Asphalt Contractor June/July 2015

NEW rubber modifiedhelps asphalt products stateson taking another lookPage at GTR Technology meet nightlyhave deadlines airport project 30 Page 16

EXCLUSIVE REPORT How intelligent compaction increases your bottom line

•

Page 56

Recycled asphalt takes a

LEAP

forward Page 14

Asphalt made from

algae?

Page 70

UPSCALED

STORAGE Charles Blalock & Sons adds long-term storage to increase the number & type of mixes offered during production

Page 42 JUNE/JULY 2015 • www.ForConstructionPros.com/Asphalt

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U N MATC HED O VE RF IL L PROT E CT I O N Overfilling an asphalt tank can create a big mess and require a lot of cleanup effort. Tank gauge boards, radar level systems and/or level systems using pressure transmitters are normally setup to prevent overfilling a tank.

They are wired into circuits that shutoff the unloading pump when the tank is full. But these can fail unexpectedly, especially if they are not properly maintained.

Our backup system uses a highly reliable float with proximity switch to shut off the pump in case the other device fails.

It is included on every asphalt storage tank and will pay for itself by preventing overfills and eliminating their cleanup costs. For payback you only need to prevent a single overfill.

Our goal has never been to make the lowest priced products. Instead, we strive for our products to be the best in quality and best value for the buyer.

Please call today for more information.

HEATEC H E AT E C , I N C .

®

an Astec Industries Company

5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com Search: 10073245

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GENCOR MEGAPLANTS Bigger, cleaner, faster

Only Gencor builds MegaPlants that use less energy and produce more tonnage faster than any other manufacturer. When you want real performance, think fast, think big, think Gencor.

Call 407.290.6000 or visit www.gencor.com for more information.

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COVER STORY

CONTENTS

JUNE/JULY 2015

14 PAVING INNOVATIONS

14 Recycled Asphalt Takes a LEAP Forward

PLANT MATTERS

Low Energy Asphalt Pavement (or LEAP) is a durable HMA that’s made with 100% recylced material.

42 Upscaled Storage Helps Meet Customer Demand

Charles Blalock & Sons added long-term storage to increase the number of mixes that can be offered during a production cycle.

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C li f N ot f’s es 24 24 EJ Paving Takes Lead on Massachusetts Race Course Project

Tracked paver tackles tight turns and dual passes on the Palmer Motorsports Park project.

26 Paving Products

Pavers, rollers, screeds, material transfer vehicles & more.

30

48

PAVEMENT PRESERVATION

PLANT MATTERS

30 Nightly Deadlines No

Match for Technology in Albany Runway Repaving Project A new paver and paving control system help Rifenberg meet tough tolerances and a performance-based spec for roughness and rideability.

48 Cliff’s Notes

How to choose the right asphalt plant operator.

50 Plant Products

Plants, baghouses, mixers, dryers, silos, automation system

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

50

Dillman builds tough equipment.

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

Dillman gets the job done

Search: 10072736

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CONTENTS QUALITY CONTROL TECHNOLOGY GUIDE

56 How Intelligent

Compaction is Important to Your Bottom Line The latest IC technology can help contractors save time, reduce fuel consumption, improve job quality and increase their ROI.

WHAT’S ONLINE www.ForConstructionPros.com/Asphalt AGC WANTS TOUGHER LAWS TO PROTECT ROAD CONSTRUCTION WORKERS New data shows nearly half of road contractors suffered car crashes in work zones.

Search: 12076555

HOUSE PASSES SUMMER ROAD FUNDING FIX Two-month extension approved in House by 387-35 vote; moves on to Senate.

Search: 12075948

In Every Issue 8 Editor’s Perspective A “grass” roots effort for funding roads.

10 New Product Preview 69 Advertiser Index 70 The Last Exit Green is the new black with asphalt made from algae.

BETTER RURAL ROADS NEEDED, SAYS TRIP TRIP (The Road Information Program) recently released an important study, “Rural Connections: Challenges and Opportunities in America’s Heartland.” Like the rest of the country, the research shows that rural America needs infrastructure upgrades.

Search: 12076610

WHAT DOES SEARCH: 100000000 MEAN? Each product and advertisement found in Asphalt Contractor’s pages has a unique 8-digit code that can be entered into the search bar found at the top of www.ForConstructionPros.com/ASPHALT. By searching for the unique number, you will be instantly taken to the specific piece of online content where you can find more images, online exclusive information, related products and videos, and more!

June/July 2015 Vol. 29, No. 5

Published by AC Business Media Inc.

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

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Published and copyrighted 2014 by AC Business Media Inc. 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 Inc., 201 N. Main Street, Fort Atkinson, Wisconsin 53538. Periodicals postage paid at Fort Atkinson, Wisconsin and additional entry offices.

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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June/July 2015 • Vol. 29, No. 4

EDITOR'S PERSPECTIVE

A “grass” roots effort for funding roads

W

ith highway funding in a constant place of uncertainty, many states are looking for unique ways to find money to pay for our roads. One legislator may have found a very green alternative to traditional funding sources.

With attitudes toward marijuana quickly changing in the U.S., one state legislator in Michigan has recently suggested raising a “grass” tax instead of a gas tax to fund roads, police and schools.

Democratic state Rep. Brandon Dillon represents the 75th House District, which includes part of the city of Grand Rapids. East Lansing recently became the latest city in Michigan to decriminalize marijuana, following other cities such as Ann Arbor, Detroit, Ferndale and Mount Pleasant. When decriminalization was put before Grand Rapids voters in 2012, 60% said yes. In an opinion piece on mlive. com, Dillion wrote that recent surveys show more than half of Michigan residents are in favor of legalizing, regulating and taxing the adult use of marijuana.

There are many concerns with legalizing marijuana – one being an increase in crime. That hasn’t been the case in Colorado, Oregon, Washington and Alaska, however, where marijuana is already legal and regulated. In fact, Dillion points out, the year after regulated marijuana was approved in Colorado, violent and property crimes fell 6.9%.

Similarly, in states that have approved the medical use of marijuana, alcohol-related fatalities have fallen 12%. Dillion also feels taking marijuana off street corners and tightly regulating its production and sale will make it less available to minors.

Legalizing marijuana can bring a lot of money into a state. This has been proven by states that not only regulate, but tax marijuana. Colorado imposes a 15% wholesale excise tax and 10% sales tax on marijuana. Along with other various license fees, medical and recreational marijuana receipts have added $76 million to state coffers last year. Other states are experimenting with different tax structures, but all anticipate higher state revenues that can be spent on roads, schools, police and other priorities, says Dillion.

Of course, taxes raised from regulating marijuana won’t be a magic bullet for Michigan or any other state looking to fund roads. It would be a big step, however, for generating some much needed revenue which could help us avoid raising user fees like the gas tax. What do you think about legalizing marijuana to fund roads?

Let me know at LCleaver@ACBusinessmedia.com.

On a different note, this month our website, ForConstructionPros.com, debuted its Profit Matters channel which highlights how contractors are improving profitability by implementing technology and best practices throughout their company operating structure. Be sure to check it out at ForConstructionPros.com/ profit-matters.

Thanks for reading! ■

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Published by AC Business Media Inc.

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

Publication Staff Publisher

Amy Schwandt

aschwandt@ACBusinessMedia.com Editor

Lisa Cleaver

lcleaver@ACBusinessMedia.com

Associate Editor

Jessica Stoikes

jstoikes@ACBusinessMedia.com

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Patti Brown

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ForConstructionPros.com Digital Operations Manager

Nick Raether

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Editor

Larry Stewart

Managing Editor

Kimberly Hegeman

Change of Address & Subscriptions PO Box 3605, Northbrook, IL 60065-3605, Phone: (877) 201-3915 • Fax: (800) 543-5055 circ.AsphaltContractor@omeda.com

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Anil Narang

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Debbie George

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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THE UNIFIED “UF” SERIES DRUM

SINGLE DRUM COUNTERFLOW

PROS: RUGGED! SKID MOUNTED or PORTABLE Built to last WARPAGE Resistant

NO

SACRIFICES COMPROMISES

CONS:

YOU DON’T OWN ONE YET 13333 Highway 24 West Fort Wayne, IN 46814 Tel. (260) 672-3004 Fax. (260) 672-3020 www.almix.com Search: 10071910

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NEW PRODUCTS

Topcon P-32 PAVING SYSTEM Control asphalt in the heat of the moment

T

opcon Positioning Group announces advances to its P-32 asphalt paving system with new components including the ST-3 sonic tracker, anti-vibration slope sensor and a firmware update to the full-color, graphical display GC-35 control box.

The P-32 paver system was built to improve smoothness and ensure accurate slope and material thickness.

A firmware upgrade to the GC-35 full-color, graphical display control box provides enhanced slope accuracy data.

Additionally, block slope calibration protects users from accidently changing the slope sensor while the P-32 system is in operation.

Search: 11322813

Hydronix Hydro-Probe The latest version of the Hydronix Hydro-Probe has been re-engineered to take advantage of increased microprocessor speeds and memory.

• Designed for measuring moisture in bins and on conveyors • Offers additional analog output • Allows the simultaneous output of moisture and temperature • Sensor’s filtering and averaging functions have also been enhanced to give greater flexibility when optimizing the sensor’s performance in continuous type applications such as conveyor belts Search: 10078809

Cedarapids CRS620S Screen Plant Neal ESSP 1500 Sealcoating Machine The 1,500 capacity of the ESSP 1500S reduces the time associated with refilling tank on large projects and the number of trips needed to make to the sealer manufacturer or distributor.

• Electric super sand pump (ESSP) system features variable speed control and produces up to 100 gpm • In-line surge tank that reduces material surging to ensure continuous flow of material for uniform coverage • Hydraulic agitation system with chain reduction features a unique threeblade design; the blades are offset to ensure two blades are in the material at all times, which produces a more thoroughly mixed product • Shaft of the agitator is made with solid steel for exceptional strength, durability and long wear life

Terex Minerals Processing Systems expands its CR Series portable plant line with the addition of the Cedarapids CRS620S screen plant.

• Patent-pending LJ-TSV screen combined with El-Jay high G-force oval stroke motion with adjustable slope operation • Can handle larger deck loads and larger screen openings • Hydraulics quickly change the screen slope in 2.5° increments up to a maximum of 7.5° to best fit the application • Screen openings up to 6 in.

• Patent pending “slant spring” screen suspension provides stability • Two 30-in.-wide reversible cross conveyors which extend up to 42 in.

Search: 12047145

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Hamm GRW 280i Pneumatic Roller The GRW 280i pneumatic roller updates its predecessor with subtle design changes and a new 114-hp Deutz Tier 4i engine.

• 82-in. working width • Basic operating weight ratings available from 19,371 to 58,947 lbs.

• Revised ballast compartment allows users to vary the operating weight • Includes a high-speed tire inflation system and standard oil service valve • Viewing channels in the frame structure offer a view of the edges and the tires of the outer wheels • Operator’s platform with movable, pivoting driver’s seat rests on an asymmetrical frame • Speed controlled via joysticks • Hydrostatic rear xle drive allows for higher speeds during transport and compaction Search: 12039375

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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NEW PRODUCTS

Plant Operation Web Training with Personal Mentoring from Clarence Richard

Carlson LED Blade Light Utilizing an innovative mounting system that allows simple adjustments to direct light to where it is needed, the LED Blade Light eliminates shadows and extends the distance for delivering light.

