Test Drive

Recycled asphalt had never been used on roadways in the city before a paving contractor presented them with the evidence of its performance

48

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s the fifth largest metro in the U.S. with a population of more than 4.8 million and 1,400 miles of paved roads, the city of Phoenix, AZ conducted its first ever recycled asphalt pavement (RAP) overlay pilot project on a laned road in 2020.

Historically, the city and the road construction industry haven’t explored the benefits of RAP on

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laned roads given misconceptions of its performance and a lack of shared research.

All of that changed when the team at Solterra Materials, a Phoenix-based asphalt mix company, presented a compelling case to the city that it was time to roll out a trial section to demonstrate what they already knew.

The City of Phoenix admits

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3/9/21 10:20 AM

ASPHALT PLANTS AND

COMPONENTS

www.tarmacinc.com

they have been slow to adopt RAP because they hadn’t had the opportunity to really analyze its properties first-hand until Solterra Materials shared their findings. Based on those initial lab results, the city understood that RAP used in conjunction with a rejuvenator, was the best option and gained the confidence needed to move forward with the pilot program.

Solterra Materials, working with the city and its street transportation department, as well as input from the Arizona Department of Transportation, set out to demonstrate the benefits of RAP on city streets (beyond use for dust suppression in alleys

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contact tarmac at 816-220-0700 or info@tarmacinc.com MARCH/APRIL 2021 ASPHALT CONTRACTOR

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PRESERVATION UPDATE

damaged properties while adding many other performance benefits. These benefits include reduced compaction temperatures up to 45° F, lower VOCs, low volatile mass loss and enhanced low temperature cracking resistance.”

Following extensive lab evaluation of RAP properties at 10%, 15% and 25%, a nearly onemile test section of the heavilytrafficked arterial Buckeye Road, just west of downtown Phoenix, was selected for the pilot program.

and road shoulders), a first for this large metro market.

Using Cargill’s Anova® Rejuvenator, the City of Phoenix can now realize cost savings and environmental benefits including a reduced need for virgin materials, minimized energy use and a reduction in greenhouse gas emissions.

for the surface course containing 20% RAP. “The mix with Cargill’s Anova Rejuvenator performed the best compared to all of the other mixes and costs less,” said Pat Weaver, president of Solterra Materials. “Today’s biobased chemistries actually restore the RAP binder’s rheological and other

SOLUTION Because Arizona asphalt is extremely stiff and brittle, Solterra looked at a number of rejuvenator types (fatty acids, vegetable oils, petroleum-based and vegetable oil blends) to see which application provided the best results.

It was determined that Cargill’s engineered vegetable oil-based Anova Rejuvenator, with a slight asphalt grade bump, was the most effective.

Following extensive lab evaluation of RAP properties at 10%, 15% and 25%, a nearly one-mile test section of the heavily-trafficked arterial Buckeye Road, just west of downtown Phoenix, was selected for the pilot program. Solterra worked closely with the Cargill team to dial in the right Anova Rejuvenator dosage, producing 2,300 tons of hot mix

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RESULTS Lab testing showed that the 20% highly-aged RAP with the correct dosage of Anova Rejuvenator performed as well as virgin mixes.

The mix delivered a 10% cost savings and overall performance indicators are also showing positive results, including flexibility index increase from 12 to 18.5 as measured by the I-FIT. The laydown contractor on the job shared that it was very easy to place, handle and compact.

“The mix with the rejuvenator handled well, was very easy to place and behaves like any standard warm mix asphalt. It’s awesome,” said Weaver. “I have been working with Cargill since we started our business 2.5 years ago and this project experience did not disappoint.”

Performance to date has prompted the city to compare its current surface mix against the 20% RAP version and will continue to make plans for expanding this with future paving.

“After several months since it was paved, we’re seeing strong results in terms of performance with no cracking

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3/9/21 10:21 AM

or rutting,” said Weaver. “I’ve personally driven on the road several times and it’s great. This is encouraging as this section is in a heavy industrial zone, so we see it holding up even better on residential streets.”

KEY LEARNING The city quickly realized the benefit and further potential of incorporating more RAP into its paving work moving forward. After seeing the performance first-hand and analyzing the initial results, it was evident to civic leaders that they have been missing out on key benefits such as reducing the need for virgin materials, reducing energy use at the mix plant, minimizing landfill space and greenhouse emissions as well as cost savings to local taxpayers.

Based on these initial results, the city has adjusted its spec to include more RAP and has plans to expand this in the future. The performance, cost and environmental benefits made it a clear decision to incorporate RAP as part of its standard paving strategy for the future. In April 2021, they plan to test even more road sections around the city with RAP to reinforce those early findings.

By being proactive in sharing industry best practices like using Anova Rejuvenator and being transparent

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with its mix development and testing, Solterra Materials was able to shift perceptions and begin to grow trust with a once skeptical audience.

“I believe the City of Phoenix is sold on it and is looking forward to seeing performance results in about six months to determine a longer term strategy with RAP,” said Weaver.

