Asphalt Contractor September 2015

Milling industry tackles the silica issue Page 34

How to optimize your asphalt plant in the off season Page 54

Maximum SMOOTHNESS Shelly & Sands’ new MTV helps attain ride numbers on I-71 in Ohio Page 18

September 2015 • www.ForConstructionPros.com/Asphalt

ACON0915_01_CoverFinal_LJ.indd 1

E,

T OT

NC

RL D HA SE C , LO ER NC NT E E E C UR N H IO OC T N BR E NV CE CO EN E T ER OT ONF L C AR

CH

8/26/15 2:57 PM

UNMATCHE D INSUL AT ION Our tanks have fully insulated bottoms, as well as tops and sides, to minimize heat loss and reduce fuel usage. We use 3 inches of insulation on the bottom and 6 inches on the sides and top.

We then install a metal plate over the entire bottom to cover the insulation and protect it from damage.

Awhile back we created a spreadsheet to compare the heat losses for our TAV30 tank with the heat losses of a similar tank from a competitor. The competitor tank has a much greater heat loss because it has no insulation on its bottom and only 4 inches on its sides and top.

So heat loss for the competitor tank is 129 million Btu/year greater than ours.

Consequently, it takes almost 1,000 more gallons of No. 2 fuel to heat the competitor tank every year than to heat our tank. Think of what that adds up to over a period of 20 years. The difference is stunning!

H E AT E C , I N C .

Please call today for more information.

HEATEC

®

an Astec Industries Company

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

ACON915_02-06_TOC_JL.indd 2

8/26/15 2:58 PM

Upcycle:

(verb) \uhp-sahy-kuh l\:

To reuse material in such a way as to create a product of higher quality than the original:

Ultradrum A.R.E. 50%

UltraRAP 70%

MegaRAP 100%

It seems any plant these days can recycle, but have you ever asked about the quality of the mix produced? With higher RAP percentages comes the problems of degradation of the mix.

That’s why Gencor developed the innovative UltraRAP and MegaRAP concepts, which can process 70% and 100% recycle without superheating and degrading the quality of the mix. The result is a noticeably superior and consistent mix.

So if you want superior high RAP capability, don’t just recycle ... Upcycle.

Call Gencor today and learn how you can “Upcycle”.

407.290.6000 or visit www. gencor.com Search: 10073090

ACON915_02-06_TOC_JL.indd 3

8/26/15 2:59 PM

โ บ TABLE OF CONTENTS SEPTEMBER 2015

COVER STORY

DEPARTMENTS PAVING INNOVATIONS

18 PAVEMENT PRESERVATION

34 PAVING INNOVATIONS

PLANT MATTERS

18 Shelly & Sands Earns Maximum Smoothness Bonus with New MTV

The new MT 3000-2i MTV from Vรถgele helped the contractor attain the kind of ride numbers it needed on the I-71 reconstruction project in Ohio.

ACON915_02-06_TOC_JL.indd 4

54

8/26/15 2:59 PM

SPECIAL REPORT: RECYCLING & CRUSHING

PLANT MATTERS

PAVING INNOVATIONS

54 How to Optimize

28 Paving Products

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

PAVEMENT PRESERVATION

34 Milling Industry Stays a Step Ahead of OSHA

An historic partnership to keep workers safe leads to innovation and an effort to comply with OSHA before enforcement of the imposed silica dust rule.

48 Preservation Products

Asphalt Plant Downtime In many areas, the winter months can provide valuable downtime for your plant operations. Make the most of that time with these maintenance tips.

69 How to Maintain Mobile Crushers

Here’s a look at the top 5 wear items on these machines and how you can optimize your productivity.

73 Recycling &

64 Cliff’s Notes

How to ace the EPA Stack Test.

65 Plant Products

Crushing Products Crushers, grinders, screens, recycling systems & more.

Plants, baghouses, mixers, dryers, silos, automation systems & more.

Milling machines, reclaimers, infrared equipment & more.

48

73

28

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

ACON915_02-06_TOC_JL.indd 5

8/26/15 2:59 PM

TABLE OF CONTENTS IN EVERY ISSUE

LAST EXIT

81 Advertising Index

8 Editorial

Teach employees to make decisions on their own.

82 The Last Exit

10 New Product Preview

Asphalt gets new ink.

82

PaveXpress adds asphalt overlay design feature.

10

WHAT’S ONLINE www.ForConstructionPros.com/Asphalt

TOP 10 PROJECTS VIDEO: US CONSTRUCTION INDUSTRY SPEAKS - “QUIT KICKING THE CAN DOWN THE ROAD” Construction industry professionals across the country talk about the need for Congress to pass a longterm federal highway and transit funding bill.

COMPETE FOR NATIONAL AWARDS

The American Association of State Highway and Transportation Officials (AASHTO), AAA and the U.S. Chamber of Commerce have announced the 2015 America’s Transportation Awards competition top 10 project finalists.

Search: 12103745

Search: 12102849

U.S. ASPHALT PRICES COULD DECLINE BY YEARS END

As the paving season winds down late in the year, asphalt markets are far more susceptible to sharp declines in underlying crude pricing, posing the potential for significant volatility.

Search: 12099769

SEPTEMBER 2015 Vol. 29, No. 7

Published by AC Business Media Inc.

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

BUYER’S GUIDE Hundreds more products available for your asphalt production and paving business can be found in our digital Buyer’s Guide.

Available at www.Asphalt.com

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.

POSTMASTER: Please send change of address to ASPHALT CONTRACTOR, PO Box 3605, Northbrook, Illinois 60065-3605.

Printed in the U.S.A. Canada Post PM40612608.

Return Undeliverable Canadian Addresses to: Asphalt Contractor, PO Box 25542, London, ON N6C 6B2.

SUBSCRIPTION POLICY: Individual subscriptions are available without charge only in the USA. The Publisher reserves the right to reject nonqualifying subscribers. One-year subscription to nonqualifying individuals: U.S. $45.00, Canada & Mexico $65.00, and $95.00 all other countries (payable in U.S. funds, drawn on U.S. bank). Single copies available (prepaid only) $10.00 each (U.S., Canada & Mexico), $15.00 each (International).

6 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • SEPTEMBER 2015

ACON915_02-06_TOC_JL.indd 6

8/26/15 2:59 PM

Search: 10072820

ACON915_02-06_TOC_JL.indd 7

8/26/15 2:59 PM

September 2015 • Vol. 29, No. 7

EDITOR'S PERSPECTIVE

How to Teach Employees to Make Decisions on Their Own

Published by AC Business Media Inc.

Lisa Cleaver, Editor

lcleaver@ ACBusinessMedia.com

A

s the owner of an asphalt company, you can’t be everywhere at once. Trusting your employees to get the job done when you’re not there is a must, but it’s not always a given.

Brad Humphrey has been around the construction industry for over 30 years.

Known as The Contractor’s Best Friend, he regularly blogs on training issues for ForConstructionPros.com.

He says construction leaders tell him it’s not even about making the RIGHT decision at times but just making a decision that can slow down the process.

Humphrey offers five tips for getting everyone on the same page when it comes to decision making: • Inform employees that decision making IS NOT an option: “You might think that employees inherently know that they are expected to make decisions, but I have found many contractors who might disagree with this assessment,” Humphrey says. Make it part of your new employee orientation, remind your workers at crew or companywide meetings and share again at employee performance reviews the need for them to make decisions on their own.

• Define what decisions can be made by level of authority: Most employees simply want to know what they can and cannot do. Review each level of work and consider – and document – what decisions can be made at each level.

• Teach your workers how to make decisions: “Many contractors are finding that younger workers have had limited training or nurturing on how to make decisions … much less good decisions,” he says. So if you have a worker who just isn’t making decisions, consider the fact that she might not have had any formal training on how to go about making a decision.

• Teach your workers “Return on Decision Made” (RODM): RODM simply means every decision has some consequence or “return” behind it. It could be financial, but it might also be some level of customer satisfaction, doing something only one time versus having to repeat an effort, etc.

Employees need to understand that good decisions mean a better return.

• Trust … then trust again: Not every decision your workers make will be the right decision. “This is where you must hold on to your shorts and, while wanting to correct the results, not display any negativity to the employee,” Humphrey says. “We must control our tendency to pull back from employees when they have decided poorly.”

For more training insight, check out ForConstructionPros.com and search “Brad Humphrey.”

Thanks for reading!

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

Ad Production Manager

Patti Brown

Art Director

April Van Etten

Sr. Audience Development Mgr

Wendy Chady

Audience Development Mgr

Tammy Steller

Advertising Sales (800) 538-5544 Sean Dunphy sdunphy@ACBusinessMedia.com Jill Draeger jdraeger@ACBusinessMedia.com Erica Finger efinger@ACBusinessMedia.com Tom Lutzke tlutzke@ACBusinessMedia.com Amy Schwandt aschwandt@ACBusinessMedia.com Eric Servais eservais@ACBusinessMedia.com Denise Singsime dsingsime@ACBusinessMedia.com

ForConstructionPros.com Digital Operations Manager

Nick Raether

Digital Sales Manager

Monique Terrazas

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

Reprint Services For reprints and licensing please contact Denise Singsime at (800) 538-5544 ext. 1245 dsingsime@ACBusinessMedia.com

List Rental Elizabeth Jackson, Account Executive, Merit Direct LLC, Phone: (847) 492-1350 ext. 18 Fax: (847) 492-0085 • ejackson@meritdirect.com

AC Business Media Inc. Chairman

Anil Narang

President and CEO

Carl Wistreich

Executive Vice President

Kris Flitcroft

CFO

JoAnn Breuchel

Vice President, Content

Greg Udelhofen

Vice President, Marketing

Debbie George

8 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_08-9_Editor_JL.indd 8

8/26/15 3:00 PM

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

ACON0915_08-9_Editor_JL.indd 9

8/26/15 3:00 PM

NEW PRODUCTS PaveXpress Adds Asphalt Overlay Design Feature

P

aveXpress, a free Web-based pavement design tool, has been upgraded to version 2.0 with a new module for asphalt overlay designs. The majority of road projects managed by public works and road agencies today involve pavement maintenance and preservation; the new module makes it easy to design asphalt overlays that preserve a pavement’s structure while improving smoothness, safety, and drivability.

PaveXpress creates technically sound pavement structural designs for flexible and rigid pavements based on widely accepted industry standards from the American Association of State Highway Transportation Officials (AASHTO). It is designed for use by local agencies, engineers, architects, consultants, and engineering students who need a reliable way to quickly determine the necessary pavement thickness for a given section of roadway or project.

For both overlays and new pavements, the software only asks users for inputs required to create technically sound pavement designs, and it suggests industry-accepted defaults where appropriate. The default values can be adjusted to meet locally calibrated values, and contextsensitive help and guidance tools are available at every step of the design process. The overlay module uses 1993 AASHTO Guide Chapter 5 pavement evaluation guidelines to evaluate the existing pavement structure prior to placing an overlay with different decision pathways for condition surveys or non-destructive testing.

PaveXpress is based upon design equations from the 1993 AASHTO Guide for the Design of Pavement Structures and the 1998 Supplement to the AASHTO Guide for the Design of Pavement Structures. It supports the design of new flexible and rigid roadway pavements, asphalt overlays and heavy-duty asphalt parking lots. For light-duty parking lots, the tool provides access to statespecific flexible pavement designs based upon industryaccepted standards and guidance.

Projects created in PaveXpress can be printed, shared and saved, and design options can easily be evaluated in a side-by-side comparison. As a browser-based tool, PaveXpress can be accessed from any computer or mobile device, regardless of screen size or operating system.

Since its introduction in September 2014, there have been more than 5,000 users of PaveXpress, including users at state and federal departments of transportation, local agencies, tollway authorities and educational institutions.

Search: 12092637

Ray-Tech Mini TMV Ray-Tech's Total Maintenance Vehicle (TMV) is a combination reclaimer and infrared pavement heater that enables the user to make yearround permanent restorations.