• 90% less power needed than a traditional 2000-watt halogen balloon light • 12/24vdc or 120/240vac platforms enable use on wide range of equipment • Longlife LED’s with a life span of 50,000 hours • Available in one- or two-blade configurations, available in a 120/240VAC version or a 12/24VDC version, allowing it to be mounted on a wide array of equipment

Clarence Richard Services offers Plant Operation Web Training without leaving your home or office and completing it when you want.

• Training takes about 32 hours to complete segments at your own pace with no deadline • Training is available indefinitely • Training is narrated with animation and videos and can be completed from most computers with Internet connection • When you’ve completed a set of homework modules, e-mail request to set up a personal webinar for personal training to go over tests and other information; participant and the participant’s employer receives a Two Way Assessment and Transcript of achievements • Curriculum includes Plant Operation, Electro-Mechanical, Safety Director and Quality Control

The skid-mount RAP-100-SM is designed for small- scale production of recycled asphalt for pothole repair.

• Fully insulated mixing chamber consisting of a 24-in.-diameter double-ribbon mixer screw • 100,000-Btu propane-fired heater emits high-intensity heat from a 4’ x 16” fullsurface infrared heater, allowing re-heating of RAP or waste chunks of asphalt at a rate of 1 to 2 tons per hour • 1/2-ton batch can be processed at a time, and a batch can be re-heated in as little as 15 minutes with full heating capacity and minimal moisture conditions of RAP • Once processing is complete, the 6” x 6” discharge gate can be opened and the material augered out

Search: 12040410

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BOMAG BW11RH-5 Roller

Road Science ArrMuls 1315 Asphalt Emulsifier

The BOMAG BW11RH-5 pneumatic tire roller boasts 35° centerpoint articulated steering, delivering a short 10-ft (3.0-m) inside turn radius.

• Five front tires and four rear tires of the BW11RH-5 deliver a compaction width of 68 in (1,727 mm) with zero frame overhang, making this versatile roller for intermediate compaction of highways, urban roads, parking lots, driveways and chip-and-seal applications • Centerpoint steering joint offers +/10° oscillation to help maintain wheel contact with material at all times Search: 12056935

Search: 12041607

Heat Design Equipment RAP-100-SM Asphalt Recycler

Road Science launches ArrMuls 1315, an anionic slow-setting emulsifier that allows customers to produce emulsions with outstanding stability and pave roads faster and more efficiently.

• For multiple end-use applications, including tack coat, fog seal, pavement sealer, mixing-grade and industrial coatings • Designed for producing dilute and non-dilute emulsions that remain stable during extended storage and after repeated pumping cycles • Offers efficiency by being 70% active, requiring lower dosage requirements and reducing freight expenses • Non-lignin based, which protects against biological growth that can result in emulsion foul odor issues Search: 12058937

Guardian Angel from 425 Inc. 425 Inc.’s Guardian Angel, a wearable, portable, lighted safety device, gives construction workers extra visibility when needed, including on dark rural roads, the side of a major freeway, or in the middle of a large crowd.

• Provides enhanced safety and visibility for the wearer – and serves as a valuable compliment to HVSA • Provides greater enhanced light that can be seen from more than two miles away, from above, and from a nearly 360-degree radius around the wearer • Rechargeable, long-lasting batteries • Rugged housing design prevents damage in extreme work conditions • Modular mounting system Search: 12071984

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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THE FACES OF ASTEC PARTS

When Astec parts salesman GREG PAINTER is not calling on customers to support their parts needs, you can find him on the water fishing or in the woods hunting. But when you call, he’ll trade that fishing hat for a hard hat, because he is always your parts man.

An ASTEC parts salesman knows that being successful in his job means that you count on him to deliver when needed. So when you need a part, he will take the call because no matter what else he is, he is always your parts man.

Anyone can stock parts and ASTEC stocks the world’s largest inventory of parts for asphalt plants. But ASTEC doesn’t just stock parts.

ASTEC delivers the industry’s best customer service. That is what sets us apart.

Any part, any brand. We can help.

Search: 10072061

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PAVING INNOVATIONS

Recycled Asphalt Takes a LEAP Forward Low Energy Asphalt Pavement (or LEAP) is a durable HMA that’s made with 100% RAP

By Jessica Stoikes, associate editor

W

e like our acronyms in this industry: WMA, RAS, RAP, IC, etc. Each stand for innovative advancements in the asphalt paving industry. Well it’s time to add another to your vocabulary: LEAP. Low Energy Asphalt Pavement or LEAP is just like the hot mix asphalt you know and love, but cleaner, cheaper, greener and strong, all at the same time. Does this sound like what you’re customers are asking for? We thought so.

The LEAP product is a high performance hot mix asphalt (HMA) that’s made from up to 100% recycled asphalt pavement (RAP). As a contractor, you’re probably thinking a mix that contains that much recycled material will never last.

But what if it could? Typically, in most mature markets where mill and overlays are commonplace, for each ton of virgin asphalt produced there is ¾ of a ton of waste RAP placed in a pile for disposal; and these piles are everywhere. Just think about how much money your company would save making a mix with all recycled materials, not to mention how much better it would be for the environment.

“The Superpave specification, and most derivative state specifications, do not permit the use of more than 25% to 50% RAP within the HMA mix design,” says

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LEAP is a high performance hot mix asphalt (HMA) that’s made from up to 100% recycled asphalt pavement (RAP).

Mark Eliot, CEO of LEAP Technologies, Inc. “This is due to the inability of traditional batch and drum HMA plants to sufficiently heat the aggregate within the RAP to the temperatures necessary to meet baseline performance requirements.”

This is true as high RAP mix designs produced through conventional asphalt plants can cause lower than normal mix performance and often high concentrations of excess smoke, which can violate standard air permit regulations.

“The HMA produced using the LEAP process meets or exceeds minimum performance standards including TSR specifications for most states when using 100% RAP,” Eliot says.

How it’s made But how? Initially LEAP started working to produce a high performance, allweather pothole patch product.

“There are other companies around the globe working to produce high RAP mix designs, but it’s not simple or easy,” Eliot says. “The Japanese have developed a plant that produces a 65% RAP HMA mix design with 180-tph production rate, but the plant investment is a staggering $25 million.”

Advancements in PG modification, RAP handling and experimentation using alternative heat sources lead to the LEAP technology breakthrough in the Spring of 2012. Today, the LEAP patents cover design and process to convert 100% RAP

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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LLC

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PAVING INNOVATIONS into high performance HMA. Here’s how they do it: STEP 1: HARVEST. Old or failed pavement is milled off or removed. Material is trucked to the LEAP processing center.

STEP 2: IMPROVE. Aged pavement material is sized, stabilized and infused.

LEAP uses different PG emulsion formulas based on region and performance requirements.

STEP 3: INSTALL. Contractors pick up and install LEAP High Performance HMA using the same equipment and methods as conventional HMA. The IMPROVE phase is really all that seems different here, right? So what goes on at the LEAP plant?

Traditional drum asphalt plants heat virgin aggregates to 400° or 550°F using direct or in-direct open flame heat source.

After the aggregate has been heated, PG and RAP are introduced and mixed for a short time before exiting to the silo for storage.

LEAP plants on the other hand, have a smaller footprint than conventional asphalt plants. LEAP processes the RAP into injected/stabilized recycled asphalt pavement (I-RAP) which is kept at ambient temperature in storage until heating. On demand, the I-RAP is loaded into feed hoppers and conveyed through LEAP’s Low Energy Heating System (LEHs) unit. The production room is a clean room with advanced digital control features.

“There were companies in the ‘80s and ‘90s that experimented using microwave heating with limited success,” Eliot says.

“The LEAP discovery isn’t the heating method alone, but a combination of several unique processes that work in concert providing the ability to utilize 100% RAP mix designs to create a highperformance product.”

Eliot says LEAP utilizes an advanced microwave heating system, not the kind you would typically find in your home kitchen, to heat the I-RAP to a prespecified temperature prior to delivery to the paving contractors. This system, LEHs, uses the microwave energy to selectively heat the aggregate within the I-RAP, enabling LEAP to heat the mixture without degrading the asphalt cement within the emulsion.

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“Companies in the 80s and 90s experimented using microwave heating with limited success. The LEAP discovery isn’t the heating method alone, but a combination of several unique processes that work in concert providing the ability to utilize 100% RAP mix designs to create a high-performance product,” says Mark Eliot, CEO at LEAP.

The LEAP production room is a clean room with advanced digital control features.

LEAP plants have a smaller footprint than conventional asphalt plants.

LEAP processes the RAP into injected/ stabilized recycled asphalt pavement (I-RAP) which is kept at ambient temperature in storage until heating.

Old or failed pavement is milled off or removed and the material is trucked to LEAP processing center. There, the aged pavement material is sized, stabilized and infused. LEAP uses different PG emulsion formulas based on region and performance requirements.

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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UPGRADE YOUR DOWNWIND. Customized odor control for Asphalt and Bitumen Ecosorb – a leader in odor control for over 15 years – advances odor control with new customized odor control additives for asphalt and bitumen.

Scientifically adjusted to suit your unique asphalt formula, one gallon of Ecosorb® can treat up to 10,000 gallons of liquid asphalt or waste oil. Your customized formulation will quickly neutralize rather than mask smelly emissions.

Best of all, it’s cost-effective and safe for employees and the environment.

1-800-662-6367

omi-industries.com

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PAVING INNOVATIONS The energy wave produced is strong enough to fracture aggregate if desired, but because the product is heated from within, Eliot says there is no pollution created during production.

“After heating, the material is conveyed to a storage silo and ready for contractor pick up, similar to conventional asphalt plants,” Eliot says. “The simplicity of the plant design and ease of operation allows for 12-month production in any climate.”

Put to the test Any advancement in HMA technology can always seem too good to be true. No one ever thinks that the product that is being produced is going to be as good as what they’re used to using. That’s why they tested it.

LEAP retained American Engineering Testing (AET), out of St Paul, MN as their third party lab and advisor to test the HMA such that it may be compared against Superpave standards developed

by the U.S. Department of Transportation, Federal Highway Administration, and used for all paving projects that are funded in a whole or in part by federal funds.

The current principal measurement used for the evaluation of HMA is the tensile strength ratio (“TSR”) which is used to predict the durability of the HMA. Some southern states, notably Texas and Louisiana, have replaced the TSR measurement with the Hamburg Rut Test measurement, as HMA laid in elevated temperatures can become brittle.

Other states are slowly migrating to the Hamburg Rut Test for the more robust measurement of durability of the HMA “Dave Rettner, senior engineer at AET, was helpful designing extreme testing protocols for LEAP that revolve around mix performance; he is a fan of the Hamburg Rut Test,” Eliot says. “This test is performed using a wheel which is passed over an HMA sample until the ensuing rut exceeds 12.5 millimeters in depth.

Currently, LEAP’s High Performance HMA is being used by 26 cities/counties in the U.S.

The Hamburg Rut Test is used as a proxy measurement to ensure that the maltene fraction was not damaged during applications in areas where summer paving temperatures can prematurely age the HMA.” Eliot says this test was an important benchmark for the LEAP HMA (see Table 3) as the asphalt cement within RAP has been aged, and traditional HMA using RAP in excess of 25% has a proclivity to fail early due to the relative lack of maltenes.