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Solterra worked closely with the Cargill team to dial in the right Anova Rejuvenator dosage, producing 2,300 tons of hot mix for the surface course containing 20% RAP.

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MARCH/APRIL 2021 ASPHALT CONTRACTOR

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PRESERVATION UPDATE Rio Rubber Track Inc. Carbide Milling Teeth Carbide Milling Teeth help increase proficiency on cold-milling planers and compact milling-head attachments.

• Structurally designed to last longer and increase material removal rates on equipment • Premium tungsten carbide tip with fortified body brazement • 100% structural wear-life integrity • Heat-treated hardened upper body superstructure • Full body/tip wear-life utilization • Heat–treated hardened retainer ring • Full wear-life tool holder protection

Trimble PCS900 Paving Control System for Milling Machines Version 2.1 of the PCS900 3D paving control system for milling machines helps contractors mill a smoother and higher quality surface, reduce machine stoppage and minimize rework.

• Hot swap functionality in the SPS930 universal total station maintains continuity and accuracy of milling operations without stopping the machine • Can be used on multiple machines and jobsites • Communicates directly with factory-installed 2D systems for most milling machines • Allows the operator to control 2D and 3D sensor configurations from a single display ForConstructionPros.com/10083522

Cimline DuraPatcher The DuraPatcher Truck mount is the solution for ready to work patching. The spray patcher removes the pothole in one quick and cost effective 4 step process.

1. Clean the area with compressed air 2. Apply an emulsion tack coat 3. Fill the hole with coated aggregate

ForConstructionPros. com/10942546

Caterpillar RM400 Rotary Mixer The 51,809-lb. RM400 rotary mixer features an 8-ft. cutting width and is powered by a 417-hp C9.3 Tier 4 Final engine.

Weiler S200 Soil Stabilizer The S200 soil stabilizer features either a soil or combination rear-mounted rotor powered by dual planetary drive motors with a 150-rpm maximum drum speed.

• The 78-in.-wide drum has a 14-in. maximum working depth • Automatic depth set point feature allows the operator to set the desired rotor depth and return to it with the push of a button • Automatic load control anti-stall feature monitors system pressures to set ground speed to maximize efficiency and eliminate overloading the mixing chamber and stalling the rotor • Operator seat slides across the platform and rotates 357° for enhanced visibility.

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• Standard all-wheel drive utilizes four independent drive pumps for maximum torque, traction and speed • Three different rotor speeds help deliver the desired material gradation and the electronic controller keeps the rotor at the proper depth and machine at a consistent speed to ensure optimal blending performance • Four rotor options are available

4. Cover with dry aggregate so traffic can resume immediately • Vent-Flo nozzle • Ergonomic no-stress Boom • 6 yd. aggregate hopper ForConstructionPros. com/12270445

ForConstructionPros. com/21086837

Roadtec SX-5e Stabilizer-Reclaimer The Roadtec mid-size SX-5e stabilizer-reclaimer features a new 513 hp Cummins QSG12 engine.

• The SX-5e complies with Tier 4 Final and Stage IV emission standards • Weighing in at less than 58,000 lbs, the SX-5e is nimble yet powerful • A high torque hydrostatic cutter drive and multiple cutter speeds provide performance in both soil stabilization and asphalt reclamation • A climate controlled cab extends the width of the machine providing a comfortable work space and enhanced visibility ForConstructionPros.com/21092531

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3/9/21 10:25 AM

· Gencor 300 TPH counterflow drum mix plant · CMI 350 tph portable drum mix plant · Astec 350 tph Relo Double Barrel plant w/4 silos · Barber Greene 350 tph portable drum mix plant · 350 tph counterflow drum mix plant · Gencor 7’X40’ counterflow plant · Adm 100 tph stationary plant with silo & RAP · ADM 110 tph portable drum plant · Cedarapids 350 tph counterflow drum and baghouse · 150 TPH Stationary drum mix plant · Barber Greene 10,000# Asphalt Batch Plant · Astec control house with Astec PM ll controls

· · · · · · · · · · · ·

80,000 CFM Stationary Baghouse Astec 6’X33’ Double Barrel drum only Astec 36” x 96’ slat conveyor Gencor 70,000 CFM baghouse Astec 400 tph Double Barrel only Astec 75 ton self-erect silo ADM 42,000 CFM portable baghouse Bituma 100 ton silo & slat conveyor Astec pugmill coater Dillman mixing drum Gencor 88”X32’ aggregate dryer 15,000 gallon asphalt tank with hot oil heater · 35,000 gallon skid mounted coiled asphalt tank

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             

ASPHALT PLANTS

 

 

   





 

 

          

t

CLASSIFIEDS             

       

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CLASSIFIEDS

Pri

ts

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www.ForConstructionPros.com/Asphalt

3/9/21 10:26 AM

t

CLASSIFIEDS

USED GILSON ASPHALT CONTENT FURNACES

ALL INQUIRIES: Taylor Hawbaker • tph@goh-inc.com • 814.404.5105 PUMP PACKING Stop your pumps from leaking!