• TMV can reclaim waste asphalt into permanent patch material and hold fresh asphalt at the proper working temperature • 8’ x 6’ pavement heater • 2-ton asphalt reclaimer • Mounted on a Ford 550 chassis • Non-CDL: The unit is smaller in size than typical maintenance vehicles, operators do not need a CDL to drive • Non-HazMat: Five propane tanks in the back to run the infrared unit do not require any special HazMat permits Search: 12041231

ZycoTherm from Zydex

Bitu-Ox 400 Multi-Use Asphalt Remover Solution Bitu-Ox 400 is designed to liquefy and remove asphalt instantly from machinery, equipment, conveyor belts, chutes and more.

• 400°F flash point makes Bitu-Ox 400 nonflammable and safe it extreme heat • Used as a release agent or daily cleaner on job sites • Prevents and loosens rust while leaving a protective coating to prevent future corrosion • 100% biodegradable and safe for waterways • Available in 5-gal. pails or 55-gal. drums Search: 12071893

ZycoTherm is based on an Organo-silane nanotechnology re-active chemistry that loves water and oil (hydrophobic) and will not stick to steel.

• Odor-free additive increases moisture resistance and lowers mixing compaction temperatures up to 80° C • Typically uses about 1/10th the dosage as amines • Can be used in multiple applications for anti-strip, warm mix, coating and compactability, polymer modified asphalt, ground tire rubber and RAP/RAS mix designs • Prime and tack coats become 100% waterproofed due to penetration and chemical bonding, ensuring uniform load transfer • Chemical bonding between aggregates and asphalt eliminates moisture induced damage of asphaltic layers Search: 12061757

10 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_10-17_NewProd_JL.indd 10

8/26/15 3:01 PM

A FULL LINE OF EQUIPMENT & PRODUCT SUPPORT SOLUTIONS FOR ALL YOUR ROAD BUILDING NEEDS. PAVERS | MTVS | COLD PLANERS | STABILIZERS BROOMS | COMPETITIVE PARTS | GUARDIAN

roadtec.com 1.800.272.7100 423.265.0600

© 2015 ROADTEC.INC. ALL RIGHTS RESERVED Search: 10074458

ACON0915_10-17_NewProd_JL.indd 11

8/26/15 3:01 PM

NEW PRODUCTS Atlas Copco Dynapac F800T Tracked Paver The Dynapac F800T 10-ft. tracked paver features a Carlson EZIV08-15 front-mounted electrical screed offering 8- to 19-ft. working widths and a mat as high as 1 ft.

• 173-hp Cummins six-cylinder diesel engine meets Tier 4 Final emissions regulations • Feed control system ensures continuous, uniform material flow to the center of the screed by using four ultrasonic sensors and a 6-in.-wide center chain box auger system • Augers include 17-in.-diameter flights designed to further eliminate centerline segregation • Dual, swing-out operator platform with ergonomically designed control panels provides high visibility to the paving surface Search: 12051900

Wirtgen W 100 Fi, W 120 Fi and W 130 Fi Cold Mills The W 100 Fi, W 120 Fi and W 130 Fi mid-sized cold mills feature a maximum milling depth of 13 in., and are powered by a Cummins six-cylinder Tier 4i engine generating 320 hp.

• Standard working widths of 39 in. (W 100 Fi), 47 in. (W 120 Fi) and 51 in. (W 130 Fi) with a front-loading system and all based on a common platform • Front-loading conveyor enables swift and smooth loading of large quantities of milled material • WIDRIVE machine control system keeps the engine speed within the optimal range during the milling process • Available as track-mounted or wheel-mounted models • Front travel drive units can be raised and lowered hydraulically and feature a large steering lock to allow for narrow bends and flush-to-curb milling Search: 12039394

WHAT DOES SEARCH: 10000000 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!

Heat Activated Asphalt Patch (H.A.A.P.) from Appliqué Technologies Heat Activated Asphalt Patch (H.A.A.P.) from Appliqué Technologies is manufactured with virgin DOT-approved asphalt — no millings or old recycled asphalt.

• Contains ballistic fibers for a permanent repair • Contains polyolefin wax that melts when exposed to heat for superior adhesion to old asphalt, greater flexibility and a waterproof repair • No hot box, large infrared heaters or other equipment needed • No shelf life- stores indefinitely • Takes 2 to 3 minutes for complete pothole repair • Material is available year round for delivery or pick up

Road Science ArrTekk 860 Asphalt Emulsifiers Road Science, a division of ArrMaz, launches ArrTekk 860 asphalt emulsifier for applications such as tack coat, fog seal, slurry seal, central plant recycling and mixing-grade CIR and FDR recycling.

• Designed for quicker traffic return to roadways and improved short and long-term product performance • Compatible with most types of asphalt and polymer modifiers • Easily mixes, coats and adheres to damp and/ or dusty aggregates, granular materials and recycled asphalt pavement (RAP) • Allows for easy pickup, lay down and compaction of RAP with CIR machinery equipment Search; 12064210

Search: 12082568

SealMaster OptiPave Surface Sealer SealMaster OptiPave is an eco-friendly asphalt-based emulsion pavement rejuvenator and surface sealer.

• Seals, protects and replenishes pavement binder, extends the service life of pavement and is designed to make roads look like new • Provides a barrier against damaging effects of moisture intrusion into asphalt pavement • One-coat application process with minimal traffic disruption Search: 12069518

12 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_10-17_NewProd_JL.indd 12

8/26/15 3:01 PM

THE FACES OF ASTEC PARTS

SHE’S ALWAYS YOUR PARTS PERSON When parts tech DONNA FLOYD is not helping her customers, you’ll find her camping in a matador red replica 1961 Shasta Airflyte. And when she gets back to the office and takes your call, she takes as much care to find the part you need as she does to find the perfect campsite, because she’s always your parts person.

An ASTEC parts tech knows that being successful in her job means that you count on her to deliver when needed. So when she takes your call she takes care to find exactly the part you need and then gets it to you as fast as possible. She’s always your parts person.

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

With a team of 35 parts professionals, ASTEC delivers the industry’s best customer service.

Any part, any brand. We can help.

Search: 10072061

ACON0915_10-17_NewProd_JL.indd 13

8/26/15 3:01 PM

NEW PRODUCTS Thunder Creek FST Series Trailers The FST Series trailers are available in 500-, 750- and 990-gal. diesel capacities with a 100-gal. DEF tank and an optional field-installed rear utility box that is 55% larger than previous designs.

• Closed-loop DEF delivery system includes a two-in-one DEF pumping system, 100-gal. poly tank and auto shut-off when filling • Low-profile and baffled fuel tanks suitable for traveling both on- and off-road • 75 cu. ft. of space in the front and pump enclosures and an additional 60 cu. ft. in the optional rear utility box • Hatch-style doors provide unrestricted access to the pumping systems, controls and options • Includes 7-gauge steel and double-welded seams, replaceable fenders and a rock guard

Carlson CP75 Commercial Class Paver Carlson's latest paver, the CP75 commercial class paver, features a 74-hp Cummins Tier IVi engine.

• Screed-mounted controls provide intuitive platform, keeping the controls relative always to the operator • One-piece forward tilting hood and forward access panel over the hopper for easy maintenance and serviceability • Heavy-duty replaceable floor plates, hardened steel auger flights and durable components • Electrically-heated EZC813 screed offers standard paving width from 8 to 13 ft.; optional EZC815 screed with 8- to 15-ft. widths Search: 12087872

Search: 12077109

Invarion RapidPlan Traffic Control Software

Multiquip AR14H Tandem Drum Roller The AR14H tandem drum ride-on roller produces 3,400 lbs. of centrifugal force from an eccentric housed within a 35.6-in. drum.

• Honda GX630 engine with a 9.5-gal. fuel tank • Pressurized 35-gal. water tank standard • Compact design with high curb clearance and clear line of sight visibility for better steering • Easy to use and access controls for throttle, vibration, water pump and water flow • Engine compartment places all filters, oil fills, fluid drains and hydraulic hoses within easy access • No greasing required for the articulation joint or vibratory assembly Search: 12034732

BOMAG BW177DH-5 & BW177PDH-5 Vibratory Rollers Built with no-spin rear differential, the smooth drum BW177DH-5 and padfoot drum BW177PDH-5 feature a dual travel pump drive system that enables up to 58% gradeability with vibration and 61% without.

• Both models offer vibration frequencies of 1,860/2,280 vpm, as well as 25,179 lbs. of centrifugal force in high amplitude and 16,636 lbs. in low to quickly compact up to 18-in. lifts of granular soil and up to 14-in. mixed soil lifts.

• 74-hp Kubota Tier 4 Final turbocharged diesel engine Search: 12047520

The RapidPlan Traffic Control Software is designed to make the creation of traffic control plans such as temporary traffic control plans, shortterm work zone traffic control diagrams, event management plans and evacuation diagrams easier.

• Regional sign libraries included • Sign creation engine • Full 24x5 support • Regular online training sessions • Import from CAD, GIS or use aerial photography • Use included templates for all standard plans • Automatically generate plan manifests • Add all road markings, devices and custom annotations

Attachments International Side Shooter Attachments International offers the Side Shooter cutter for side profiling and cutting shoulders.

• Quick disconnect in less than one minute • Flush-mount external or internal on bucket, blades or moldboards • AI-X400 alloy construction • Chromed induction hardened axles Search: 12050060

Search: 1207430

WHAT DOES SEARCH: 10000000 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!

14 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_10-17_NewProd_JL.indd 14

8/26/15 3:01 PM

SO FUEL EFFICIENT, IT MAKES YOUR HYBRID LOOK LIKE A MONSTER TRUCK.

GENERAL COMBUSTION OFFERS A FULL LINE OF MULTI-FUEL BURNERS GENCO ULTRA II · EQUINOX · ULTRA FLAME · ASTRAFLAME

Nothing can compare to fuel efficiency of the Ultra II burner. Unbelievable power, unshakable reliability and faster response make it the most dependable burner available. It also runs on almost any fuel making it the greenest burner on the planet. Just one of the many brilliant systems from General Combustion.

5201 N. Orange Blossom Trail ∙ Orlando, FL 32810 ∙ 407.290.6000 ∙ GeneralCombustion.com Search: 10073093

ACON0915_10-17_NewProd_JL.indd 15 119784_Gencor_GenComb.indd 2

8/26/15 3:01 PM 8/11/10 2:28 PM

WATCH THIS TRUCK COME TO LIFE.

ACON0915_10-17_NewProd_JL.indd 16

Competitive financing available through Daimler Truck Financial. For the Freightliner Trucks dealer nearest you, call 1-800-FTL-HELP. www.freightlinertrucks. com. FTL/MC-A-1152 Specifications are subject to change without notice. Copyright Š 2015. Daimler Trucks North America LLC. All rights reserved.

Freightliner Trucks is a division of Daimler Trucks North America LLC, a Daimler company.

8/26/15 3:01 PM

The Freightliner 114SD truck enables these guys to handle demanding paving jobs with greater efficiency. It offers a 114-inch BBC cab made of corrosion-resistant aluminum, reinforced with e-coated steel. It has a contoured hood slope for superior visibility and a 50-degree wheel cut for better maneuverability. Add key weight-saving components and our proprietary SmartPlex™ Electrical System, and you’ve definitely got the latest and greatest equipment for any construction job. To learn more, visit FreightlinerTrucks.com/WorkSmart.

ACON0915_10-17_NewProd_JL.indd 17

Search: 10073061

8/26/15 3:01 PM

PAVING INNOVATIONS

Shelly & Sands Earns Maximum Smoothness Bonus with New

18 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_18-27_PavingShelly_JL.indd 18

8/26/15 3:03 PM

MTV

The new MT 3000-2i MTV from Vögele helped Shelly & Sands attain the kind of ride numbers it needed on the I-71 reconstruction project in Ohio

By Tom Kuennen, Contributing Editor

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_18-27_PavingShelly_JL.indd 19

19

8/26/15 3:03 PM

PAVING INNOVATIONS The new MT 3000-2i material transfer vehicle feeds the Vision 5200-2 paver with VF 600 screed.

I

n early summer, Shelly & Sands Inc., Zanesville, OH, completely reconstructed over nine miles of I-71 between Mansfield and Columbus in the central part of Ohio.