“LEAP’s initial mix design (nicknamed ‘gorilla-mix’) was on pace to fail around 26,000 passes on the Hamburg Rut Machine had the machine not been regulated to stop at 20,000 passes,” Eliot says.

Performance mix specifications have yet to be developed by HMA manufacturers or adopted by DOTs. Current specifications are recipe-based aggregate mix designs or stone matrix designs. Understanding the barriers in place surrounding high RAP mix designs, LEAP is publishing performance mix specifications as a standard.

Why LEAP can work LEAP processes the RAP into injected/ stabilized recycled asphalt pavement (I-RAP) which is kept at ambient temperature in storage until heating.

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Virgin asphalt cement has two primary chemical components, asphaltenes and maltenes. Asphaltenes are hard materials that provide the mechanical strength while maltenes are the oily fraction which

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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50 YEARS OF INNOVATION. THAT’S A HECK OF A RÉSUMÉ.

VECTOR CONTROL

With over five decades of experience fueling it, the Equinox™ burner delivers unrivaled productivity while achieving the lowest NOx emissions of any burner on the market.

Combine it with the Vector Control for unbelievable fuel savings and the advantage is clear.

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PAVING INNOVATIONS

• What Can LEAP Do For You? • LEAP HMA will be priced similarly or slightly lower than comparable mix designs.

• Quicker compaction timeline reduces the need to wait for the mix to cool.

• Close out jobs sooner — LEAP mix provides the ability to install multiple lifts in a single day.

• LEAP mix has increased strength properties and terrific compaction traits which can translate to thicker single pass paving reducing the need to pave multiple passes on low to medium traffic installations.

• Quicker compaction and mix set time results in faster job completion and reduced traffic control costs.

• LEAP’s low emissions plant provides better strategic plant locations resulting in lower hauling rates.

• LEAP’s plant design allows for 12-month plant operation and thereby extending the contractor’s season. This can provide new high-profit revenue streams, i.e. emergency patching services for potholes or water main breaks.

• LEAP is a major CSR (Corporate Social Responsibility) player for businesses; contractors may increase their marketplace impact by using LEAP. LEAP’s Greenhouse Gas/Carbon footprint reduction and recycled content can help to earn LEED credits.

- CSR “is no longer an option – it is emphatically and indisputably a must-do” says 2013 Cone Communications Social Impact Study and Global CSR Study - 84% of Millennials (19-35) = 80+million Americans (first generation to grow up alongside cause marketing) consider a company’s CSR before deciding what and where to buy - CSR is a big factor in corporate dollar allocations; LEAP provides a path toward LEED

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Table 3 LEAP HMA Property Testing Results per AET, January 12, 2013(1) Property Superpave HMA SPWEB340B(2) LEAP Asphalt Cement or Emulsion 5.5 5.0 Content - % by weight TSR 80.9 83.4 Percent Air Voids 4.0 3.8 Hamburg Rut Test - 12.5 millimeter 8,500 20,000+(3) depths Bulk Specific Gravity 2.438 2.356 3(4) 152.1 147.0 Density, lb/ft Maximum Specific Gravity 2.540 2.396 (5) 68.1 226.3 Dry Tensile Strength, psi Soaked Tensile Strenth, psi 55.1 188.8 functions as the sticky component in HMA. Maltenes oxidize with age or excess heat to form asphaltenes which causes the HMA to become hard and brittle. The aged or heat damaged HMA cracks under heavy loads causing failures of the road surface.

“LEAPs handling and treatment of the RAP prior to injection, along with the emulsion formulation used in the injection, defines the final results of performance,” Eliot says.

“The microwave heating allows the new emulsion to bond with the old asphalt cement creating a fused surface material. Plant throughput is a function of the number of heating lines, power and desired exit temperature. LEAP has plant designs for 50 to 250 tph for less than half the investment of Japanese asphalt plants.”

Plant matters The entire production process of LEAP produces little to no VOCs or particulate matter, which provides the ability for production to take place indoors unlike conventional HMA plants. This advantage can allow for strategic plant placement in zones where conventional asphalt plants may be prohibited due to air pollution regulations. Optimal plant locations can reduce HMA haul rates potentially lowering the cost for installations.

LEAP is currently building several more plants throughout the U.S.,

LEAP’s initial mix design (nicknamed “gorilla-mix”) was on pace to fail around 26,000 passes on the Hamburg Rut Machine had the machine not been regulated to stop at 20,000 passes.

and in addition to the companyowned plants, LEAPs’ licensed plants and plant retrofits will enable this environmentally friendly technology to be incorporated into existing plants around the country.

“LEAP is excited to announce the development of a conventional plant retrofit design,” Eliot says. “LEAP will be licensing the technology this year to interested parties. The retrofit will allow conventional plants to monetize and dispose of the large piles of RAP while producing high performance, high percentage RAP mix designs, up to 100%. The cost is nominal compared to that of a new plant.

“The goal is to create a more sustainable and green way to produce asphalt here in the U.S. and beyond. We are interested in looking at supplying this technology to other countries to help them in their efforts of reducing greenhouse gas emissions/pollution and increasing their overall recycling commitment.”

Currently, LEAP’s High Performance HMA is being used by over 26 cities/counties as well as a number of paving contractors with regularity and success, and at any time of year. ■

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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The P385A Commercial Paver The P385A Commercial Paver

Outstanding Performance Powerful Results • Versatile Screed • Durable Undercarriage • Optimal Visibility and Comfort See your Cat dealer or visit www.weilerproducts.com

© 2015 Weiler ACON0615_14-23_PavingLeap_JL.indd 21

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LISTEN TO OUR CUSTOMERS NOT OUR COMPETITORS For 40 years and counting, ADM has been committed to producing quality, high-production asphalt plants. On top of that, we take great pride in delivering an unmatched level of service before, during and after the sale.

At the end of the day, our plants speak for themselves.

But we certainly appreciate that our customers have so many good things to say. They’re the ones we listen to, and we think you should, too.

BEVILACQUA ASPHALT EX SERIES PLANT Uxbridge, MA

Commissioned: 2013

Production: 300 TPH

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

- Steve Bevilacqua President/Owner Bevilacqua Asphalt

Scan to read more about Bevilacqua’s experience.

VISIT WWW.ADMASPHALTPLANTS.COM

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PAVING INNOVATIONS

EJ Paving Takes the Lead on Massachusetts Race Course

A tracked paver tackles tight turns and dual passes on the Palmer Motorsports Park project

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assachusetts, a state in New England close to the size of Belgium, may be only the seventh smallest state in the U.S., but is home to the oldest university, Harvard, which was founded in 1636.

This year, it also became home to an exciting high-quality race track.

In April 2014, the Palmer Motorsports Park project was shown the green flag and construction soon began on the state’s first private road racing course.

The track will be used for driver training, demonstrations, vehicle testing, a range of motorsports and competitions.

To ensure driver safety, the track must be smooth, even and high quality.

EJ Paving Co., a local general paving contractor, took the lead in laying the

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2.25-mile track using a team of five Volvo machines to do so. Established in 1987

by Tom Evangelista, EJ Paving currently owns nine Volvo machines.

“This was a unique job that required specific paving requirements,” says John Sullivan, paving director and general manager at EJ Paving. “We used a Volvo P7110 and a PF4410 paver to lay the asphalt track, along with three doubledrum compactors – two Volvo DD112 machines and one DD14. The P7110 was used for 90% of the paving work.”

The right tools to stay on track The Palmer Motorsports Park project was completed in April 2015 and covers 658 acres on the Palmer-Ware line off West Ware Road in the Thorndike area, a

The 2.25-mile track was constructed using over 24,000 tons of asphalt and will be Massachusetts first private road racing course.

former logging property.

The track features exciting twists and turns and the topography of the site and surrounding hills creates an ideal acoustic buffer.

EJ Paving was contracted to complete the track with pits, garage areas and an access road leading to the race course, placing more than 24,000 U.S. tons of asphalt. The project’s specifications required a coarse aggregate stone, 2.5 in. thick as a base layer. The top coat is a warm mix of latex modified polymer.

The job presented several challenges due to the unique nature of the track, as

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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Asphalt Binder Analyzer

The 40-ft wide track only allowed for one longitudinal joint. Pavers had to lay two 20-ft passes side-by-side.

the course needs to reach a compaction density of 97%.

A transfer machine fed the paver for the top coat, since a heavy contact between the truck and paver could create surface imperfections on the finished mat.

The 40-ft.-wide track only allowed one longitudinal joint – right down the middle – which means the pavers had to lay two separate 20-ft. passes, side-by-side. With a maximum paving width of 26 ft., the P7110 easily managed the two passes.

In addition, the track features 15 turns, some tight and others steep, up to a 20% incline. The P7110 has rubber tracks and a large surface area, providing the traction and stability required to hold the steep banks without slipping.

“We were impressed with the performance of our Volvo equipment,” says William Muse, EJ’s on-site paving superintendent, with more than 23 years in the industry. “In particular, the operators are satisfied with the visibility the pavers offer, making operation easier and helping to ensure the safety of everyone on site. The machines produce a high-quality mat, and we are happy with the level of customer service we get from our Volvo dealer, Woodco Machinery, that has been associated with Volvo since 1975.” ■

Rubber tracks on the pavers counteracted slippage on steep inclines along sections of the race track.

The CARBOLITE ABA 7/35B is designed to measure the asphalt binder content of hot mix asphalt as well as warm mix asphalt using loss on ignition, in accordance with AASHTO T 308-10, ASTM D6307-10, & BS/EN 12697-39:2012. n Reduced emissions due to high temperature afterburner n Controlled via a multilingual touchscreen interface n Automatic calculation of final sample weight & binder % result

1-866-473-8724

www.carbolite.com Search: 10075345

June/July 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVING INNOVATIONS

Caterpillar F Series Pavers LeeBoy Legend Electric Screed The electrically heated Legend Screed System is available for commercial class pavers in the 16,000-lb. and under range.

• Available for the 8500 and 8515 models with an 8- to 15-ft. paving width, and on the 24,000-lb. 8816 model with an 8- to 15.5-ft. paving width • Features include bull-nose screed plates, angle of attack controls, frontmounted screed extensions and crown/invert control Search: 10079337

Generator power on board the AP1055F tracked and AP1000F wheeled asphalt pavers has been doubled to 70 kw to heat the standard 8-ft. screed from 40° F to 265° F operating temperature in 15 minutes and the SE60V XW screed extended to 33 ft. up to operating temperature in 25 minutes.

• SE60V, SE60V XW and SE60 VT XW screed options offer both vibratory and tamper bars • Backlit touch-panel controls run Cat grade and slope systems from either side of the machine, up on the tractor or down on the screed • 1,766-tph throughput capacity • 225-hp C7.1 Tier 4 Final engine with Eco Mode Search: 12017712

International Cybernetics ACCU-SLOPE The ACCU-SLOPE is designed to rapidly and accurately measure and check cross-slope readings during the paving process.

• Fully automated with single-person operation • Lightweight, portable and cost effective • Eliminates the need for multi-person measurements • Made with traditional rod and level equipment Search: 10713898

Case DV209 and DV210 Tier 4 Interim Asphalt Compactors The 21,030-lb. DV209 and 22,730-lb. DV210 highfrequency, double-drum compactors are equipped with Tier 4i engines with automatic idle control systems that improve fuel efficiency by 10%.