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Viking®, Roper, Rotan, etc.

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Index Advertiser Index

PAGE

ALMix

9

Asphalt Drum Mixers Inc. (ADM)

12-13

Astec Inc.

30-31

Bomag Americas

19

Cargill Inc.

2

Carlson Paving Products Inc.

59

Etnyre International

45

Eager Beaver Trailers

53

Gencor Industries Inc.

3, 5

Homestead Valve

29

LeeBoy, Inc.

17

Libra Systems Corp.

44

Meeker Equipment Co. Inc.

25

Minds, Inc.

39

Pegasus Vans & Trailers, Inc.

41

Process Heating Co.

11

Roadtec

60

Sapphire Gas Solutions

43

SealMaster

15

Site Safe

51

Superior Tire & Rubber Corp

37

Systems Equipment

47

Tarmac International, Inc.

49

TransTech Systems, Inc.

27

Weiler Products

21

Wirtgen America Inc.

7, 35

MARCH/APRIL 2021 ASPHALT CONTRACTOR

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3/9/21 10:27 AM

THE LAST EXIT |

JESSICA LOMBARDO, EDITOR-IN-CHIEF

Road Building Industry Fights for Surface Transportation Funding

AdobeStock/ adam121

Experts say the highway materials sectors need to push for higher amounts of funding for a robust surface transportation bill and to do that, Congress needs to enact a sustainable and equitable funding mechanism for the Highway Trust Fund

I

t's no secret that the lack of sustainable highway funding is the biggest challenge in the industry. The Biden Administration has made it clear that infrastructure funding is a priority on their agenda, but what that funding looks like for highway contractors remains to be seen. For Democrats, infrastructure funding means finding ways to combat climate change and build structures using green initiatives.

Biden is putting these green initiatives front-and-center in his “Build Back Better” infrastructure proposal that calls not only for building roads and bridges, but also for investments in electric vehicle charging stations, zeroemission buses, transit and zero-carbon electricity generation by 2035.

This expansive look at what infrastructure means to our nation, puts what money we will receive for our roadways on the backburner as Democrats look to add funding for waterways, broadband and more to an infrastructure package.

During the National Asphalt

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Pavement Association virtual annual meeting, experts weighed in on where they think the industry should focus.

"Democrats are trying to reduce money for highways, forcing people to get out of cars and into public transportation," Stan Bass, chief growth officer at Vulcan Materials says. "We need to focus on the highway program. When we talk about infrastructure, we can’t assume people on The Hill know we’re talking about highways. We need to make it known that we need a multi-year surface transportation measure. No matter what other infrastructure is captured in these funding packages, we need to focus on a surface transportation package."

FINDING A SUSTAINABLE, EQUITABLE FUNDING MECHANISM Driving green initiatives forward puts the road building industry at risk, especially as vehicles transition to electric and gas tax revenues continue to dwindle. Democrats have not come up with a clear proposal to replace the gas tax, which has been the traditional source of funding for surface transportation infrastructure, leaving the Highway Trust Fund (HTF) in dire need of a new funding mechanism.

Democrats have been quick to push an increase to the corporate tax rate to fund infrastructure but experts say that isn't the answer.

"Corporate tax increases head towards eliminating the Highway Trust Fund which won’t give states the visibility to see the money they are going to have to build long term projects," Bass says. "If they don't have visibility to those funds, how will they know what projects to invest in?"

The industry instead should continue to push for new user-based fees that are

more sustainable long term than the gas tax.

"When we look at the electric vehicle space today, it represents 1% of vehicles on the road. But when you look at the polices to push EVs, that’s the principle concern from the financing standpoint with the gas tax becoming obsolete and underfunded," John Janes, president & CEO of Associated Asphalt says. "We need to find a funding mechanism that is balanced, equitable and sustainable.

Something that reflects usage and consumption."

Many states are already experimenting with pilot programs for vehicle miles traveled (VMT) or road usage charges and even Transportation Secretary Pete Buttigieg talked of these fees at his confirmation hearing, acknowledging that privacy and technological concerns accompanying a VMT fee would need to be resolved before being rolled out nationwide.

At the end of the day, everyone seems to be in favor of the concept of infrastructure, or at the very least the word infrastructure. It’s when you start getting into the specifics of what kind of infrastructure you build, where you build it — and the big one no one wants to answer, how do you pay for it — that’s when you get into difficulties.

"As an industry, we are optimistic about a highway bill coming through," Kirk Randolph, senior vice president, strategy & development at CRH Americas Materials, Inc says. "We need everyone in our industry to mobilize their grass roots efforts. This is the best opportunity we've seen in 10-15 years to get a substantial bill."

For more information on infrastructure funding, visit ForConstructionPros. com/21283858

www.ForConstructionPros.com/Asphalt

3/9/21 10:28 AM

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3/9/21 10:28 AM

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