In a $54 million project, the Ohio DOT took the opportunity of widening I-71 from two lanes to three to completely rebuild the highway from the base up.

This project represents the last stage of “three-laning” the busy interstate from Columbus to Cleveland, and the segment between Columbus and Cincinnati also is being widened to three lanes.

The star of the show on I-71 was Shelly & Sand’s new Vögele MT 30002i material transfer vehicle (MTV), feeding a Vision 5200-2 paver with VF 600 screed. The compact low-centerof-gravity of the MTV offers an alternative to the “silo” or shuttle-type MTVs which have been the standard up to now.

The MT 3000-2i fed an innovative insert mounted in the hopper of a Vision 5200-2 paver with VF 600 screed, both from Vögele.

The VF 600 is a front-mount screed designed for main line paving. The paver operates with the Niveltronic

The MTV fed an innovative hopper insert mounted in the paver’s hopper.

Plus leveling system from Vögele, and Shelly & Sands has settled on that system.

For smooth mats, both high frequency and exclusive Hamm Oscillation compaction figured into the job: breakdown compaction was provided by a Hamm HD+ 120i VV HF roller, intermediate compaction by a Hamm HD+ 110i VV HF roller, and finish compaction by an HD+ 120i VO with vibration compaction in the front and oscillation in the rear. Shelly & Sands’ long-time equipment distributor is The McLean Company.

The high-vibe Hamm rollers were critical in meeting state density specs, says Tom Ellis, area manager for Shelly & Sands.

“As long as they’re on it, good and hot, we’re getting densities above 94%,” he says. “Behind the intermediate roller we’re in the 93-94% ranges, and with finish we’re above 94%.

The oscillation in the finish roller allows us to continue to compact even if the mat is at a lower temperature.

Oscillation is like a ‘get out of jail free’ card, as it will continue to compact at lower temperatures.”

To begin, 9 in. of aged asphalt was milled by milling subcontractor BOCA Construction Inc., Norwalk, OH, from the existing two-lanes, both north- and southbound, revealing an original concrete pavement. This was rubblized

by Shelly & Sands using a towed rotating breaker, and then dug out by an excavator. These pieces were crushed using its Kleemann MR 110 Z EVO mobile impact crusher located in the median.

In the meantime, the underlying stone base was removed. A 10-in.deep cement-treated base was created by the Cleveland area-based subcontractor Cem-Base Inc., using two Wirtgen WR 2500s.

A virgin aggregate base of 6 in. was placed on the CTB, topped by an 11-in. base course of PG 64-22 binder with NMAS of 1-½ in., placed in two lifts of 6 and 5 in.

This was followed by 1-¾ in. of a 9 mm intermediate lift with PG 64-28 binder, and topped with 1½-in. of 12 mm surface course using a PG 70-22 binder containing SBS polymer modifer, blended at Shelly & Sands’ own terminal.

20 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_18-27_PavingShelly_JL.indd 20

8/26/15 3:03 PM

You’re serious about getting your bonus. And your crew thanks you.

Our line of pavers and compactors sets the standard for reliable asphalt paving. We have a long history of proven technology and a reputation for industry-leading innovation. When it comes to maximizing your earnings, these machines deliver. See smart in action at volvoce.com/smartroads.

Search: 10075146

ACON0915_18-27_PavingShelly_JL.indd 21

8/26/15 3:03 PM

PAVING INNOVATIONS

For this three-lane interstate with 12-ft. shoulders, Shelly & Sands placed three pulls, 23 ft. 6 in., 13 ft. and 23 ft. 6 in.

For this new three-lane interstate with 12-ft. shoulders, Shelly & Sands was using its Vision 5200-2 to place three pulls, 23 ft. 6 in., 13 ft. and 23 ft. 6 in.

“We’re paving the middle 13 ft.,” Ellis says. “The reason for that is to maintain traffic and put striping in the proper place, offset from the joint.”

Front-mount screed For wide paving like on I-71, the VF 600 screed with bolt-on extensions was used, and that offered advantages to Shelly & Sands. “We made the right choice with that screed,” says Steve Schlosser, equipment superintendent at Shelly & Sands. “It’s working out well, and the feedback from the group is positive.

“I believe the front-mount VF 600 is more versatile than a rear-mount, because it’s easier to see and manage the material than with a rear-mount,”

Schlosser continues. “The visibility is better, and on a two-lane highway it’s easier to move the wing in and out. You can go narrow, or you can go wide. We found that for us, the frontmount screed works best.”

In fact, of all of Shelly & Sands’ screeds, only two are rear-mount.

The contractor finds that while rearmount screeds may be ideal for long-pull highway work, they are less manageable in tight urban quarters, and material management issues can develop as the screed is brought in, causing the screed to rise.

“With the front screed, the ability to

Hamm Oscillation rollers were used for breakdown, intermediate and finish compaction on the project.

go in and out is so much easier with the material,” says Scott McLean, vice president/field sales manager of McLean’s Columbus branch. “You don’t have to change the head of the material.”

At the start of the project, the contractor found the VF 600 was easier to set up than most of their other screeds.

“It’s easier to put the extensions on and adjusted properly, so you can pave a good mat,” Schlosser

22 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_18-27_PavingShelly_JL.indd 22

8/26/15 3:03 PM

速

Search: 10074707

ACON0915_18-27_PavingShelly_JL.indd 23

8/26/15 3:04 PM

PAVING INNOVATIONS

says. “It’s less time-consuming to set up. From the first couple of hundred feet, the mat quality was high.

The crews really like it. Structurally, it’s heavier than screeds we’ve used in the past, and that’s really good, as lighter weight is one of the downfalls of screeds.”

The VF 600’s versatility shows in

its applications. “We could take that paver with front-mount screed up on a high-volume highway and lay two lanes at once,” Schlosser says. “Then the paver could end up on a two-lane highway, and then to an airport where it will be spreading 25 ft. wide.”

The Vision 5200-2 used on this project is one of 23 Vögele pavers

owned by Shelly & Sands. The firm also owns 36 Hamm rollers.

“The Wirtgen Group, along with The McLean Company, has proven themselves over time with us,” Schlosser says. “We expect good bonus money because of Jake Christina’s crew, plus the hard work of Chad Evans’ Mar-Zane Plant 12. The combination of our good people, good equipment, dealer and factory support has helped this project.”

Some 624,984 sq. yds. of pavement will have been placed by the end of the project completion in June.

MTV on surface course The MT 3000-2i was used only on the surface course, says Ed Morrison quality control manager at Shelly & Sands.

“For paving at night, state spec requires an MTV for any surface work over a continuous mile, but we used one whether paving day or night,” Morrison says. “We do it to minimize segregation, and it helps us achieve density and smoother pavement.”

That’s important as this project carries a $450,000 bonus if all IRI specifications are met.

“This MTV is helping us get there,” Morrison says. “The main advantages are, number one, smoothness, and number two, density.

“Regarding smoothness, we have better truck exchanges because the MTV acts as a buffer,” he continues. “And we keep a consistent head of material in the paver Search: 10073668

24 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_18-27_PavingShelly_JL.indd 24

8/26/15 3:04 PM

paver wings.Shelly & Sands follows that best practice.

“We like the trucks to come back to the paver or MTV with their beds halfway up, and as soon as they contact the machine, they tip their load all at once, and all the material moves in in mass,” Morrison says. “That helps fight segregation. With this

MTV, more so than others we’ve used in the past, you can dump in mass without it plugging up. With the MT 3000-2i, we can dump ‘shock’ loads, and it never fazes it.”

For more information on innovative paving equipment, visit ForConstructionPros.com/asphalt.

For wide paving like on I-71, the frontmounted VF 600 screed with bolt-on extensions was used.

hopper. Consistency is the big thing for smoothness; it takes error out of the equation. And the reduction in segregation helps us maintain density.”

Segregation can develop at the plant, at the silos with the way the trucks are loaded and in the paver, he added.

“The plant and drivers need to follow the three-drop system, a drop in the front, one in the back, and one in the middle of the trailer,” Morrison says. “And if crews let the paver hopper run too low, it can lead to segregation.”

According to the new National Cooperative Highway Research Program synthesis, NCHRP 477, Methods and Practices on Reduction and Elimination of Asphalt Mix Segregation (2015, Google “NCHRP Synthesis 477”), end-of-truck segregation is one of three types of material segregation that can result in coarse mat finishes.

End-of-truck segregation also is known as truck-to-truck and truckload-to-truckload segregation.

According to NCHRP 477, segregation can be reduced when the end dump haul truck bed is raised before opening the back gate.

When the gate is finally opened, the mix is discharged from the truck bed in mass into the paver hopper.

This process rapidly fills the paver hopper and prevents the coarser particles from collecting in the Search: 10074524

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_18-27_PavingShelly_JL.indd 25

25

8/26/15 3:04 PM

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

ACON0915_18-27_PavingShelly_JL.indd 26

8/26/15 3:04 PM

Search: 10072036

ACON0915_18-27_PavingShelly_JL.indd 27

8/26/15 3:04 PM

PAVING INNOVATIONS Hot Mix Mobile RoadMixer The RoadMixer mobile volumetric hot mix asphalt mixing and delivery system is capable of producing 10 tph of hot mix asphalt from raw materials carried on-board or from materials on the jobsite.

• 12.8-ton overall capacity • Includes one material bins for sand, two for stone and variable multi-aggregate bins for fine or coarse material • 114-gal. onboard containment tank for liquid asphalt • Insulated discharge hopper stores 1.25 tons of hot mix Search: 11295674

Topcon C-63 Intelligent Compaction Control The GPS-based C-63 intelligent compaction (IC) control solution is now available for aftermarket integration into soil and asphalt roller systems.

• Allows the operator to collect and use data in real time for stiffness, density and temperature control • 6.5-in. graphical display tracks cumulative compaction Search: 12024935

Vögele Dash 3 Paver Super 2100-3i Paver

Carlson LED Blade Light Carlson’s LED Blade Light has the ability to mount on a wide range of equipment including rollers, pavers, milling machines and more.

• Available in 110/220v and 12/24v platforms • Produces equivalent light output of a 2,000-watt halogen while offering a lifespan of 50,000 hours • Low profile and directional light creates safe working environments by eliminating dangerous glare while illuminating positions and mobile equipment • Cool-to-touch LEDs enable quick breakdown and storage in durable, hard-sided case Search: 12041607

The Super 2100-3i paver in the new ”Dash 3“ generation from Vögele is equipped with an AB 600 extending screed in the TP2 Plus version for high compaction.

• EcoPlus low-emissions package combines a number of individual measures distinctly reducing the fuel consumption and noise of the paver • PaveDock Assistant facilitates communication between the paver operator and the driver of the feed truck and ensures that the material is supplied to the paver safely and without jolts • “PaveDock” push-rollers optional • ErgoPlus operating system • AutoSet Plus offers an automatic repositioning function and an automatic function for paving programs Search: 11328712

Dynapac F800T Paver The F800T 8-ft. tracked paver has a working width of 8 to 19 ft. and paves to 12 in. thick.

• 13.5-ton material hopper with chamfered corners • EZIV08-15 front-mounted electrical screed powered by a tractor-mounted 34-kV hydraulically driven generator • Independently controlled, dual-bar feed conveyor system with 17-in.-diameter auger flights • 6-in.-wide center chain box designed to eliminate centerline segregation • Integrated feed control system with four ultrasonic sensors • 173-hp Cummins Tier 4 Final engine Search: 11322495 Search: 10073532

28 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_28-33_PavProd_JL.indd 28

8/26/15 3:05 PM

THE ONE-STOP-SOURCE FOR

PAVEMENT

PRODUCTS& EQUIPMENT

Additives

Pavement Sealers

SealMaster® has all the pavement maintenance products, equipment and tools you need – Under One Roof – to help you get the job done fast and right.

And we’ve got the best trained professionals in the business to provide unmatched service and guidance to help your business grow and succeed. Contact us today and find out why more pavement professionals turn to SealMaster than any other brand.

Crack Fillers

Traffic Paints

Equipment & Tools

SPORT SURFACING PRODUCTS AND MORE LOCATIONS NATIONWIDE CALL TODAY!