• Just over 66-in. standard drum width • Centrifugal force can be dialed in to match thickness of lift and desired depth of compaction • Feature more maneuverability in the operator compartment and a color monitor and operator interface • Optional ACEforce asphalt compaction technologies help provide precise measurement over varying asphalt conditions Search: 11321625

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Search: 10074806

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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TransTech SDG Soil Density Gauge

Bomag BW190ADO-5 Tandem Vibratory Roller The BOMAG BW190 ADO-5 tandem vibratory roller offers traditional frontdrum vibration and BOMAG TanGO rear-drum tangential oscillation, increasing the machine’s flexibility.

TanGO, vibration forces are always directed horizontally, and the drum maintains continuous ground contact, so the roller delivers efficient compaction results after only a few passes • The versatile BW190ADO-5 roller can be used to compact more sensitive applications such as working within close proximity to buildings and on bridge structures • Mainline 78.3-in (1,990-mm) rolling width • Rear drum boasts a highly wear resistant drum wrapper surface, covered by an 8-year/8,000operating-hour warranty, ensuring years of reliable service with low operating costs • The roller’s front drum offers both dual vibration frequencies – 3,000/4,200 vpm (50/70 Hz) – and dual amplitudes – 0.036/0.013 in (0.91/0.33) to quickly compact asphalt lifts Search: 12056912

WHAT DOES SEARCH: 100000000 MEAN? Each product and advertisement found in Asphalt Contractor’s pages has a unique 8-digit code that can be entered into the search bar found at the top of www.ForConstructionPros.com/ASPHALT. By searching for the unique number, you will be instantly taken to the specific piece of online content where you can find more images, online exclusive information, related products and videos, and more!

To meet the need for a fast, accurate, non-nuclear soil density/compaction and moisture gauge, TransTech Systems has developed an innovative alternative, the electrical impedancebased Soil Density Gauge (SDG) for use as a QC tool during the soil compaction process.

• Full-color VGA display • LED backlight for easy visibility in light or dark situations • Customizable project and material entries • Diagnostics reading mode • Data management screen and the ability to disable data logging • Rugged, lightweight, aluminum shell (reflective vinyl graphics for safety)

Asphalt Distributors

ChipSpreaders

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Hamm Compact Roller Line The Compact line of articulated tandem rollers now includes the HD 12 VO and HD 14 VO with standard vibration in the front drum, and non-aggressive oscillation technology in the rear.

• Line also includes the HD 8 VV, HD 10C VV and HD 10 VV with conventional vibration in both drums and HD 10 VT, HD 12 VT, HD 13 VT and HD 14 VT combination models with smooth drum in front and four smooth pneumatic tires in rear • Offset capability enables compaction right up against a curb without risking damage from the trailing drum • Feature hydrostatic dual drum drive, automatic/manual vibration system, hydrostatic articulated steering

Heavy Duty Trailers

Asphalt Transports

E. D. Etnyre & Co.

www.etnyre.com 800-995-2116 email: sales@etnyre.com

Search: 12033048 Search: 10072816

June/July 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVING INNOVATIONS

Sakai ND Series Rollers

Atlas Copco Dynapac F1000T Paver The Dynapac F1000T highway class paver features a 225-hp Cummins Tier 4 Final-compliant engine that uses a diesel oxidation catalyst and selective catalyst reduction technology.

• Carlson EZ IV 1019 screed offers a minimum paving width of 8 ft. and a maximum paving width of 26 ft.

• 34-kW hydraulically driven generator delivers a constant 60-Hz frequency regardless of engine speed or load, enabling full screed heating at idle • Regeneration of the diesel particulate filter system occurs without disturbing paving operations under most conditions • Auger conveyor feed control system uses four independent, ultrasonic sensors to precisely maintain the head of material • 78-in. platform height and 63-in. deck height allow full visibility to all working areas • Dual swing-out interactive operator panels

The 57-in. SW652ND, 67-in. SW770ND and 79-in.

SW850ND are designed to handle no-vibe asphalt paving jobs where structural integrity is a concern.

• Allows operator to easily switch back and forth between oscillation and vibration in both drums • 16,865-, 23,810- and 29,480-lb. operating weights respectively • Gear-based oscillating system on the SW850ND means no belts • Controls within easy reach on instrument panel Search: 11587272

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EDGE OUT THE COMPETITION! FLEXIBILITY AND PRODUCTIVITY

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THE VERSATILE ROAD WIDENER ATTACHMENT CONNECTS TO ALL COMMON SKID STEERS, LOADERS OR GRADERS WITH THE UNIVERSAL QUICK-CONNECT COUPLER Learn more at www.roadwidenerllc.com or 844-494-3363

Carlson Joint Density Attachment Through use of a higher angle of attack and an electrically heated element, the 4-in. bolt-on forces increased material into the side cut, greatly reducing voids and yielding higher density numbers at the joint. This enables contractors to hit specific job requirements by increasing the overall density of joints creating longer lasting and more dense joints while maintaining consistent heat with the main screed and extensions.

• The electronically heated element maintains consistent heat of the element, allowing greater extrusion of material while preventing cold spots • While increasing the angle of attack, the 4-in. bolt-on does not lift the screed giving operators ease of mind while paving.

• Easily adjustable through use of a wrench on the exterior of the screed attachment, enabling operators to maximize joint density • Universal attachment can be fitted on the right or left hand side Search: 12041568

Search: 10076385

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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Search: 10072820

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PAVEMENT PRESERVATION

Nightly Deadlines No M for Technology in Alba Runway Repaving Project

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ifenburg Construction is no stranger to tight, demanding project schedules. The Troy, NY-based company regularly performs work for New York State DOT in which temporary road or intersection closures dictate how quickly work must be done. Recently, however, for four weeks straight, a nighttime-only runway repaving job at the Albany International Airport — the first of two phases — put that “response-ability” to the test.

Using a combination of solid planning and advanced paving technology, not only did Rifenburg meet the challenge, it earned the maximum possible performance-based incentives in doing so. And,

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based on experience gained during the project, the company anticipates even better performance opportunities when the second phase kicks off in spring.

Overdue project Serving more than one million people each year, Albany International Airport plays a key role in meeting the travel needs of the residents of New York State’s capital district and surrounding areas.

The airport utilizes two runways and rotates major construction on each, generally in five year increments. However, runway 01/19, the airport’s main runway, hadn’t been paved since 2002 leading to

the $4 million project in which Rifenburg was involved “We won the bid, I believe, largely based on the fact that we are a full service company,” says Mike Momrow, Rifenburg’s project surveyor. “In addition to earthwork and other heavy construction, we own our own HMA plant, we do our own paving, we do our own milling. Because of the need to avoid disrupting air traffic into and out of the airport, we were given a window between the hours of 10 p.m. and 6 a.m. each night to do our work.

We did utilize one milling subcontractor, but, for the most part, having control of

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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o Match bany

all facets of the job — and minimizing the risk of unforeseen downtime — was key.”

Two different projects As mentioned, the Albany Airport runway project is being completed in two phases. The north section, which Rifenburg tackled last fall, involved roughly 4,000 feet of paving using a traditional “mill and fill” approach, while the remaining 4,500 feet south of cross runway 10/28 will be a profile-to-grade project.

“The north side of the project was a bit

more straightforward because almost one-third of that section — about 1,300 feet — was actually an extension to the existing runway done back in 2006,” Momrow says. “So it didn’t have the cumulative years of wear that the south section has had. On the north side, for each segment of the 150-foot-wide runway, we had to mill down 2 ½ inches and pave that same depth in the course of the eight hours we had each night.”

The first four-week phase of the airport job resulted in the milling and removal

of more than 9,600 tons of asphalt.

That material was stockpiled just off site for future use, quite possibly in areas adjacent to the airport. An equal volume of P-201 airport mix asphalt — provided by New Castle Asphalt, one of Rifenburg’s companies — was laid down during the paving portion of that phase.

Technology answers the call While planning was an integral part of their success at Albany Airport,

June/July 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVEMENT PRESERVATION

The first four-week phase of the airport job resulted in the milling and removal of more than 9,600 tons of asphalt. An equal volume of P-201 airport mix asphalt was laid down during the paving portion of that phase.

On previous projects, says Momrow, he would be more or less tethered to the paving screed, continually monitoring and correcting to ensure they got the performance and results they needed. The new control box’s “both sides from one screen” capability freed him up to do other work throughout the project.

“Particularly on a job like this in which the schedule is so compressed, every person’s time is valuable. So, for me to be able perform other tasks like marking the offsets for chaining and paving was a huge benefit that paid off over the length of this phase of the job.”

Demands met

Momrow added that there’s no doubt they benefitted from having some of the newest technology available for jobs of that type.

“We had just taken delivery of a new Cat AP 1055E paver which, in itself was a really nice plus,” he says. “But we also wanted the latest paving control system running it and, having done a fair amount of research into what was available at that time, we contacted Admar Supply about a new asphalt paving system just introduced by Topcon.”

The system Momrow and Rifenburg chose, the Topcon P-32, is the successor to the company’s highly successful System Five, which Rifenburg was already using.

While the new paving system builds upon many of the existing strengths of System Five, it also offered Rifenburg some advantages they’d not had before.

“The new system has enhanced versions of the components we’ve come to rely upon in System Five,” says Momrow. “These include the dual

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port slope sensor and the company’s Smoothtrac which uses four Sonic Trackers to give us the best level of electronic averaging possible. However, what won us over was the new GC-35 control box which is not only faster and easier to read than previous models, it now allows us to view critical data such as elevation and slope for both sides of the paver from a single screen.”

The project’s pavement specifications called for tolerances to within +/- 25-in. and offered a performance-based spec for roughness and rideability. According to Momrow, they were able to easily meet both demands.

“We really benefited from having both the new paver and the latest Topcon system to control it,” he says. “As a result were able to easily meet the FAA mandated tolerances and maintain an IRI of 1 which helped ensure that we capitalized on the available 5% bonus. Even though probably 30% of our business today is airport work, every project is a bit different and every one is a learning experience. At the outset of the Albany job, just to make certain we could be off the runway in time for opening in the morning, we were very conservative on how much we milled each night.”

He added that, as they learned the ins and outs of the airport, and saw the number of trucks that worked best — in this case, between 20 and 25 — they were able

The new paving system Rifenburg used during the first phase was the Topcon P-32 featuring a new control box that allows users to see critical data from both sides of the paver on one screen.

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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CAT® F-SERIES pAvERS

THE NEW STANDARD Improved controls. Better displays.

• • • •

LCD touchscreen display Integrated Grade Controls stay on the machine Water-resistant consoles with “million-cycle” switches Remote pendent controls

Learn more at www.cat.com/paving

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QEXC1847 © 2015 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Search: 10075307

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PAVEMENT PRESERVATION As the project progressed, the crew was able to double production — going from 375 feet per night to 725 feet per night.

to really ramp things up.

“We started out milling and paving about 375 feet per night, but by the time the last week of work rolled around, we were doing 725 feet per night — we nearly doubled production. There were some nights when, usually because of delays caused by tedious start/stop-type paving work, we came close to not making the morning cut-off, but we always managed to pull it off and avoid the costly fines attached to the project.”

Starting south soon With the north side Phase One project completed, Rifenberg had an entire winter to contemplate their strategy for attacking the south project, a phase that will be eight weeks long and more complex in nature.

“Phase Two is roughly 4,500 feet in length and, though it will once again involve milling, because of grade modifications on that section, we will be paving to profile,” says Momrow. “However, being regular users of Topcon Millimeter GPS,

we are well-equipped to handle that facet of the job.”

His faith in Millimeter GPS is wellplaced: Rifenburg recently wrapped up a major reconstruction of a nine-mile section of the NYS Thruway in which the technology was the centerpiece of the job.

“We know that, by using Millimeter GPS in Phase Two, the accuracies will consistently be there, and we will once again

On the north side, for each segment of the 150-foot-wide runway, the crew had to mill down 2 ½ inches and pave that same depth in the eight hours they had each night.

meet the challenges a project like this can present. When it’s all wrapped up, we will have a quality product and a very satisfied customer — and that’s really what Rifenburg is all about.” ■

Rifenberg will now begin Phase Two of the runway project, which is more complicated due to grade modifications. They will use Topcon Millimeter GPS to ensure consistent accuracy of milling depth.

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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PAVEMENT PRESERVATION

Etnyre Centennial Black-Topper Asphalt Distributor Etnyre Centennial Asphalt Distributors provide one-person operation.

• Fingertip control of distributor functions • Computer-controlled spray • Available with cab controlled variable width or standard spray bar Search: 10147283

SAKAI Road Planer & Stabilizer The ER552F high-speed pneumatic-tire road planer and PM550 road stabilizer offer easy access to the cutting teeth and toothholders for servicing and tool repairs and replacement.

• ER552F road planer features a motor grader-like bogey suspension system, 561-hp Tier III diesel engine and an 81-in.-wide cutter drum assembly that cuts to 9 in. deep in one pass • Four-wheel-drive PM550 road stabilizer includes a high-torque, two-speed rotor, a 57-gpm top working speed and a 496hp Komatsu six-cylinder Tier III diesel engine • Optional auto-spray emulsion system Search: 10240407

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Bergkamp Smart Patching Pothole Repair Management Bergkamp’s Smart Patching process monitors and manages pothole patching performance for government agencies and contractors.

• Now standard on the FP5 Flameless Pothole Patcher and SP Series Spray Injection Pothole Patchers • Allows managers and owners to monitor production, performance and location of each patcher and crew • Supported by the InPave Technology Pothole Patching Management System • Information can be used to verify patching performance and material usage, troubleshoot pothole problems and help increase efficiencies Search: 12006121

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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Dynapac PL 500 Planers These 20-in. compact cold planers are available as three- or four-wheeled units with maximum cutting depths of 6.3 (PL500T) and 7.9 in. (PL500TD).

• 110- and 130-hp Cummins QSB 4.5 C110/C130 diesel engines • Hydraulically-operated front sealing of cutter housing • Optional 39.5-in. conveyor for loading a loader bucket or 18-ft. conveyor for loading trucks

Roadtec ACE Grade and Slope Control

Search: 10085884

Roadtec’s ACE Grade and Slope Control System is available on all half-lane and full-lane milling machines.

• Automates the elevation of the milling machine using a network of grade and slope sensors combined with one central microcontroller • Three graphic displays • Can readily incorporate the additional hardware, sensors, and other components needed for single or dual averaging skis • Can be directly connected to the Guardian Telematic System Search: 12055696

Bomag BM-35 Series Milling Machines The rear rotor design BM-35 Series includes the BM1000/35, BM1200/35 and BM1300/35, featuring an advanced cutter system for optimal milling performance.

• BMS 15 interchangeable holder system uses a single bolt for holder retention and requires a low tightening torque of 75 ft.-lbs.

• Low front face position increases efficiency and overall milling power, while allowing full tooth rotation • Includes logical operating layout, easy intuitive controls, vibration-isolated operator’s stand and low noise levels Search: 11281998

Search: 10074524

June/July 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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PAVEMENT PRESERVATION

Wirtgen W 250i Cold Milling Machine The W 250i includes an extralarge milling drum unit that enables up to a 12-ft. 6-in. working width and a 14-in. milling depth.

• Features the intelligent WIDRIVE machine management system, a Dual Engine Concept, PTS (Parallel To Surface) system and intelligent speed control (ISC) • Three selectable milling drum speeds of 1,600, 1,800 and 2,00 rpm • FCS Light quick-change system allows various milling operations to be carried out using different drums • Multifunctional control display and LEVEL PRO control panel Search: 11272726

Heat Design RAP100-SM Recycler The skid-mount RAP-100-SM is designed for small- scale production of recycled asphalt for pothole repair.

• Fully insulated mixing chamber consisting of a 24-in.diameter double-ribbon mixer screw • 100,000-Btu propane-fired heater emits high-intensity heat from a 4’ x 16” full-surface infrared heater, allowing re-heating of RAP or waste chunks of asphalt at a rate of 1 to 2 tons per hour.

• 1/2-ton batch can be processed at a time, and a batch can be re-heated in as little as 15 minutes with full heating capacity and minimal moisture conditions of the RAP. Search: 12044352

Cat RM500B Rotary Mixer The RM500B replaces the current RM500 Rotary Mixer and offers many new features and enhancements that increase operator comfort and productivity.

• Cat C15 engine with ACERT™ Technology meets Tier 4 Final requirements • Enhanced operator’s environment • Automatic rotor depth control • Four mode steering • All wheel drive and three rotor design options • Operating weight for the RM500B is approximately 62,611 lbs when equipped with a ROPS, a cab and a universal rotor Search: 12055195 Search: 10074819

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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POWER AND PRODUCTIVITY

The Vogele Vision 5203-2i paired with a Vogele VR 600 or VF 600 Screed deliver results.

Superior Technology with the ErgoPlus operating concept and integrated NIVELTRONIC leveling system Operator Comfort and unsurpassed visibility to all areas Precision Material Flow including our exclusive apron design Powerful Traction with electronic drive control of two or four powered front wheel configurations Robust front and rear mounted screeds provide smoothness, texture and quality second-to-none When quality of pavement matters, rely on Vรถgele pavers and screeds to get the job done.

WIRTGEN AMERICA . 6030 Dana Way . Antioch, TN 37013 Tel.: (615) 501-0600 . www.wirtgenamerica.com

Search: 10075240

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PLANT MATTERS

Upscaled Storage Helps Meet Customer Demand

Charles Blalock & Sons added long-term storage to increase the number of mixes that can be offered during a production cycle

M

ore than 75 years ago in Tennessee, Charles L. Blalock began a business endeavor that grew into Blalock Companies. Today, the companies started so long ago are still operating successfully, including divisions for highway and bridge construction, site excavation and

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utilities, asphalt paving and production, ready mix concrete production, concrete and precast construction, property development, and building material sales.

It was 1963 when Charlie and his sons formed Charles Blalock & Sons Inc. This venture was dedicated to road construction and became a major asphalt supplier in Sevier County, TN.

With more than one asphalt plant currently in the Great Smoky Mountains area, being environmentally aware is a top priority, which means using the latest technology to reduce the impact on the surroundings. To meet this need and requirement, Will Smith, asphalt plant manager with Charles Blalock & Sons, introduced Kevin Blalock, vice president

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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速

Search: 10074707

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PLANT MATTERS

• Silo design for long-term storage Astec New Generation storage silos are designed to store mix for four days without loss of mix quality, with the exception of polymer modified and open-graded mixes.

• Can be used as conventional surge bins during uninterrupted production or for long-term storage • 12 inches of insulation at top of silos; 6 inches of insulation along the cylinder; 4 inches of insulation at the cone

Charles Blalock & Sons’ new asphalt plant includes a 10 ft. x 14 ft. eight-bin cold feed system.

used long-term storage for its mixes. This adjustment meant learning new skills for productivity.

“Our operators had to learn to put the mix in at the right temperature,” says Blalock. “Once we overcame the learning curve, the storage of our mixes has been fantastic. We have consistently stored mix for up to three days knowing the silos could store up to four days.”

Smith adds: “I would recommend to anyone looking into an asphalt plant and considering long-term storage to speak to Astec. We’ve sent operators and other staff, including myself, to its Advanced Customer Schools to increase our knowledge and hands-on ability to make our plant as efficient as possible.”

• Insulated cone design incorporates electric heating blanket • Fully enclosed, insulated batcher with manual grease seal • Oil-heated discharge gate

of Charles Blalock & Sons, to Astec.

“We met with Don Brock and discussed the plant features and options that would be best for our location to meet environmental standards,” says Blalock.

“We aim to be good environmental stewards across all platforms of our business, from construction to plant design to utilizing recycled materials.”

High recycled mixes

Long-term storage After finalizing the plant design, Charles Blalock & Sons purchased Astec’s relocatable 400-tph Double Barrel plant for the Park Road location in Sevierville, TN. The new asphalt plant features natural gas heating, recycled aggregate feeds, and grid power to minimize its environmental footprint while increasing output.

Another key feature of the new plant is the four-silo configuration consisting of the 600-ton New Generation storage system (two silos) and two additional 300ton silos. The silos increase the number of mixes that can be offered during a production cycle. This gives customers more options for their paving needs.

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Charles Blalock & Sons uses a longterm storage solution for a variety of mixes to meet its customers’ needs at its asphalt plant on Park Road in Sevierville, TN.

“We supply a majority of the asphalt on the Tennessee side of the Great Smoky Mountains National Park,” says Blalock.

“Having the ability to store mixes maximizes the availability to provide materials to our customers on demand.”

Prior to the New Generation storage system, Charles Blalock & Sons had not

According to Blalock, the Astec Double Barrel plant is running RAP (reclaimed asphalt pavement) for various projects.

“The plant is equipped to run RAP up to 50%, which is what we used to pave our parking lot,” he says. “The Tennessee Department of Transportation (TDOT) specs 35% in its mixes. We’ve been running at maximum capacity since we fired up the plant.”

The plant has other notable features that offer various benefits.

“The variable speed motors have been a great benefit to us — not just on energy savings, but helping us control heat and production,” says Smith. “We have the Self-Cleaning System on the Double

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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6/3/15 4:50 PM

Search: 10074806

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PLANT MATTERS

Barrel drum mixer and it all but eliminates the buildup.”

For Smith, having a plant with the latest in technology has its advantages.

“It’s a good thing to not have to get up as early to make the mix,” he says. “The

storage silos are a time-saving feature we didn’t have before and that’s a good thing.”

Blalock emphasizes the importance of having the best equipment and technology to improve the bottom line.

“As an asphalt producer working to

• The benefits of long-term storage Storage is insurance. With storage silos, the worry of storing is eliminated, allowing the proper use of the bin for every ton produced by the plant.

Surge bins can often be used to store mix overnight. But if the mix can’t be used the next day due to rain, paver breakdowns, etc., the mix may not come out of the surge bin. Such a bad experience makes the plant operator reluctant to ever fill the surge bin again at night. Thereafter, he starts and stops the plant from noon to quitting time each day to make sure the surge bin is empty and then comes in at 4 a.m. the next morning to fill the bin. This type of operation is a very poor utilization of the system.