(800) 395-7325

www.sealmaster.net ACON0915_28-33_PavProd_JL.indd 29

Be sure to visit us at Booth #1343!

Search: 10074572

8/26/15 3:05 PM

PAVING INNOVATIONS Doosan BX-60 Vibratory Plate Compactor The BX-60 single-direction vibratory plate compactor compacts granular soils, crushed aggregates and hot mix asphalt (HMA) on small- to large-sized open jobsites.

• Compact design provides maneuverability, enables compaction in confined areas and allows for ease of storage with its fold-over handles • Power is supplied by a Honda four-cycle engine rated at 3,600 rpm with recoil start • Delivers a centrifugal force of 3,400 lbs. and a vibration frequency of 5,600 vpm • Maximum travel speed of 82 fpm, with an area capacity covering 6,943 sq. ft. per hour • Compaction depth is recommended to 12 in.

• Operator comfort maximized with adjustable vibration-reducing, padded grip handles Search: 12093500

BOMAG BW11RH-5 Pneumatic Tire Roller

L-VIS

u No pre-heating necessary u Ready to pump as low as 10°F (-12°C) u Viscosity substantially reduced compared to traditional PPA u Cost savings up to 50% on PPA storage and handling u INNOVALT® renowned asphalt modification performance

™

Ready To Mix It Up NEW

Low Viscosity Polyphosphoric Acid

Contact us today: 866.631.7394 www.INNOVALT.com

Purchase of these products confers the right to practice these applications under the following patents: u XL – WO9714753, WO9743342, WO07143016, WO06047044 u E – WO984404 u R – WO04081098, WO06119354, WO06119470, WO11047032 u T – WO09026390, WO07034081 u Other patents pending

INNOVATE WITH PHOSPHATE ™

INNOVALT® L-VIS™ – Ready When You Are

The BOMAG BW11RH-5 pneumatic tire roller boasts 35° centerpoint articulated steering, delivering a short 10-ft inside turn radius, which allows the front and rear tires to maintain tracking in turns, offering full width compaction in tight, winding curves to reduce the number of passes to reach desired densities.

• Five front tires and four rear tires of the BW11RH-5 deliver a compaction width of 68 in. with zero frame overhang for intermediate compaction of highways, urban development roads, parking lots, driveways and chip-and-seals • Front tires deliver +/- 4° oscillation on the two outside tires and +/-5° oscillation at the three center to kneed and manipulate asphalt, improving mat density • Centerpoint steering joint offers +/- 10° oscillation to help maintain wheel contact with material • Nine 7.5x15, 14-ply pneumatic tires offer standard fully ballasted wheel loads reaching 2,222-lb. and ground contact pressure up to 82 psi • Standard 12,231-lb. operating weight, which can be increased to 20,000 lb. by adding ballast to maximize compaction forces • 74-hp liquid-cooled Kubota Tier 4 Final engine Search: 12056935

Search: 10073374

30 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_28-33_PavProd_JL.indd 30

8/26/15 3:05 PM

Atlas Copco Intelligent Compaction System The easy-to-use intelligent compaction system gives contractors real-time material stiffness readings from within the cab to help minimize the number of passes on both soil and asphalt.

• Uses GNSS (such as GPS) to track the number of completed passes and a drum-mounted accelerometer to measure the surface’s relative material stiffness • Also detects temperature of asphalt to provide consistent, relative stiffness readings • Alerts the operator once desired compaction is achieved • Stored data readily available to print off or display as needed • Available on CC2200 to CC6200 asphalt and CA2500 to CA6500 soil rollers • Can be used on a tablet to set project parameters and view compaction data Search: 12051916

Roadtec RP-195e Asphalt Paver The rubber-track highway class RP-195e paver is powered by 230-hp Cummins QSB 6.7 Tier 4 Finalcompliant diesel engine.

• Anti-segregation design encompasses the feed tunnel, feed tunnel discharge and rear augers • Fully oscillating bogies and smooth tread aide in laying a smoother mat • Operator stations hydraulically swing out, allowing the operator to see down the side of the machine • Consoles located at the operator’s fingertips with adjustable operator seat for optimal comfort • Includes the Clearview FXS fume extraction system and Guardian remote telematics and diagnostics system Search: 12055680

WHAT DOES SEARCH: 10000000 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!

SU

S TA IN A BLE

Safe • Consistent • Sustainable • Controllable Easy-To-Maintain • Customizable • Low-Watt Density Electric Tank Heaters That Last For Decades

Call 866-682-1582 or visit www.processheating.com.

PROCESS HEATING COMPANY

Search: 10074285

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_28-33_PavProd_JL.indd 31

31

8/26/15 3:05 PM

PAVING INNOVATIONS

Sakai SW990 Roller

Volvo P7110 & P7170 Pavers

The SW990 double-drum, highfrequency vibratory asphalt roller offers a drum width of 84 in. and 4,000 vpm to allow for 10 to 12 impacts per foot at 4.55 mph.

• 166-hp Deutz TCD2012L06-2V watercooled, turbocharged diesel engine • Dual-drum drive system eliminates bow wave buildup in the front of the machine • Standard ExactCompact system measures impact spacing and determines the speed the roller should travel to obtain compaction

The tracked P7110 and wheeled P7170 feature a SmokEater fume extraction system to remove fumes without obstructing the view into the auger channel.

• 26-ft. maximum paving width and 12-in. maximum paving depth • Four-sensor feed system automatically regulates delivery and flow of material to match paver speed • 12-ton hopper with synchronized folding, hydraulic front hopper wings • Proportional auger speed control and hydraulic auger height adjustments • 235-hp Tier 4i D8 engine

Search: 10080223

Search: 10898378

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 Search: 12039375

MAKE CRACK SEALING PART OF YOUR PROFIT PLAN Add crack sealing to your business with minimal investment. Choose our total package with routers and melters to add a valuable service to your operation.

Choose Magma for crack sealing productivity, with: Simple Start-Up and Operation Faster Heat-Up Low Loading Height Better Visibility Rout those cracks before crack sealing for even more revenue.

Fuel Efficiency TH

IV ANN ERSA

RY

45

Ergonomic Drip-less Wand

PMG 1970 - 2015

www.CIMLINEPMG.com

Search: 10072434

32 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_28-33_PavProd_JL.indd 32

8/26/15 3:05 PM

Search: 10074806

ACON0915_28-33_PavProd_JL.indd 33

8/26/15 3:05 PM

PAVEMENT PRESERVATION

Milling Industry Stays a Step Ahead of

The Roadtec RX-600e, RX-700e, and RX-900e models include a dust extraction system which uses a hydraulic fan to remove dust from the primary conveyor and channel the material to the dump truck alongside the secondary conveyor.

OSHA

An historic partnership to keep workers safe leads to innovation and an effort to comply with OSHA before enforcement of the imposed silica dust rule

by Lisa Cleaver, Editor

34 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_34-47_PresSilica_JL.indd 34

8/26/15 3:06 PM

You can’t crush and track at the same time.

WE DISAGREE.

The FT4250 is part of the exclusive continuous crushing and tracking family.

Up to 30 percent more uptime than competitive models.

Up to 25 percent more production than competitive models.

TOUGHNESS REFINED.

Aggregate

Recycle

Construction

Infrastructure

Mining

Loading/Unloading

Energy

www.kpijci.com

Search: 10075552

ACON0915_34-47_PresSilica_JL.indd 35

8/26/15 3:06 PM

PAVEMENT PRESERVATION

I

n 2003, an industry came together to find a way to control workers’ exposure to respirable crystalline silica during asphalt pavement milling in highway construction.

The Silica/Asphalt Milling Machine Partnership — which is made up of milling machine manufacturers, the National Asphalt Pavement Association (NAPA), labor, academia, and the National Institute for Occupational Safety and Health (NIOSH) — has worked over the past decade to design, test and implement engineering controls for milling machines that effectively reduce potential silica exposure below OSHA’s new proposed Permissible Exposure Limit (PEL).

Approximately 367,000 U.S. workers employed in highway, street and

bridge construction are at risk of exposure to respirable crystalline silica.

Workers use a variety of machines when removing and recycling asphalt pavement, including cold milling machines which feature toothed, rotating cutters that grind and remove pavement for recycling.

During operation, workers can inhale silica dust, which can cause silicosis, a debilitating and potentially fatal lung disease. Silica exposure has also been associated with lung cancer, chronic obstructive pulmonary disease (COPD) and renal disease.

“Silicosis is a serious issue,” says Tony Bodway with Payne & Dolan, headquartered in Waukesha, WI. “As a contractor, it’s a priority that we ensure employees are working in a safe,

Introduced in 2010, the Vacuum Cutting System (VCS) can be found on all of Wirtgen’s larger cold mills – the W 250, W 210 and W 200, and the new W 200i and W 210i.

healthy environment. Exposure to silica dust is something we can prevent on the jobsite, and we should be striving to do that.”

OSHA has an established PEL, which is the maximum amount of crystalline silica to which workers may be exposed during an 8-hour work shift, set at 50 micrograms of respirable crystalline silica per cubic meter of air (50 g/m3).

This is consistent with NIOSH’s current

36 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_34-47_PresSilica_JL.indd 36

8/26/15 3:06 PM

Meeker has installed more of these RAP-PAK systems than any of our competitors AND we have the reputation and quality to back up each and every one.

• Allows batch plants to add up to 30%-40% RAP in high quality mixes

Your Preferred Asphalt Equipment Resource

• Unique vapor recovery system and control system for positive control of steam

888.333.0323

• RAP-PAK can be coupled with our warm mix system to produce superior mixes

www.meekerequipment.com

Search: 10073849

ACON0915_34-47_PresSilica_JL.indd 37

8/26/15 3:06 PM

PAVEMENT PRESERVATION

Recommended Exposure Level (REL) and will help reduce the risk of developing silicosis, lung cancer, and other adverse health effects.

What manufacturers are doing Although OSHA has not yet released a final silica PEL, the industry is optimistic that the engineering controls designed between manufacturers and NIOSH will allow workers to forgo the use of respirators during roadway milling operations.

The accumulated efforts of the silica coalition has resulted in new industry cold milling guidelines, also known as the Best Practice Engineering Control Guidelines to Control Worker Exposure to Respirable Crystalline Silica during Asphalt Pavement Milling.

Silica dust controls, such as ventilation controls, used in combination

with water-spray controls on asphalt pavement milling machines, can consistently reduce exposures below the NIOSH REL and the proposed OSHA PEL. Following is how each manufacturer has designed its milling machines to help limit operator and crew exposure to silica dust.

Wirtgen America Introduced in 2010, the Vacuum Cutting System (VCS) can be found on all of Wirtgen’s larger cold mills – the W 250, W 210 and W 200, and the new W 200i and W 210i.

Its principle is simple: by creating a negative pressure in the drum housing, the mix of air and water vapor is evacuated and then fed back into the flow of the milled material transported on the conveyor via a hose system.

“Wirtgen has made the machine operator and his workplace the center

of its engineering and development work for many years,” says Brodie Hutchins, vice president of dealer development at Wirtgen America.

Roadtec Inc. Roadtec milling machines have long included a water system with dual spray bars inside the cutter housing, says Kyle Hammon, product manager – Mills, Stabilizers and Brooms at Roadtec.

“The spray bars are positioned at opposite ends of the cutter housing to facilitate both dust control and heat reduction at the cutter drum,” he explains. “The flow rate of the water system is easily adjustable to meet the desired levels of the milling crew.”

The Roadtec RX-600e, RX-700e, and RX-900e models also include a dust extraction system which uses a hydraulic fan to remove dust from the

Starting in 2016, Caterpillar will offer an optional high-powered vacuum ventilation system on its milling machines.

38 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_34-47_PresSilica_JL.indd 38

8/26/15 3:06 PM

Introducing ...

PROFIT MATTERS Channel on ForConstructionPros.com SQUEEZE MORE PROFIT FROM EVERY JOB!