A recent survey showed that approximately 95% of asphalt plant breakdowns occur at start-up in the morning. But with only a surge bin, no mix would be available and all the trucks and paving crews would be backed up and stopped.

With 400 to 600 tons of storage, the first rounds of trucks can be sent to the paving crew and paving can proceed as normal.

The plant can also be operated continuously all day long without stopping and starting. It can be shut down around 4 or 5 p.m. with silos completely full.

The plant crew can stop work, saving significant overtime, or complete maintenance tasks as needed. One person can then load the last truck, which may not happen until 6 or 7 p.m.

Some plants in metropolitan areas cannot be operated at night. Even so, paving must often be done at night when there is less traffic. By filling silos, depending on the size, 200 to 2,700 tons of mix can be placed at night without operating the plant. By filling silos on Friday, mix can be sold on Saturday without paying overtime for the plant crew.

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The new asphalt plant includes Astec’s warm mix system and the 8 ft. x 40 ft. Double Barrel drum mixer.

maximize the potential job opportunities in a certain market or region, having the ability to produce various mixes is crucial, and so is the means for storing the finished products for availability upon demand,” he says. “The benefits of having long-term storage silos can mean the difference between having a good year and having a great year; we’re off to a great start.” ■

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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1000G PAVER 49 HP Kubota Tier 4 Final Diesel Engine Tilt-Hopper Designed Material Delivery System 8’ - 13’ LP Legend Screed Opt - Two-Speed Track Drive Opt - Sonic Auger, Sensors, and Cords

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or contact us at: 704.966.3300

6/3/15 4:51 PM

PLANT MATTERS

How to Choose the Right Asphalt Plant Operator

C li f N ot f’s es

Mechanical skills top the list

By Cliff Mansfield

I

’ve traveled the world since the early 1980s training plant operators and repairing asphalt plants. The question I hear most: “What kind of person makes a good plant operator?”

It always amuses me how much weight management assigns to computer skills.

With today’s computerized control systems, almost all operations are “menu driven.” If a person can operate a mouse, the computer operations are relatively simple. I assign a much higher value to mechanical skills. After all, if the plant is broken down, what good is the computer?

I recommend finding a reasonably intelligent person with a mechanical background. A person from the company’s shop is a good choice. These people normally have an interest in mechanical things and are less likely to be intimidated by the noisy environment of a plant.

If at all possible, the candidate should first be assigned to the asphalt plant as ground-man. Care should be taken at this time to completely answer every question the person asks. The answers these people receive at this point in their training bear heavily on their success later on.

Hands-on experience important The most important thing is to teach a prospective operator is the repair and maintenance phase. Anyone can pick-up the fundamentals of the control room in relatively short order, it’s a matter of pressing the right buttons in the correct sequence, given a certain set of circumstances. What separates exceptional asphalt plant operators from the rest is the ability to address problems before they mushroom into a crisis that causes major downtime. To do that an operator must

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be intimately familiar with the machine which comes from hands-on experience.

As with any training program, success is directly proportional to the amount of time the trainee spends in that environment. I’ve encountered situations where companies have streamlined this ‘outside’ phase of the operator’s training. Gaps in training, however, could surface in costly manifestations of shattered parts which cost money to repair. More importantly, a plant fails to make money while it’s idle.

Once the trainee begins to demonstrate an understanding of the hot mix process and function of the different components, it’s time to move them into the controlroom for short stints in the driver’s seat.

During this time it’s essential to cement in the trainee’s mind the fact that if things don’t work outside, there’s no need for anyone to occupy the operator’s chair in the comfort of the control room.

I also find it advantageous to insulate the trainee from the worry of mix designs or specifications at this time. Most companies have a member of management whose attention is firmly focused on these issues and would be able to guide the trainee through any adjustments needed.

As the trainee becomes more familiar with the day-to-day plant operations and feels comfortable at the controls, it’s helpful to send them out with the paving crew for a few days. This gives them a sense of purpose for what they are learning. It allows them to see what their product is used for and the reasons why the paving crew sometimes call for hotter/cooler temperatures or courser/finer mixes under certain conditions. The best plant operators have a certain amount of empathy for the crews who are using their mix. Experience is an unparalleled instructor.

Learning the nuance of troubleshooting The skill that will take the most effort to acquire is the ability to troubleshoot the plant. Most times mechanical problems are self explanatory. It’s not hard to see why the dryer won’t turn when the drive belts are lying on the ground under the gearbox.

Electronic troubleshooting is different.

Repair companies specializing in electronics abound for good reason. In recent years, advances in computerized AC plant controls have simplified plant operations immeasurably. In doing so, those systems have become so complicated that only the most experienced plant operators have exposure needed to demonstrate diagnostic skills in contemporary electronics.

Remember, AC plants are complex facilities, which is why not everyone can operate one. Training a good operator requires patience and a willingness to risk a certain amount of money. Very few plant operators can say that, early in their career, they didn’t make mistakes which resulted in wasted time and product. This is to be expected. But the more thorough a person’s primary training, the less likely it is the person will experience a catastrophic problem of their own making. ■ Cliff Mansfield is owner of Cliff Mansfield Inc. and operates C.M. Consulting, an asphalt plant repairing, upgrading and operational training company. He is an asphalt plant engineer with 38 years of experience working with various brands and styles of asphalt plants. For more information on this topic, contact Cliff by calling 541-352-7942 or visiting hotplantconsulting.com.

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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When it comes to compaction Evotherm is on a roll

Smoother surfaces and consistent compaction densities.

Evotherm warm mix asphalt is known for its cold weather performance, extended haul capabilities, and fuel saving technology. But did you know it also improves mix consistency while providing greater predictability in meeting compaction density numbers? Smoother surfaces, reduced oxidation and lower emissions are also in the mix. Step up to the proven technology of Evotherm—and get on a roll to perfect compaction.

www.evotherm.com Search: 10073842

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PLANT MATTERS

Hauck MegaStar Multi-Fuel Burner

Stansteel Combo Plants Combo Plants combine new, used or reconditioned equipment from different suppliers and manufacturers to create an effective and low cost alternative to buying an all brand new plant.

• Can save the contractor $1 million, $2 million or more over the price of an all new hotmix asphalt facility Search: 10146942

Hauck’s MegaStar multi-fuel burner employs variable frequency drive (VFD) technology for precise air flow control offering excellent energy and combustion efficiency.

• Burner package is compact and easy to install, yet remains accessible and simple to service • Linkages have been eliminated to make the burner easy to maintain and adjust • Available in sizes ranging from a nominal 50 to 150 million Btu/hr • Designed to meet various production needs • Standard design can be applied to applications up to 1,500º F • Custom lengths are available for warm mix applications

Rotochopper RG-1 Shingle Grinder The RG-1 shingle grinder is designed to process asphalt shingle waste for use as a paving mix supplement, boiler fuel and other end products.

• Available with diesel or electric power • Designed to offer lower wear costs and less downtime • Available in a compact stationary version designed to operate in-line with sorting or screening equipment Search: 10139824

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

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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Introducing ...

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PLANT MATTERS

Gencor MEGAPLANT

KPI-JCI AMS FT400 Cone Crusher

Gencor designs and builds the biggest installed base of Megaplants across North America each producing over 50% RAP and achieving production levels of over 800 tph.

• Incorporates the Ultradrum design which maximizes heat transfer • Use RAP and RAS • Patented positive reclaim system Search: 10860316

The FT400DF track-mounted cone crushing plant features a Cummins GSX15 Tier 4 Final engine.

• Kodiak Plus K400+ track-mounted cone crushing plant • Tramp iron relief (TIR) system minimizes crusher overload impact • Digsy control system • Roller bearing construction improves production and energy efficiencies compared to crushers with bushing construction Search: 12004955

Eagle Crusher RAP Recycling System Eagle’s skid-mounted RAP Recycling System features a one-touch computer screen that switches product from top to base and back.

• Introduces RAP into drum mixers for any size specifications • Produces up to 50% RAP for the necessary mix in 400-600 TPH recycling drum mix plants Search: 10360694

Moisture measurement in RAP and Aggregates

The Hydro-Probe II sensor will give reliable and precise real time moisture measurement in both RAP and aggregates.

The sensor may be used as a stand-alone system to simply display a moisture value or trend for manual adjustment of the plant (including on-board alarms) or may be immediately or at a later stage fully integrated with your automation system.

Even the simplest installation will give immediate cost benefits resulting in a quick return on investment.

•

Product quality and repeatability improvements.

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Ensure efficient use of asphalt cement.

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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EXPAND YOUR KNOWLEDGE WITH OUR EXTENSIVE PAVEMENT MAINTENANCE LIBRARY

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PLANT MATTERS

Libra Camera ID Libra Camera ID eliminates the delays/costs of paper signatures and provides proof-of-purchase for quick, full-proof resolution of billing disputes.

• Eliminates the need for driver’s signatures • Requires absolutely no action by the driver • Billing clerk can easily retrieve transaction images and email them to the customer • Supports multiple cameras/images for each transaction or process • Allows management to view live video to serve as a logistics tool or theft deterrent Search: 10296041

ADM EX Series Asphalt Plants Asphalt Drum Mixers’ EX Series asphalt plants with single-drum counterflow technology produces 100 to 425 tph.

• Long aggregate drying and mixing times • Can process high percentages of RAP • Using counterflow technology, unit has separate drying and mixing zones to achieve the maximum level of heat transfer and fuel efficiency • Designed to virtually eliminate unsafe hydrocarbon emissions • System reintroduces residual gases back to the drum’s combustion zone • Available in portable or stationary versions; meet all federal and state specifications Search: 10658422

ALmix UF Series Drum Mixers The ALmix UF Series Drum Mixers feature an elongated single drum incorporating the latest technology in counterflow drying and mixing.

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Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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Astec V-Pack Stack Temperature Control Astec’s V-Pack Stack Temperature Control System extends the range of mixes that can be produced without requiring the flights be adjusted.

• “V-flights,” unique drum flights with a deep V-shape, and its use of variable frequency drives (VFDs), which provide control of the drum rotational speed, are keys to the control system managing an asphalt plant’s exhaust gas temperature and increasing overall efficiency • Automatically controls exhaust gas temperature across a range of mix types and operating conditions by making drum speed changes • Enables asphalt plants that produce mix with RAP content from zero to 70% without any physical changes Search: 12058427

All Plant Parts.

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PHCo Lo-Density Unitized Storage Tank Heaters Process Heating Company’s Lo-Density unitized storage tank heaters may be installed into any above-ground tank or vat, and dissipate controlled heat as low as three watts per square inch on the heater’s sheath to prevent coking or damaging of material.

• Unique drywell-style elements reside inside the sheath making them accessible from outside of the tank and eliminating the need to drain the tank to service the elements • Electric heat offers 100% energy efficiency • Customizable dimensions make units easy to install • UL-listed controls offer easy-to-use automation of temperature regulation

ADM customers have long known about our excellent parts quality and availability. Now, users of nonADM equipment can get that same level of confidence in replacement parts.

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Meeker Batch Plant RAP Kit

For more information call (260) 637-5729

Heatec Polymer Blending Systems

The Meeker Batch Plant Rap Kitfeatures precise control of RAP material.