Visit our new PROFIT MATTERS Channel to learn about: • Contractors who are pioneering technologies and policies • A systems approach to cutting costs and improving productivity • New profitability management strategies • Real-world examples of construction cost-efficiency Sponsored by

From the editors of ForConstructionPros.com, the construction industry’s trusted source for news, equipment, products, video and analysis.

ACON0915_34-47_PresSilica_JL.indd 39

8/26/15 3:06 PM

PAVEMENT PRESERVATION

Maintain your dust control systems Dust control systems are designed to keep you protected – use these tips to ensure they’re working up to speed:

primary conveyor and channel the material to the dump truck alongside the secondary conveyor.

“The dust extraction system is a more recent design change, but the system is included as a standard feature for the safety and comfort of the milling crew,” Hammon says.

BOMAG Americas Inc. BOMAG is releasing a complete new line of milling machines presently, says John Hood, director of sales, heavy equipment at BOMAG. The BM2000/75 comes into the country fitted with a Dust Suppression System as a standard feature.

The smaller BM1200/35 machines have the ability to install the dust suppression kits from the factory or in the field.

“These are quite simply a plenum system that fits into the cutting housing, connects with a powerful suction fan to remove silica and fine dust particulates and blows them thorough a series of hoses or tubes into the bed of the dump truck with the milled asphalt,” says Hood.

BOMAG’s BM2000/75 comes into the country fitted with a Dust Suppression System as a standard feature.

Caterpillar Starting in 2016, Caterpillar will offer an optional high-powered vacuum ventilation system.

“This system will use a vacuum fan to extract milling dust from two key areas: the foot of the primary conveyor and the transition point between the primary conveyor and the loading conveyor,” says AJ Lee, global sales consultant with Caterpillar Paving Products.

Cat cold planers also offer an advanced water spray system that provides an ample number of nozzles ideally positioned in the chamber and areas of the conveyors prone to dust. The nozzles are controlled electronically to maintain a precise spray rate that balances water use with optimal dust control.

“Some contractors choose the option of an additional chamber spray bar, but the system is designed

• Locate the machine operator’s manual that contains a maintenance schedule for the water-spray or ventilation controls. Each operator’s manual should include detailed sketches, performance criteria, and troubleshooting instructions for equipment owners to use in their periodic inspection of the controls.

• Inspect and maintain the systems according to the manufacturer’s recommendations and record the dates of periodic inspections in the operator’s manual.

• Check the air-flow indicator to verify that the ventilation control is operating within the designed operating range. The manufacturer should attach a plate to the milling machine showing a simple diagram of the ventilation control and a list of fieldmaintenance procedures.

• Implement a water-spray and ventilation control system daily checklist to verify that the dust controls are being operated according to the manufacturer’s instructions.

40 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_34-47_PresSilica_JL.indd 40

8/26/15 3:06 PM

RG-1 Purpose-Built Shingle Grinder

Up-Time vs Up-Keep Each Rotochopper shingle grinder is designed with one simple goal—maximizing the value of your shingle waste by minimizing wear costs and maintenance downtime.

• No weekly hardfacing • Less spillage • Most uptime • Best horsepower efficiency

B-66 Multi-Purpose Shingle Grinder

• Fast tooth & screen changes

320-548-3586 www.rotochopper.com

• No augers, sprockets, or chains operating in abrasive fines • 350-765 HP, electric or diesel

Which Rotochopper grinder is right for your volume of shingle waste? Contact us today to learn more.

Search: 10139820

ACON0915_34-47_PresSilica_JL.indd 41

8/26/15 3:07 PM

ASTEC

PAT E N T E D S TA C K T E M P Run dense graded mix, warm mix, high RAP and OGFC all with no flight changes and no loss of production rate or fuel efficiency.

ACON0915_34-47_PresSilica_JL.indd 42

8/26/15 3:07 PM

M P E R AT U R E C O N T R O L S Y S T E M “The V-Pack stack temperature control system is the most important improvement to asphalt production since long-term storage.�

Dr. J. Don Brock

Founder, Chairman of the Board Astec Industries, Inc.

Search: 10072061

ACON0915_34-47_PresSilica_JL.indd 43

8/26/15 3:07 PM

PAVEMENT PRESERVATION

to apply exactly the amount of water necessary,” Lee says.

Manufacturers are also required to provide field retrofit kits for sale for older, larger half-lane milling machines.

What you can do While machine innovations will help limit you and your workers’ exposure to silica dust, there are still more steps you can take to reduce silica dust.

Recognize the hazard. Milling, cutting, or otherwise disturbing asphalt pavement can create airborne dust containing silica. Pay attention to wind direction and any visible dust emissions.

Use ventilation and water-spray controls on asphalt pavement milling machines. Water-spray plus ventilation controls are collectively considered to be the best practice approach to

asphalt pavement milling dust control and can reduce exposures below the NIOSH REL. Typical ventilation controls designed to reduce silica exposures on asphalt pavement milling machines include a collection hood, fan and ductwork. Milling machines should also be designed to allow the operator to temporarily turn the ventilation control off when milling into the wind.

If the ventilation control can be shut off, however, then a feature should be in place to automatically turn the ventilation control back on when it has been off for longer than 60 minutes.

Water-spray controls should always remain ON regardless of wind direction.

Always use water-spray controls on asphalt pavement milling machines that do not have ventilation controls.

When ventilation controls are

unavailable, water-spray systems that are properly designed, operated, and maintained can provide a significant reduction in the milling machine’s dust generation.

Other best practice water spray recommendations were developed for contractors that are not using ventilation controls on their asphalt milling machines. The two best methods are: • Spray water on the pavement being milled to suppress any dust • Knock down airborne dust by spraying the dust cloud Many in the industry feel that since a key component of milling machines is the water spray system used for cooling cutter bits on the cutter drum, the same spray system can also be used for silica dust control.

To maximize the effectiveness of water spray systems, several alterations

Wirtgen’s Vacuum Cutting System works by creating a negative pressure in the drum housing while the mix of air and water vapor is evacuated then fed back into the flow of the milled material transported on the conveyor via a hose system.

44 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_34-47_PresSilica_JL.indd 44

8/26/15 3:07 PM

SEAL THE DEAL ON SITE PROVIDE PROJECT QUOTES BEFORE YOU LEAVE THE JOBSITE. The FREE BidGuru App, developed

by Pavement Maintenance & Reconstruction, creates immediate, custom quotes for: Sealcoating Asphalt overlays Cracksealing Other pavement maintenance IT’S FAST. EASY. FREE. Visit ForConstructionPros.com/bidguru for details and download link.

BROUGHT TO YOU BY:

BidGuru_FPad_PVM0115.indd ACON0915_34-47_PresSilica_JL.indd 1 45

12/29/14 8/26/15 3:07 2:42 PM PM

PAVEMENT PRESERVATION

may need to be made to optimize the flow, pressure and nozzle locations.

Training required Finally, the simplest way to be your best advocate is to make sure you and your staff are properly trained.

“The number one best practice is education & training,” Bodway with Payne & Dolan says. “Don’t let your employees get complacent. Not only do they need to understand the hazards of silica dust, but they also need regular training on how to properly operate and maintain the machines they’re working with.”

Equipment manufacturers are great to partner with when it comes to this. Ask them for training on the operation, maintenance and repair of the dust control systems.

“All milling equipment manufacturers offer training when equipment

is purchased,” Bodway says. “But take advantage of annual training sessions that are offered as well to keep employees up to speed.”

Milling machine operators should be trained on the control systems and be provided with the operating specifications (water quantity, water pressure, air velocity) that must be maintained in order for the control systems to be effective.

Equipment mechanics responsible for maintaining the water-spray and ventilation control systems on asphalt pavement milling machines may require specialized training.

Operators should also be trained to temporarily disable the ventilation control system when milling directly into the wind.

In addition to using equipment manufacturers, Bodway says there are myriad places to get information.

He mentions equipment manuals, NAPA and NIOSH as great sources to stay informed.

“If you need to know, ask questions,” Bodway says. “There’s plenty of information and tools out there on this subject. Our top priority is to ensure workers are in an environment that keeps them healthy and safe and allows them to go home at the end of the day.”

For more information To access the best practices guide, visit goaspha.lt/1JvV4Lv. The Center for Construction Research and Training and NAPA also released a user-friendly Field Guide for Controlling Silica Dust Exposure on Asphalt Paving Machines. Visit goaspha.lt/1DxPbLr to access the field guide.

What YOU do is what WE protect.

You make the way smoother. So do we.

Get together with your independent insurance agent and verify our industry knowledge, quality coverages and outstanding financial security. Learn about our consistent and constructive risk control attention and our expert and timely responses in claim situations.

Full service branch offices: Atlanta Charlotte Dallas Denver Des Moines

Indianapolis Kansas City Little Rock Nashville New Orleans

Oklahoma City Pittsburgh St. Louis San Antonio

All programs may not be available in all states.

Insurance contracts are underwritten and issued by one or more of the following: BITCO General Insurance Corporation and BITCO National Insurance Company, rated A+ (Excellent) by A.M. Best, A2 Stable by Moody’s, and A+ Stable by Standard and Poor’s.

1-800-475-4477 | www.BITCO.com Search: 10723982

46 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_34-47_PresSilica_JL.indd 46

8/26/15 3:07 PM

THE RACE TO PAVEMENT PROFITS

SEE MORE. DO MORE. REGISTER TODAY:

NationalPavementExpo.com TE, NC

ARLOT TER, CH

CEN VENTION

TE CON

T CHARLO

Y R A U N JA HT TO

BROUG

6 1 0 2 , 27–30

Y

YOU B

S®TH U L P P OROEYT CAANMUARY 26 B Y A D H L P J AL RAD HUM

Hall xhibit E d e ever! and ELaxrgepst NPE exhibit hall ce sessions nfuersrtheannever! + ccao !

0 5 n o ti  du ho WAYS WITH B

More e

ENT QUIPM

ght AR Ni C S A N SCAR at NA f Fame ees to Hall ofor NPE attend ges era try Free en els of food, bevon! four lev ecar competiti and rac

E

te

harlot

to C Come

ightlife,

– More n

Join us at the largest event specifically designed for paving and pavement maintenance professionals. There’s more education, more equipment, more giveaways and more nightlife than ever before!

GIVEA

, more staurants

nd do!

to see a

more re

PLAN NOW TO ATTEND NPE 2016!

ALSO BROUGHT TO YOU BY:

ACON0915_34-47_PresSilica_JL.indd 47

8/26/15 3:07 PM

PAVEMENT PRESERVATION

Caterpillar PM102 Cold Planer

Maxam AQUA Patch AQUA Patch can be used to repair asphalt or concrete by just adding water.

• Dries hard for a permanent fix that’s traffic-ready in one hour • Use in winter or summer, rain or shine • No hydrocarbon leaching or evaporation Search: 11567974

The compact PM102 performs controlled, fulldepth removal of asphalt layers in a single pass and is also capable of concrete removal.

• Features a 40-in.-wide conical tool holder and a 12-in. maximum cutting depth • Includes a hydraulically controlled front folding conveyor, load control, traction control device, two propel speeds, rotor with quick-release conical tool-holders and flushcutting featurel • 225-hp C7 7.2L, sixcylinder engine with ACERT Technology Search: 10983762

EDGE OUT THE COMPETITION! FLEXIBILITY AND PRODUCTIVITY

FOR CONTRACTORS, MUNICIPALITIES AND UTILITY COMPANIES

Roadtec RX-900e/ex Cold Planer Roadtec’s RX-900e half/full lane cold planer features a 950-hp Tier 4i Caterpillar engine.

• Three- or four-track assemblies • Guardian Remote Telematics System • 120° load-out conveyor swing capability • Left/right side full-function operator stations on shockabsorbing operator platform with joy stick controls • 14-in. maximum cutting depth • Sollami triple wrap, single hit drum with cutter bits for traditional milling • Kennametal drum optional Search: 10913576

BIORESTOR Asphalt Rejuvenator BIORESTOR is a family of USDA Bio Preferred products to enhance asphalt pavement.