• Unique weighing system allows for higher RAP percentages in mix • Positive control of stem release • Steep sloped bin walls on rap bins for trouble free operation • PLC touch screen controls

Heatec polymer blending system is one of the many polymer systems the company has provided for terminals in the US and overseas.

• Available in both fixed and portable configurations • Company was an early pioneer in producing systems to blend polymer with asphalt cement to make PMAC (Polymer Modified Asphalt Cement)

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June/July 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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6/3/15 4:52 PM

QUALITY CONTROL TECHNOLOGY GUIDE

How Intelligent Compaction is Important to Your Bottom Line The latest IC technology can help contractors save time, reduce fuel consumption, improve job quality and increase ROI

By Jessica Stoikes, associate editor

I

ntelligent Compaction (IC) has been a buzzword in the construction industry since the 1980s. At that time, contractors were mainly using the technology to track and document their compaction efforts on the soil side.

It wasn’t until the early 2000s that the U.S. started adopting the technology for asphalt compaction due to a push by the Federal Highway Administration (FHWA).

The demand for this type of technology came as a result of under-performing pavements and a growing need for documented quality assurance.

“Asphalt pavements are designed to last a specific number of years,” says Fares Beainy, research engineer emerging technologies at Volvo Construction Equipment. “However, construction involves several stages that would shorten the designed life span if not performed properly. Compaction is the last and one of the most important phases that needs to be properly executed to ensure quality of the constructed pavement.”

This is exactly what IC helps contractors accomplish. The latest trends in IC remove the guesswork from compaction,

56

help contractors save time and money and also ensure pavement performance through quality documentation.

Real-time results One of the main benefits of equipping your rollers with IC technology is that that machine is giving you immediate feedback on your compactive efforts.

Atlas Copco’s intelligent compaction system is designed for asphalt and soil applications. Its touch-screen interface is also easy to navigate, keeping the operator’s attention on the worksite and the surroundings.

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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IC helps achieve optimum compaction with fewer passes, allowing contractors to be more cost efficient Modern IC systems are are not difficult to learn. Some suppliers, like Wirtgen America, offer full-day training not only for operators, but for the foreman, QC manager and superintendent as well.

Many IC technologies use pass mapping to show where a roller has been on the mat and which areas still need attention.

“The IC system removes the guesswork in asphalt and soil compaction since it gives you real-time information,” says Tim Hoffman, product manager, heavy compaction at Atlas Copco. “It also tests the entire compacted surface, verifying the quality of compaction and maximizing operator productivity to ensure compaction quality.”

Real-time data allows for an immediate response to fix any problems before compaction is complete and the mat is compromised.

“IC systems can save contractors a considerable amount of time since they no longer need to do manual readings,

and that can equate to a lot of labor costs over time,” Hoffman adds. “IC systems alert operators once they achieve optimal compaction, so they can continue moving through the project without slowing or stopping for workers to take and interpret samples. Also, because the system helps ensure operators reach the optimal stiffness on every square inch of the project, there is minimal risk of premature failures, which saves contractors costs associated with repairs.”

Tim Kowalski, Hamm applications support manager at Wirtgen America, adds, “The main reason IC was developed was to find out what the roller was actually measuring on the fly, and the operator could see if there were problems right away vs. waiting until someone came out and took a test to see how well things were getting compacted.

“The biggest benefit is being able to see what you are doing in real time and not just hoping you are doing the right thing while compacting,” Kowalski continues.

“This system will help any operator do a better job.”

Better jobs = bonuses It’s no secret that contractors are driven by job bonuses. The possible incentive of gaining a monetary bonus with the use of IC is just another reason to equip your roller fleet with the technology.

“By giving the roller operator critical information — to know when spec densities have been achieved and to know when to stop compacting — this can most definitely lead to achieving maximum bonus on projects that pay bonuses for achieving specified densities,” says John

• How IC works IC works by outfitting vibratory rollers with instrumentation that’s fed to a documentation and feedback control system, which then processes compaction data in real time for the roller operator. The precise location of the roller, its speed and the number of passes over a given location are mapped using the Global Positioning System (GPS) or a similar system.

To determine the effectiveness of the compaction process, compaction meters or accelerometers are mounted in or about the drum to monitor applied compaction effort, frequency and response from the material being compacted.

Many contractors are overwhelmed by IC since the technology can seem daunting and advanced. However, current procedures using conventional compaction machines may result in inadequate and/or non-uniform material densities, which can be one of the major factors in premature pavement failure. IC helps users overcome this issue by optimizing the compaction process.

Manufacturers of compaction equipment have made it their passion to help create IC technology that’s both user friendly and effective in achieving the best compaction results possible.

June/July 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

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QUALITY CONTROL TECHNOLOGY GUIDE

• Evolution of intelligent compaction “At its genesis, IC included rollers that would change the direction of the vibrating drum from full vertical (maximum compaction energy) to full horizontal (minimum compaction energy) as the stiffness values increased,” says Bert Erdmann, product manager, heavy compaction at BOMAG Americas, Inc. “These vectoring drums generated higher amplitudes than standard vibrating drums on traditional rollers, allowing spec densities to be achieved in fewer passes and/or compact thicker lifts. Originally, the IC was designed for single-drum rollers, and capabilities existed for printouts of compaction performance as documentation.”

As technology evolved, so too did the capabilities of the systems. Today, IC is available for both asphalt and soil rollers. The reporting capabilities have expanded. For example, for asphalt, the systems can record temperature, roller location and speed and material stiffness, and all this information can be downloaded to a USB drive for documentation of the entire project. Multiple rollers on the same job can be networked together, so the operators can have real-time compaction output for each roller on the job.

“At the other end of the spectrum, systems like the BOMAG Economizer have recently been developed for a broad spectrum of contractors working in both soil and asphalt applications to improve compaction quality,” Erdmann says. “It offers intuitive control — employing a stoplight-like dial — so the operator does not need to be trained on the system. Economizer is available for traditional rollers, so there is no vectoring drum. However, with its real-time reporting of material stiffness on the dashboard dial, the operator can see when optimum compaction is achieved, proof roll for soft spots and reduce the chances for over compaction.”

says. “More and more agencies consider contractors that are using IC systems because it contributes to a quality product and helps get projects done faster by enhancing operator productivity with its mapping capabilities.

“The sooner a contractor gains experience on the technology, the more proficiency he or she will have while bidding on future projects that might require intelligent compaction on rollers, such as airport runways or in states where the technology is mandatory.”

“If a contractor develops a reputation for delivering quality compaction results, and IC helps with this, then it is entirely possible for contractors to win more bids because of IC,” Hood adds.

Comparatively, if the technology can help you avoid penalties, all the more reason to implement IC. “These job bids are in millions of dollars and penalties can add up,” Beainy says. “This is related to reducing penalties caused by missing target densities. The return on investment could be quicker than one might think.”

More productivity with pass mapping

BOMAG’s Economizer offers real-time material stiffness feedback to optimize compaction results.

Advanced IC systems can record temperature, roller location and speed, and material stiffness, which can be downloaded to a USB drive for documentation of the entire project.

Hood, director of sales, heavy equipment at BOMAG Americas Inc. In addition, many federal and state agencies are now beginning to require that contractors use IC technology on jobs.

“Yes, some jobs require an IC system,” Beainy says. “In addition, any contractor who is working on a project with a density specification and pay factor can benefit from the ability to get direct reporting on density calculations. In-process and final density data is an important quality

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control metric. In addition, specifications that include Percent Within Limits (PWL) incentivizes close control of final density.”

Currently, IC technology is mandatory in approximately 20 states. However, in other states that do not require IC, having a reputation of success with the technology might be a unique selling proposition while competing against other contractors.

“IC systems can put contractors ahead of their competition and maximize their crews’ productivity,” Hoffman

We know that under compaction of an asphalt is bad; it leads to poor density numbers and an asphalt that will fail prematurely. Similarly, over compaction of the asphalt can be just as detrimental to the success of the job, plus it is a waste of the operator’s time and your money. IC puts a stop to that with pass mapping.

“Having that real-time information is critical to achieving compaction densities in as few passes as possible, saving time, fuel and money,” Hood says. “Achieving spec densities is temperature dependent, so rolling the asphalt in the desired temperature range allows the compactor to achieve densities in the prescribed number of passes. Having real-time density data allows the operator to know where more compaction is needed to reach spec densities and, more importantly, when to get off the section to prevent over compaction.”

Many IC technologies use pass mapping to show where a roller has been on the mat and which areas still need attention.

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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QUALITY CONTROL TECHNOLOGY GUIDE “Real-time pass mapping and relative stiffness data optimize operator effectiveness,” Hoffman says. “Pass mapping shows operators where they already made enough passes for optimal stiffness until the entire surface has been completed.”

• Documented results Protecting your business is important to any contractor. Being able to document results on a job is one way IC can help protect your business. It logs all of the density data, which can be downloaded to your computer and saved should the quality of the work completed on a job be called into question.

“IC systems assist contractors from a quality assurance standpoint,” Tim Hoffman, Atlas Copco, says. “The contractor can use the data to prove to regulating agencies, such as a state Department of Transportation, that compaction standards were met. This minimizes the risk of costly litigation or having to restart the project.”

However, you want to be sure that you purchase the system that will give you the results you want.

“The first place to start with IC is to determine what type of system is necessary for the types of jobs the contractor faces today and in the future,” says John Hood, BOMAG. “For a vast majority of contractors, the BOMAG Economizer system offers a costeffective method for achieving real-time, highly accurate compaction results. If the contractor will be doing state work where documentation is required, then a more advanced system such as Terrameter and Variocontrol for single-drum rollers and Asphalt Manager for tandem rollers with BCM05 will fit the need.”

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This real-time temperature data allows the operator to stay within the compaction time window before the asphalt material is too cold to compact. “Pass mapping gives the operator the ability to track his progress and make sure of full compaction coverage of the pavement,” Beainy says.

“Pass mapping helps in the consistency of passes that should help the contractor get a more uniform compaction and density across the mat,” Kowalski adds.

“More data equals more consistent rolling patterns that can reduce the number of passes and achieve more consistent densities across the mat, giving better rideability that translates into bonuses for the contractor.”

Up to 20% fuel savings?

So what does it mean when your operators make fewer passes to achieve the desired results? Less fuel consumption, less wear on the machine and more time for them to work on other projects.

“IC has the potential to reduce the fuel consumption as it provides the operator with a quality measurement of the pavement that would allow the operator to know when the target is achieved,” Beainy says. “In some cases, they can perform a reduced number of passes and as a result consume less fuel and time.”

Many manufact urers are also implementing fuel-saving modes on their machines that can be switched on or off based on the needs of the job.

“IC systems can contribute to a reduction in fuel consumption by helping

operators avoid making more passes than needed,” Hoffman says. “The optional ECO Mode system on Atlas Copco machines also helps conserve fuel, especially with rollers featuring the rpmmanagement system, such as our large asphalt and soil rollers.

“ECO Mode reduces fuel consumption by as much as 20% by delivering to the roller only the amount of power that is necessary to operate at any given time,” he states. “So combining the two might have a significant impact on reducing fuel costs.”

“IC helps to achieve optimum compaction with fewer passes, so it allows contractors to be more cost efficient,” Hood adds. “By completing a project more economically, the contractor could bid a project lower to win more projects, which equals more money.”

Another means to save both fuel and time is by providing high-quality roadways that would last longer. “A longer life for a roadway means less road maintenance, which means less fuel consumed on the job, and by vehicles in traffic jams,” Beainy states.

Easy does it Even with all of the above benefits, contractors are still on the fence about implementation. Cost is one factor, but the complexity of the technology can seem daunting as well.

However, the IC technology of today has advanced to where it is very userfriendly. Many systems feature an easy-touse, color touch-screen interface.

Volvo IC offers pass mapping, temperature mapping and data storage features; The new Volvo IC with Density Direct includes real-time density mapping technology.

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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“Tablets are relatively easy to use because the operator can use their touch screen to navigate through systems or pull up multi-colored mapping data, including a weak area analysis, evib mapping, pass mapping and progress mapping,” Hoffman says. “This helps them focus on compaction and their surroundings instead of hassling with bulky screens and button layouts.

Operators can detach the tablet from its cradle on the operator’s platform to deter theft and to transfer data onto a PC at the end of the day. Contractors also can quickly set project parameters, including the compaction measurement value, using the touch screen which alerts operators once they reach optimal compaction.”

“The system is not difficult to learn,” Kowalski with Wirtgen America says. “We usually will have a full-day training course for not only the operator but the foreman, QC manager and

superintendent. This is usually enough time to get them on their way and they feel much more comfortable about the system by the end of the day. The more they use it, the easier it becomes. This is a system that is staying around and is not going away. The benefits outweigh the initial cost of the equipment.”

“Think about it: What is the cost of guessing when optimum compaction is achieved? What is the cost of removal and replacement of material that’s been over compacted?

We are trying to reach specified compaction densities without over compacting the material,” Hood says. “IC shows the operator when optimum compaction is achieved. It can prevent unnecessary extra passes, lower fuel consumption and save time and money for the contractor.”

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STANSTEEL Asphalt Plant Products

Hauck Model ESII combination Oil/Gas Burner • Heavy duty stationary frame and legs to grade • RAP entry Collar • Heavy duty twin drive motors and reducers • Trunnion type drive assembly in excellent condition • Later model knockout type primary collector with interconnecting ductwork between Drum and knockout box is included.

GTB-5090J 30,000 Gal. Portable Liquid Asphalt Storage Tank 30,000 gallon Portable Direct Fired liquid asphalt storage tank. This Tank is mounted on a portable chassis with a full length extended frame. Unit is fully insulated and wrapped with a metal skin. Additional features include: • Mounted AC Divert Valve assemblies with Jacketed piping and Jumper Lines • Tandem Axle portability package with Landing Gear, etc. • Ladder to top mounted for Interior Inspection Port.

• Mounted Control Panels with temperature controller on burner end.

GTB-5035 IWS CMI 85,000 ACFM Portable Baghouse • Mounted Exhaust Fan on Gooseneck equipped with Twin 150 HP motors & exhaust damper • Stack testing platform and access ladder • 1,008 total Bags & Cages • Inertial Dust Collector • Hopper mounted, twin dust collection augers with cross auger • Triple Axle Chassis with installation support legs to grade • Full perimeter safety handrails around top.

GTB-5090I CMI 65,000 CFM Nominal Pulsejet Baghouse CMI Model APL 540 pulsejet baghouse. The baghouse section includes top loading Nomex bags and cages with venturies and a fully enclosed bag cleaning system. The dust hopper section is of a single “V” trough design and includes a dust removal auger and steel support legs to grade. Features and specifications include: • The baghouse has 540- 6” diameter x 15’ nominal length bags for a total of 13,149 ft² of bag cloth • Baghouse is rated at 65,000 CFM nominal at a conservative 5.0:1 air-to-cloth ratio • Backward inclined exhaust fan with (1) 250 Hp drive motor and outlet damper.• Exhaust stack and inlet “fire” damper.

GTB-5089WS Astec Nominal 300 TPH Highly Portable Drum Mix Plant

• Astec 6-Pack Portable Dryer/Drum with Hauck SJ-360 Burner and 100 HP Blower operating on Natural Gas. The Drum Shell is a nominal 7’ diameter x 35’ long and is mounted on a heavy beam frame equipped with a triple axle suspension • Astec Portable Four Bin Cold feed system. Each bin measures a nominal 8’ x 14’ and equipped with 24” belt feeders and 3 HP DC drives • Deister Model USM-1512 5’ x 12’ single deck Virgin Scalping Screen equipped with a 10 HP Motor • Astec Portable 24” belt width x nominal 33’ long Virgin Aggregate Scale Conveyor equipped with a belt scale, wind guards, vertical gravity take-up and a single axle suspension • Dusty Dustless Portable Pulsejet Baghouse reportedly with 1,154 Bags. The mounted exhaust fan, air compressor, dust blower and ductwork are also included. The owner reports that some bags were replaced with new in 2014 • Astec Portable single RAP Bin with Grizzly that has a nominal top opening of 8’ x 14’. The fully self contained bin includes a 36” wide x nominal 15’ long inclined feed conveyor and a 3’ x 5’ Scalping Screen which feeds a Scale Conveyor. All components are mounted on a heavy duty single axle frame and chassis • Astec Control House with Motor Starters, Breakers, Astec PM-96 Plant Operating Controls and Hauck Burner Controls.

GTB-5034 JWS Standard Havens Storage Silo & Transfer Conveyor SILO SYSTEM: This Add-On Silo system consists of (1) 200 Ton capacity silo and (1) Bintop Transfer Conveyor equipped as follows: • Standard Havens 200 ton capacity hot mix storage silo: 1. Silo has an oil heated cone, electrically heated Clam Gates and Safety Gate assembly.

2. Silo is also equipped with High Level Indicators.

3. Bintop anti-segregation totally enclosed batcher.

4. Silo has cone liners as reported by the owner.

• 30” wide x nominal 15’ long CMI bintop slat conveyor: Shaft Drive Reducer.

2. The Slats are 5” x 28” and bolted to 4” double strand chain.

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

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www.stansteelused.com

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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ADVERTISERS’ INDEX Almix

9

Asphalt Reheat Systems LLC

68

Asphalt Drum Mixers Inc.

22-23, 55

Astec Inc.

13, 36-37, 63

Bitco Insurance Companies

61

Carlson Paving Products Inc.

71

Caterpillar Inc.

33

C. M. Consulting

50

Dillman

4-5

Eager Beaver Trailers

29

E. D. Etnyre & Co.

27

Evans & Daniels Inc.

64

FastMeasure By KTP Enterprises

63

Gencor Industries Inc.

3

General Combustion

19

Heatec Inc.

2

Hydronix

52

K-M International

50, 52

LeeBoy

47

Libra Systems Corp.

38

MWV

49

NAPA

54

National Highway Mntc. Systems Ltd, L. L. C.

63

OMI Industries

17

Pugmill Systems Inc.

64

R & D Trench Paver

68

Recycling & Processing

67

Reliable Asphalt Products

65

Roadtec an Astec Industries Company

11, 72

Road Widener

28

Sakai

39

Sealmaster

35, 53

Stansteel

43, 66

Systems Equipment Corp.

26, 45

Tarmac International Inc.

40

Transtech Systems Inc.

7

Verder Scientific

25

Weiler

21

WEM Automation L. L. C.

15

Wirtgen America

41

This index is provided as a service. The publisher does not assume liability for errors or omissions.

THIS COULD BE YOUR AD!

CALL TODAY!

To place an ad in Asphalt Contractor Call Denise Singsime 1-800-538-5544 ext: 1245 - dsingsime@acbusinessmedia.com June/July 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0615_69_Index.indd 69

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THE LAST EXIT

Green is the New Black with Asphalt Made from Algae

The next generation of roads might be made from discarded plant product rather than oilbased bitumen

cosmetic dyes and food supplements.

They reportedly account for nearly a third of all the organic carbon in the biosphere, and yet we really haven’t had much of a use for the material. It’s often burned to generate electricity at paper mills, but burning this material is not only wasteful, but releases soot and greenhouse gasses into the atmosphere.

That’s why Slaghek and his colleagues are excited about their success in creating a lignin-based seal for asphalt mix.

By Jessica Stoikes, associate editor

Bio not bitumen

I

t seems like every product these days is starting to be bio-based. And that’s good because resources like fossil fuels are finite and may one day no longer be an option to produce the materials, like asphalt, we use every day.

This is why researchers all over the world are looking at ways to produce a more sustainable asphalt product through different materials. The latest research from The Netherlands is showing that asphalt can actually be produced from plants. That’s a far cry from oil-based bitumen.

At the annual American Chemical Society meeting, researcher Ted Slaghek presented his lignin-based road concept.

A lignin is a common-but-complex material that makes trees sturdy and cornstalks stand.

Microalgae lingins have long been known for their use in applications like

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Traditionally, a by-product of crude oil production called bitumen is the main sticky ingredient in asphalt and roof sealants. However, it’s no secret that oil is a limited commodity, and even the by-product of its refinement may soon disappear.

“In the long term, we have to move to renewable products that we can harvest every year,” Slaghek said. “It should be logical to use natural organic raw materials instead of crude oil.”

Slaghek and his team used a hydrothermal liquefaction process, i.e. pressurized water (in a subcritical state), to transform this microalgae waste into a black, viscous, hydrophobic substance (bioasphalt) that closely resembles petroleumderived asphalt. The process currently achieves a conversion efficiency of 55%.

Even though the chemical composition of bioasphalt is completely different from its petroleum-derived counterpart, they

have similarities, including their black color. A liquid at temperatures exceeding 212° F, bioasphalt can be used to coat mineral aggregates; viscoelastic at -4° F to 140° F, it ensures the cohesion of the granular structure while supporting mechanical loads and relaxing stress.

This innovation offers a new possible option for the road building industry, which is entirely dependent on petroleum today. The types of bioasphalt developed so far relied on oils of agricultural origin (which could be needed for human nutrition) or from the paper industry, mixed with resins to improve their viscoelastic properties. Microalgae cultivation does not require the use of arable land so it offers an attractive solution.

Still, Slaghek and his team have some things to work out. As it stands, the team has developed lignin mixtures that can extend the lifespan of a road in warm temperatures. However in cold areas, these mixtures become exceptionally brittle, increasing the chances that the road will chunk and crack, potentially damaging cars. Not the kind of roads we’d want in almost two-thirds of the U.S. So the researchers are developing more than one lignin cocktail — a variety of asphalts for different climates.

The team also plans to build a 100meter stretch of bicycle path this year using one of the lignin mixtures — a proof-of-concept that a sustainable “green road” can truly work. ■

Asphalt Contractor • www.ForConstructionPros.com/Asphalt • June/July 2015

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CONSISTENCY

While Others Have Come And Gone,

Carlson Has Always Been Here For You

Consistency in innovation. Consistency in quality. Consistency in service.

For nearly 30 years Carlson’s commitment to consistency and to its customers has never changed. With the most qualified personnel in the industry backing up the most versatile, durable, and reliable screeds on the market, Carlson’s machines have and continue to win awards while giving operators a proven platform for success. Combining unmatched mat quality, wide width ability, and standard crew comfort features, it is no mystery why Carlson is the contractor’s choice for screeds.

No Screed Has Helped Win More Sheldon G. Hayes Awards Than Carlson’s Highway Class Screeds.

Period.

Search: 10072346

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Search: 10074458

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