• Testing in the field has shown that BIORESTOR makes a difference in surface ravel • Accelerated aging in the lab has shown that BIORESTOR can eliminate up to 90% of the loss of binder characteristics (penetration, viscosity and Marshall Stability) • BIORESTOR contains no harmful carcinogens as do most petroleum products • USDA Bio Preferred Search: 11299278

SHOULDERING

ASPHALT

TRENCH REPAIR

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

Wirtgen W 60i Cold Mill The W 60i rear-loading cold mill is available in three- or four-wheel models with cutting widths of 24 in. and depths of 12 in.

• 215-hp Deutz sixcylinder, Tier 4i engine • WIDRIVE fully electronic machine control system • Standard discharge conveyor or folding discharge conveyor • All-wheel drive with engageable hydraulic flow divider • Standard fold-in support wheel and detachable loading conveyor • Optional Level Pro automatic leveling system and FCS/ Flexible Cutter System Light Search: 11018283

Search: 10076385

48 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_48-53_PresProd_JL.indd 48

8/26/15 3:10 PM

Kenco Engineering

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

• Electric super sand pump (ESSP) system features a variable speed control and produces as much as 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 • The control panel on the 1500S allows users to change the direction and speed of the pump and agitator, and provides accurate control of the water cleanup system • Users can access the tank through the 21-in. manway which includes an interior safety lid and sandbag splitter • Leather cups tightly seal to the plates to prevent material from leaking and only need to be flushed once per year, which can save up to 30 minutes per day Search: 12026426

Bergkamp MA30 Frictional Mastic Surface Treatment Applicator The MA30 Frictional Mastic Surface Treatment Applicator allows contractors and government agencies to apply Frictional Mastic Surface Treatment over highways, roads, parking lots and airport runways to protect the surface and extend the life of the pavement.

• Steel 3,000-ga. material tank, which contains a hydraulically driven, fullsweep ribbon mixer with counterflow mixing technology, keeps the aggregates in suspension • In-cab controls allow the driver to operate all systems, including the mixer start/stop/reverse and spray bar start/stop, height and width, side-shift and individual nozzle controls • Easy-access mastic strainers protect the pump and spray nozzles from clogging and potential damage by aggregates and solid material • Low-pressure system operates at less than 40 psi • Single or dual pump operation, with over 100 GPM delivered through the spray bar in single pump mode and over 200 GPM delivered in dual pump mode • In dual pump operation, the product loads in less than 30 minutes • All systems are powered by PTOdriven hydraulic pumps • Hydraulically adjustable spray bar provides double overlap spray widths from 72 in. to 234 in. in 18-in. increments Search: 12055510

WHAT DOES SEARCH: 10000000 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!

Mixer Flights

Discharge Flights

Combustion Flight Castings

Slat Conveyor Liners

Slat End Protector

Cone Liners

Dry Bearings & Coupling Shafts

800-363-9859 www.kencoengineering.com Still proudly made in the USA Search: 10073542

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_48-53_PresProd_JL.indd 49

49

8/26/15 3:10 PM

PAVEMENT PRESERVATION

BOMAG BM1200/35 Cold Mill

Neyra Force Sealer Neyra’s Force water-based petroleum resin pavement sealer is designed to be environmentally friendly and safe for workers.

• Material is low-VOC, non-flammable coating that contains no coal tar • High-performance alternative to both coal tar and asphalt emulsion sealers, “providing exceptional coverage, durability and color stability” • Proprietary engineered resin is formulated to create tough and long lasting protection • A tight seal forms an impenetrable barrier to protect against the destructive effects of sun, oxidation, water and chemicals, giving pavement a jet black color • Resists damage caused by gasoline, oil jet fuel leaks and spills • Engineered to perform at temperatures as low as 40°F Search: 12060718

The BM1200/35 cold milling machine offers a 47.2-in. cutting width and 13-in. maximum cutting depth and features a rear rotor design that optimizes milling performance.

• Cutter design with the BMS 15 interchangeable holder system incorporates a single bolt for holder retention and requires a low tightening torque of 75 ft.-lbs.

• 349-hp MTU Tier 4 Final diesel engine offers power to efficiently mill asphalt at speeds reaching 105 fpm • 85-, 95- and 107-rpm milling drum speeds • 25.6-in.-wide inside and 23.6-in.-wide outside conveyors with capacities reaching 6,357 ft. per hour • 224.4-in. maximum conveyor discharge height • Pressurized water injection system offers a variable flow rate of 0 to 1.6 gpm to the cutter housing Search: 12095029

Etnyre Centennial Asphalt Distributors Unit offers one-person operation.

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

WHAT DOES SEARCH: 10000000 MEAN? Rayner PavementSaver II The PavementSaver II is designed for squeegee or spray application.

• 300 to 500 gal.

• 42-hp diesel powered engine • Three-wheel drive, full hydrostatic brakes • Fail-safe emergency braking system

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!

VSS Macropaver 12B The VSS Macropaver 12B truckmounted slurry/microsurfacing machine offers an average output of 3 to 4 tpm.

• 12-cubic-yard maximum aggregate capacity • EZ-OP Monitoring System included • Hydraulic fail-safe automatic materials sequencing • Seal Lock hydraulics • Fines feeder power and drive system offers increased power and a simpler, robust design • Tier III Low Emissions John Deere Engine • 850-gal. water and emulsion tanks • Options include CALTRANS material monitoring and control system; truck speed control on operator platform; stainless-steel additive tank/pump system; high-pressure washer/reel; and more Search: 10085540

Search: 10092362

50 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_48-53_PresProd_JL.indd 50

8/26/15 3:10 PM

The E2850 Remixing Transfer Vehicle

Engineered Innovation Rear Steering • Reduces inside turning radius from 30’ to 14’ • Manual control for coordinated or crab steering • Rear steer angle returns to center upon command • Added maneuverability for loading and unloading onto trailers See your Cat dealer or visit www.weilerproducts.com

© 2015 Weiler Products ACON0915_48-53_PresProd_JL.indd 51

Search: 10075409

8/26/15 3:10 PM

ASTEC

速

Knowledge to the

advanced cus t ACON0915_48-53_PresProd_JL.indd 52

8/26/15 3:10 PM

power

s tomer schools Registration Opens on October 1, 2015 Ph 423.867.3754 | Fax 423.867.9761 or email, sbradshaw@astecinc.com

J a n . 04-07, 2016 J a n . 11 -14, 2016 F e b . 01-04, 2016 F e b . 08-11, 2016 F e b . 15 -18, 2016 F e b . 22 -25, 2016

astecinc.com

Search: 10072061

ACON0915_48-53_PresProd_JL.indd 53

8/26/15 3:10 PM

PLANT MATTERS

How to Optimize Asphalt Plant

DOWNTIME

54 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_54-63_PlantWinterize_JL.indd 54

8/26/15 3:12 PM

In many areas of the country, the winter months can provide valuable downtime for your plant operations. Make the most of that time with these maintenance tips.

by Jessica Stoikes, Associate Editor

T

he few short months of wear and tear that is the precious paving season can be hard on your asphalt plant. Unexpected downtime during the paving season is costly not only to your plant operations, but often times for your customers as well.

With the paving season drawing to a close in some areas, many companies’ thoughts should be turning toward a winter repair regimen for their asphalt plants.

Most asphalt plant personnel have a list of ‘trouble spots’ they’ve accumulated over the course of the season that they know need to be addressed in the off-season. Be sure to thoroughly inspect those things that are often overlooked when they’ve been trouble-free. Asphalt plant manufacturers know their products and can offer insight into what you should be sure to address during plant downtime this winter.

Mixing tip wear needs to be evaluated periodically or when blending quality of the HMA appears inadequate.

These mixing tips are reversible to allow increased service life. Drum buildup removal should be performed in conjunction with rotating mixing tips (paddles).

“Simply put, proper plant maintenance helps maximize production capacities and seasonal profit potential,” says Steve Shawd with Asphalt Drum Mixers Inc. (ADM). “Furthermore, it can extend the overall service life of the plant, which again maximizes profit by keeping an established and, more importantly, paid-off plant in service and making money. A new plant is a huge capital investment.

The longer one can remain in service, the better.”

Manufacturers could easily give you a laundry list of items and these maintenance lists change quite a bit based on how the plant is equipped.

Most manufacturers agree the top “must service” items that are the backbone of a plant are as follows.

Cold/RAP feed & conveying system Proper belt tracking is crucial on weighbridge conveyors. This can be a

All maintenance actions should be performed in accordance with the manufacturer recommended procedures and intervals. Follow all OSHA Lockout/ Tagout and confined space requirements prior to beginning any inspection or service on your plant.

major factor in producing quality hot mix asphalt (HMA) that is within Job Mix Formula (JMF) specifications.

“This should be monitored daily during production,” says Chris Johnson, equipment inspection manager at Astec Inc. “A belt that is not running straight can be quickly damaged and require replacement. Not only is this a costly repair, plant downtime can adversely affect production commitments.”

Check conveyor components (i.e. troughing rollers, return rollers, and belting) for excessive wear, damage and material buildup. Tracking

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_54-63_PlantWinterize_JL.indd 55

55

8/26/15 3:12 PM

PLANT MATTERS

problems are usually more pronounced on the collecting conveyor. Mark excessive damage for repair or replacement as worn and broken components are a liability. Keep in mind that a damaged or improperly tracked conveyor belt can lead to piles of aggregate which require considerable time and effort to remove by hand.

Be sure to also examine the conveyor’s bearings and drive system. If you have chain drives, examine each sprocket for ‘fish eyeing’, taking time to mark any abnormalities you find.

For belt drives you need to look for cracked or glazed belts, excessively worn sheaves add a loose condition which may require adjustment.

Drum “There are many components of an asphalt plant, each with a healthy list of suggested maintenance items,” Shawd says. “But to boil it down to a list of ‘most important,’ that likely focuses attention on the ‘heart’ of any asphalt plant, the drum.”

Shawd says that even within this broad category, there are a wide number of checks someone should make on individual components – on a daily, weekly, monthly, semiannual and annual basis. However, since we’re mostly discussing “off-season” maintenance items, Shawd says to focus on those suggested semi-annual and annual service checks for a plant drum/dryer.

• Check drum shell thickness for wear • Clean, check and tune the burner • Change oil in drive reducers • Check the baghouse to ensure bags are in good shape • Ensure cleaning and fines-return systems are working properly • Check trunnions for excessive wear or uneven wear, and check the bearings for excessive play

Scalping screen systems Scalping screens are vital in removing (rejecting) oversized aggregate for both batch and continuous mix asphalt plants. “Ingredient quality and condition is very important to the final HMA being produced,” Johnson says. “What goes through the plant determines the final product.”

Start with an external inspection. Look for missing parts, such as lid hold-downs, and for signs of dust leaks. Look at the skirting seals under the units. Are they there or long gone? Examine the top covers. Are they worn out where they rest on the frame or other lids? All these conditions should be addressed. Check to see that the screens move freely. If they don’t, look for a buildup of aggregate under the drive end.

Check the size of the material. If it’s a useable size that normally goes into a hot bin, the accumulation could point to leaks in the oversize discharge, exacerbated by screen flooding and carry-over.

Remove all the lids and side covers. It’s a good idea to take a hose and clean the accumulated fines off the screen Search: 10074819

56 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_54-63_PlantWinterize_JL.indd 56

8/26/15 3:12 PM

POWERFEEDER MATERIAL TRANSFER VEHICLE

The Vogele MT 3000-2i offset PowerFeeder combines practical innovation with versatility and productivity.

The art of continuous, non-stop paving is made easier with innovations from Vogele.

Operator platform with excellent all-around visibility and intuitive controls.

Continuous rubber tracks for precise maneuverability and excellent floatation.

Lightweight design allowing easy transport and the ability to work on bridges.

Optimal material flow and remixing throughout the transfer process.

Low ownership cost with the fewest number of wearing parts.

Productivity and Operational Benefits that are second to none!

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

ROAD AND MINERAL TECHNOLOGIES

Search: 10075240

ACON0915_54-63_PlantWinterize_JL.indd 57

8/26/15 3:12 PM

PLANT MATTERS

frames and springs to make it easier to find damaged and cracked components. Caution: Open all the gates below to provide a way for the water to escape from under the plant. Once the unit is clean, you should inspect it for broken springs and cracks in the framework.

Closely inspect each screen cloth.

Look for excessive wear and broken wire. Check the screen trays. Are they all tight? Is the screen cloth secure? It’s good insurance to stock a complete change of screens. When stored in a custom built rack on the screen deck, they are ready for installation with a minimum of fuss. Keep a supply of bolts handy.

Follow manufacturer’s recommendations as to periodic maintenance.

Look for damaged components, worn sheaves or belts and broken motor mounts.

Batcher/silo systems

The batcher and silo are two of the most important pieces of equipment on an asphalt plant when it comes to battling mix segreation and safely storing your mix.

Anytime.

Anywhere.

new

And used

equipment !

Any device.

Get fast, relevant product information on the Buyers Guide at Forconstructionpros.com

The batcher and silo are two of the most important pieces of equipment on an asphalt plant when it comes to battling mix segregation and safely storing your mix.

Often, when a batcher unit has problems, its gates are chained open to ensure the job moves forward.

HMA quality suffers, but the price of a shut-down for repairs to the batcher are deemed excessive as long as the mix is accepted. With a little foresight, this whole scenario can be avoided.

Inspect the batcher’s sides and cone for thin spots. Mark for any plating that may be required. Look closely at the gates and their pivots.

Are they loose? Do they need to be greased? Mark for repairs any abnormalities you find.

Examine the air actuation system.

Failures here are the primary cause of batcher problems. Check the air

> Easy navigation > Browse companies and products by category > Advanced search for quick, relevant results > Content fits your device … no app needed > Product reviews > REQUEST MORE INFORMATION button speeds results

ForConstructionPros.com/directory

58 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_54-63_PlantWinterize_JL.indd 58

8/26/15 3:12 PM

Gencor Provides Superior Product Support Gencor established itself as the leader in rugged dependable equipment and superior after sale support, over a century ago, with a philosophy of hands-on training, innovative technology and common sense solutions to your needs.

Whether at a one of Gencor’s legendary annual training schools, a turnkey installation, or a parts order at 2 am, no one offers you better 24/7 support than Gencor.

When you need dependable support, look to the leader Gencor.

Search:

ACON0915_54-63_PlantWinterize_JL.indd 59

Search: 10073090

8/26/15 3:12 PM

PLANT MATTERS

“Without proper maintenance, daily costs of running the plant start to rise, which incrementally lowers profit potential,” Steve Shawd with ADM says.

cylinder(s) for excessive wear. Substandard air hoses should be slated for replacement.

The same inspection protocol is used for the storage silos as for the batchers. Check the structural thickness, especially in the cone area.

Mark any thin areas for repair or replacement. “Most manufactures offer onsite density inspections to determine wall thickness,” Johnson says.

The gate and all its actuating controls should be examined. Check the pivot pins by prying the gates around with a bar. Schedule repairs for any found lacking. Check the operation of the silo’s high and low level warning alarms.

Dryer/mixer system “Whole articles could be written on the subject of dryer/mixer maintenance,” says Daniel Francisco, director of service at Astec Inc. ”Dryer flighting and mixer tip condition is imperative for adequate aggregate moisture removal and thorough HMA blending.

Conditioning, showering and combustion flights need to be inspected for wear or damage. Replace or repair as needed. Inspect each and every flight and mixing tip for the following problems: • Excessive wear • Heat curling • Impact bending • Cracking or absence Mark for replacement any flight that exhibits these problems. Obviously, any that are cracked can be welded, and those that are worn or missing must be replaced. Mixing tip wear needs to be evaluated periodically or when blending quality of the HMA appears inadequate. These mixing tips are reversible to allow increased service life. Drum buildup

A properly maintained plant is a safe one Experience has allowed us to see that asphalt plants that are not well maintained pose a serious safety hazard. Performing scheduled maintenance and properly repairing unscheduled maintenance items can certainly mitigate this.

Most asphalt plants are equipped with safety devices and interlocks that MUST be checked to verify proper operation to protect equipment and ensure personnel safety. Some examples are: • Emergency Stop (E-Stop) pushbutton operation.

- An asphalt plant may be equipped several of these. Each should be tested individually - All motors and functions MUST immediately stop • Excess Temperature Shutdown (ETS) operation. Activated when the temperature exiting the baghouse exceeds 375°F. The following asphalt plant functions should immediately stop: - Burner stops - A/C Divert Valve closes. This prevents ingredient flow to the mixer - Baghouse cleaning stops - Exhaust fan stops and damper closes • Conveyor Safety Switch (pull cable) operation: Each switch is equipped with an attached cable on each side. These need to be activated individually to ensure proper operation. Conveyors should immediately stop.

• Asphalt Plant motor interlocks.

- Verify each motorized component stops when loss of interlock (preceding motor) is lost due to being off, tripped or stopped • Burner safety interlock operation. Verify shutdown when the following “Limit String” conditions are removed: - Exhaust fan or burner blower stops - Fuel 1 (Gas) pressure drops or Fuel 2 (Oil) pressure drops - Baghouse Inlet temperature (Stack) exceeds 400°F or baghouse Exit temperature (ETS) exceeds 375°F - Fuel temperature falls below set-point (if running waste oil) A poorly maintained plant can lead to serious injuries and/or fatalities. Good housekeeping at your plant, along with safety features like these, will pave ‘pave’ the way to a safer working environment.

60 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_54-63_PlantWinterize_JL.indd 60

8/26/15 3:12 PM

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

Search: 10075155

To find your local dealer, go to: www.

ACON0915_54-63_PlantWinterize_JL.indd 61

.com

or contact us at: 704.966.3300

8/26/15 3:12 PM

PLANT MATTERS

removal should be performed in conjunction with rotating mixing tips (paddles).

Combustion systems The main burner and hot oil heaters make up your combustion system.

“Burner maintenance/cleaning and periodic tuning are important to utilize every (BTU) the fuel has available,” Johnson says. “Test, evaluate and tune your burner as needed to optimize performance. Having a properly running burner can also help to stay within state and federal EPA guidelines.”

Examine all fuel and propane lines.

Schedule for replacement any that raise a question in your mind. Also look at the propane bottle for signs of leakage or damage. Check the fuel pump and drive mechanism. Mark any frayed belts, worn couplers or leaking seals. Schedule the fuel filters for replacement, regardless of how long they’ve been in place.

Check the piping and valving from the supply tank. Now is a good time to verify that shut-offs do in fact, work. Don’t take them for granted, it may come back to haunt you. Also take a minute and inspect the tank’s filling apparatus. Note any leaks or unsafe conditions.

“The maintenance on these burners will depend on your fuel type,” Francisco says. “If you are burning a fuel oil or gas, you will want to inspect and clean the fuel delivery system.

This would also be the time for an inspection and cleaning of the pilot assembly and burner nozzles.

“If equipped with electric heat for your hot oil, you will need to confirm your electrical connections and controllers are working properly,” he continues.

Hardworking plant, hardworking people “A well maintained HMA Plant that reliably functions properly from dayto-day has a definite positive impact on personnel morale,” Johnson says.

“Without the constant worry of unexpected breakdowns, contractor employees can concentrate on their primary duties and responsibilities.”

Keep in mind, maintenance of any asphalt plant is an ongoing effort. “I do not recommend tunnel vision by limiting or labeling these as the most important items,” Francisco says.

“Neglected or sub-par maintenance on any plant components can lead to numerous and costly repairs.”

Proper plant maintenance can be instrumental to the performance of

your plant next season, but it’s also important that you hire experienced plant personnel that are trained to spot warning signs for potential problems in plant components during the production season. Faulty parts on a plant can be costly if not addressed when first seen and can lead to troubles that are difficult to repair, even in the off season.

Remember, all maintenance actions should be performed in accordance with the manufacturer recommended procedures and intervals.

Follow all OSHA Lockout/Tagout and confined space requirements prior to beginning any inspection or service on your plant.

“These clean and well-maintained plants are achieved by very dedicated and hard-working plant personnel,” Francisco says. “Along with this comes a boost of morale and pride in a job well done.”

“Without proper maintenance, daily costs of running the plant start to rise, which incrementally lowers profit potential,” Shawd says. “Inefficiencies start to mount to the point that the plant is not keeping up with production needs. Breakdowns start to become more frequent, which further hinders an asphalt contractor’s ability to keep up with production.

“Eventually the plant needs to be overhauled or replaced prematurely, resulting in huge unnecessary expenses that could likely have been avoided.”

Additional information provided

by C.M. Consulting, www. hotplantconsulting.com.

“Burner maintenance/cleaning and periodic tuning are important to utilize every (BTU) the fuel has available,” Chris Johnson with Astec Inc. says.

“Test, evaluate and tune your burner as needed to optimize performance. Having a properly running burner can also help to stay within state and federal EPA guidelines.”

62 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_54-63_PlantWinterize_JL.indd 62

8/26/15 3:12 PM

2 0 1 6 N A PA A N N UA L M E E T I N G

February 7–10, 2016

La Quinta Resort & Club • La Quinta, California www.AsphaltPavement.org/AnnualMeeting

Search: Search: 10073981

ACON0915_54-63_PlantWinterize_JL.indd 63

8/26/15 3:12 PM

PLANT MATTERS › CLIFF’S NOTES

How to Ace the

EPA Stack Test

C li f N ot f’s es

Preparation is top priority

by Cliff Mansfield

P

reparation for an EPA stack test is crucial in the process of passing that test. While most of this seems common sense, it’s easy to overlook something and discover too late that you’re on the road to failing your test.

Certain parameters are essential to your success in that testing. These two documents are what I developed over the years to ensure successful test results.

Once all of this data has been gathered, you can easily determine if you will pass or fail the upcoming tests.

It’s important to remember that your

stack test is the most important process that you are doing on that day. The results of that test dictates HOW you are permitted to operate for the rest of the permitted period. I strongly recommend that the focus be on passing the stack test and not on the paving operations.

In recent years I have seen a number of plants fail a stack test because the plant operator ignored good plant operational practices in an attempt to satisfy the demands of a paving superintendant who simply did not understand the importance of this one day of compliance testing.

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.

64 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_64_Cliffsnotes_JL.indd 64

8/26/15 3:14 PM

Libra Systems PlantWise PlantWise Drum Mix Control System offers advanced automation for asphalt drum mix plants.

• Adaptability for retrofit or total plant control of nearly any plant • Extensive use of high-speed networking to increase accuracy and reduce wiring • Integral manual control via software control “panels” • Easy calibration of plant equipment • Real-time trending of key process parameters • Fully graphic operator interface • Instantaneous production rate changes • Tracks equipment maintenance and re-calibration schedules • Facilitates future expansion Search: 10565024

Dillman Voyager Plant Dillman introduces the 200-tph Voyager plant designed for producers who require a plant made to move several times during the paving season.

• Can be dismantled, moved to a new site and set up and ready for production in about five work days • Uses field-tested components proven to perform in a variety of conditions • Built around the Dillman unified drum • Includes a 50-ton SEB to ensure a quick set-up without the need for cranes • Whisper Jet 50 burner, 34,000 cfm pulse jet baghouse and the PMII control system • In place of the 50-ton SEB, customers can choose a 100-ton crane erect silo • Four-bin cold feed is standard with the option of adding more bins • A recycle system is also optional

Live Bottom Trailers

Heavy Duty Trailers

Crude Oil Transports

Search: 10616687

ChipSpreaders

Astec Double Barrel Drum Mixer

Meeker RAP-PAK This system features precise control of RAP for batch plants.

• Unique weighing system allows for higher RAP percentages in mix • Positive control of steam release • Steep sloped bin walls on rap bins for trouble-free operation • PLC touch screen controls Search: 10086128

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

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

Asphalt Distributors

E. D. Etnyre & Co.

www.etnyre.com 800-995-2116 email: sales@etnyre.com Search: 10072816

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_65-68_PlantProd_LJ.indd 65

65

8/26/15 3:15 PM

PLANT MATTERS Stansteel Accu-Shear Inline Blending The Accu-Shear multi-purpose inline blending unit from Stansteel is designed for multiple materials, liquids and warm mix.

• Uses a shear process for handling both the foaming warm mix as well as the liquid chemical warm mix • Systems can blend three, four, five or more liquids inline as well as add polymer asphalts to actually change the Performance Grade of the material • Design mechanically blends and forces the dissimilar liquids together as well as lowers both the base liquid asphalt temperature as well as the final warm mix process Search: 10146953

Find area dealers and suppliers … fast

ADM EX Series Asphalt Plants

Need a replacement part or additional supplies at a job site? Need it now?

Search the updated online

Industry Directory

from Asphalt Contractor and Pavement Maintenance & Reconstruction for local suppliers and dealers.

ForConstructionPros.com/locator/asphalt 1

Enter your ZIP code or city/state

2

Select a category

3

GET RESULTS!

Sponsored by:

Asphalt Drum Mixers offers its EX Series asphalt plants with single-drum counterflow technology.

• Produces 100 to 425 tph • Long aggregate drying and mixing times • Capable of processing 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 • Plant controls are sophisticated in their abilities, yet simple in operation • Available individual components to customize plants include cold feed bins, hot oil asphalt cement tanks (both horizontal and vertical), direct-fired horizontal cement tanks, portable and stationary bag houses, mineral filler systems, RAP systems, self-erect and stationary silos, weigh and drag conveyors, weigh batchers and fuel oil tanks Search: 1065842

66 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_65-68_PlantProd_LJ.indd 66

8/26/15 3:15 PM

ALL PLANT PARTS. ALL ADM QUALITY.

Eagle Skid-Mounted 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 to 600 tph recycling drum mix plants Search: 10360694

WHAT DOES SEARCH: 10000000 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!

WEM Maintenance Log The Maintenance Log helps to increase plant availability by tracking device usage and producing work orders.

• Schedule downtime • Product work orders for preventive and routine maintenance based upon calendar time, hours of run time, total tonnage or number of device actuations • Parts lists and photos can be displayed to aid in performing maintenance tasks Search: 10226318

Gencor Ultrafoam GX2 Gencor’s latest development in warm mix technology with the Ultrafoam GX2.

• Can achieve consistent foaming at varying production rates without the use of a powered mixing device • AC and water can be introduced at widely different flow rates and pressures • Compressed Air Purge releases remaining water in the piping and hose between the unit mounted on the drum when temperatures approach freezing • Water Flow Alarm senses water and transmits alert to the operator if loss of water flow to the unit occurs • Pump heater features a convective heat bulb used inside the pump enclosure to prevent pump and internal components from freezing • Weatherproof enclosure provides freeze and dust protection to the pump and electronic parts Search: 10223065

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

At ADM, we stock a huge inventory of industry-standard parts and components for all major manufacturers’ systems and can have them most anywhere for next-day delivery and installation.

You’re up and running and we’ve made another satisfied customer.

It’s what we do best.

ADM - More Than Metal For more information call

(260) 637-5729 MasterCard and Visa accepted

Asphalt Drum Mixers, Inc. 1 ADM Parkway • Huntertown, IN 46748

parts@admasphalt.com service@admasphalt.com VISIT ADMASPHALTPLANTS.COM Search: 10072036

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_65-68_PlantProd_LJ.indd 67

67

8/26/15 3:15 PM

PLANT MATTERS Tarmac Tri-Mix Warm Mix Injection System

Maxam SOLO Drum Mixer The Maxam SOLO Drum’s patented technology advances counter-flow technology to a new level of efficiency.

• Separates the control of the exhaust stack temperature from the control of the mix temperature with the MAXAMizer heat Recovery System • Directly heats the RAP without superheating the virgin aggregate and without producing blue smoke with the RAPTOR Recycle System • Support trunnions continuously selfalign with the TrooTrac alignment system • Eco-friendly advantage of AQUABlack Solutions warm mix system Search: 10280224

Tarmac’s Tri-Mix is a simple yet versatile warm mix injection system.

• Delivers consistent, lower viscosity AC giving you better coating at lower temperatures • Lower mix temperatures can save companies 20% on burner fuel costs • Simple design and non-corroding components make unit virtually maintenance-free • Fast installation and integration Search: 10456328

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

• Complete inventory of drum plants, batch plants and components • Assist in plant dismantling and set up, as well as trucking Search: 10086122

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

C.M.Consulting

NEW COUNTERFLOW AND PARALLEL ASPHALT PLANTS PLANTS FOR FOR SALE NEW COUNTERFLOW AND PARALLEL FLOW FLOW ASPHALT SALE

We sell new ADM Counter-Flow Drum Plants and Parallel Flow drum plants, portable skidded.

Any configuration you might WeFlow havedrum plants for We sell or new ADM Counter-Flow Drum Plants and need.

Parallel high RAPportable applications, configured for Hot mix, mix and Cold mix. plants, or skidded.

Any configuration you Warm might need.

We have plants for high RAPneeds. applications, configured for Hot mix, Warm mix and Call to discuss your Cold mix. to discuss needs.

I have beenCall in paving sinceyour 1972 and directly associated with asphalt plants since 1976.

I have operated maintained hundreds of asphalt plants in I have been in paving sinceand 1972 and directly associated with asphalt over 150 since countries. staffoperated of qualified Technicians service support plants 1976.Our I have andField maintained hundreds of and asphalt anything sell.150 From Mix Design to airField quality compliance, from plants inweover countries.

Our Compliance staff of qualified Technicians service and support anything weissues, sell. From Mixhelp.

Design Compliance to air quality mechanical to computer we can compliance, from mechanical issues, weon can help. ** Winter is coming. to Wecomputer offer SPECIALS Scheduled

ServiceNEW & PlantAND Upgrades.

February.

CALL ** MANY USEDNovember ASPHALTthru PLANTS FOR SALE

1978 Wylie 3140, 50 tphUSED Plant. Complete with GensPLANTS & Baghouse….FOR Call SALE MANY NEW AND ASPHALT 2006 Cummins 275kW 480v Generator. 0 hours! Selling as USED….Call

2006 Cummins 275kWPortable 480v Generator. hours!Control SellingHouse….Call as USED...............Call.

1996 ADM SPL-110 Drum mixer0W/NEW 1996 ADM SPL-110 Portable mixer W/NEW Control 1980s Boeing MS-200 250Drum TPH Portable Drum with SlingerHouse.................Call. & Burner….Call Rebuilt GenCo AF-25 250 Natural Burner,Drum w/newwith controls.

Complete 1980s Boeing MS-200 TPHGas Portable Slinger & Burner..........Call.

New, used and rebuilt Hauck & Genco burners. Burner Controls….Call 1980s Boeing MS-300 Portable Drum Plant, Wet-Scrubber, No AC Tank......Call.

1999 John Deere 544G Front End Loader. 5,000 hours….Call Rebuilt GenCo AF-25 Natural Gas Burner, w/new controls & Gas-Train. Complete.

New, usedMANSFIELD and rebuilt Hauck Burner Controls................Call.

CLIFF INC. & Genco burners.

OFFICE 541-352-7942

P.O. BOX 407Inc. Cliff Mansfield ODELL, OR 97044 P.O. Box 407 Search: 10073532

FAX541-352-7942 541-352-7943 Office WWW.HOTPLANTCONSULTING.COM Fax 541-352-7943

Search: 10072464

68 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_65-68_PlantProd_LJ.indd 68

8/26/15 3:15 PM

SPECIAL REPORT When setting up a mobile crusher, it must be level.

If the machine is unlevel left to right, this will cause increased wear on all components from the feeder, to the screens, crushing chambers and conveyor belts.

How to Maintain

Mobile Crushers

Here’s a look at the top 5 wear items on these machines and how you can optimize your productivity

by Lisa Cleaver, Editor

M

obile crushers are built to size hard, dense materials, including rock, gravel and slag — common elements in many asphalt mixes. This makes wear parts susceptible to excessive wear and, if not maintained properly, may cause greater damage.

“If a crusher’s components do not work together, the whole production process is affected, resulting in additional expenses and downtime,” says Sean Donaghy, national sales manager with IROCK Crushers.

Well-maintained equipment translates to increased uptime, increased production, and a more profitable operation, says Wade Lippert, field service technician for KPI-JCI and Astec Mobile Screens.

“Managing your maintenance allows you to budget the maintenance cost into your business plan, which gives you more control over your operating costs,” he says.

“And, of course, well-maintained equipment is safer for the employees operating it,” he continues. “Planned maintenance also creates a more positive work environment for the employees.”

The best maintenance strategy is a structured plan that is simple but effective, Lippert says. This plan should include daily checks, a proactive and planned maintenance and repair schedule, a list of available spare parts, and documentation forms to record all maintenance for planning and history.

Top 5 maintenance items Feeders The first area of wear on any machine is the feed system. Whether it’s a feeder with an integrated grizzly, or a feeder with an independent prescreen, how you feed the machine contributes to wear.

“If you feed with a loader, you have no control over the feed size, as you can’t see what’s in the bucket,” says Paul McLaren, product support manager with Kleemann. “Whereas, with an excavator, you can see what’s inside, and you have more control over the feed into the hopper.”

Another point to remember when setting up and maintaining a mobile crusher is that the machine must be level. If the machine is unlevel left to

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_69-72_SpecialReport_JL.indd 69

69

8/26/15 3:16 PM

FEEDERS right, this will cause increased wear on all components from the feeder, to the screens, crushing chambers and conveyor belts.

The standard integrated feeder is a grizzly section that is integrated into a vibrating feeder, so the feeder and the grizzly move at the same time. It’s a set of tapered fingers that allows material less than the size of the opening of the grizzly to drop through, bypassing the crusher.

“These grizzly fingers are a maintenance point and must be rebuilt and hardfaced to maintain the sizing of material that we are removing,” McLaren says.

The action of an independent prescreen is completely independent of the feeder. It also has the grizzly fingers at the top, or punch plate, but underneath material falling through goes through a woven wire mesh sized to any product the operator wants.

“In addition to maintenance on the grizzly fingers, we must also inspect the screen mesh for worn, broken or

bent wires, and the seating face and tensioning devices for the mesh,” McLaren says. “As we want to obtain a screened product it is critical to maintain the mesh so to not allow our material to fall outside of the required specification.”

Crushers The largest wear part for a mobile crushing plant is the crusher itself. On a jaw crusher, wear parts include the

The first area of wear on any machine is the feed system. Whether it’s a feeder with an integrated grizzly, or a feeder with an independent prescreen, how you feed the machine contributes to wear.

jaw die and side wear liners. In an impact crusher, wear parts are more extensive, and include blow bars, hood liners, apron liners and apron tips.

A daily visual inspection of the crusher is recommended. Wear on

CRUSHERS

System inspections on your mobile crusher should be completed daily to make sure all of the major wear parts are properly secured and lubricated.

70 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_69-72_SpecialReport_JL.indd 70

8/26/15 3:16 PM

SPECIAL REPORT this component depends on the application and the rock being crushed, therefore you need to keep a close eye on it.

the wire diameter gets smaller and smaller, the mesh becomes weaker and weaker, and is more prone to breaking.

Look for worn and broken wires, and damaged crimps within the wire that are causing the screen mesh to move and allow larger material to pass through it.

Check the tension of the mesh. If the mesh is not tensioned properly, material will bounce around inside the screen deck, and cause damage to the mesh itself and the surrounding screen box.

Conveyors Conveyors move material out of the crusher and include wear parts such as belting, skirt flashing and belt cleaners, and cleaner blades.

“With conveyors it’s really important to ensure it’s tracking in the correct path, and not all the way over to one side, rubbing on the chassis,” McLaren says. “Make sure there’s no build-up underneath that can drag against the bottom of the conveyor, or catching on it and being dragged into the machinery.”

There are several signs a belt needs to be replaced: worn rubber, patches of rubber that have been dug out,

When it comes to screens, look for worn and broken wires, and damaged crimps within the wire that are causing the screen mesh to move and allow larger material to pass through it.

SCREENS

Emphasis on education A well-rounded maintenance program cannot ignore proper employee training through factory schools and hands-on training.

“This is critical, as operating knowledge provides employees the tools they need to run the equipment,” says Wade Lippert with KPI-JCI and Astec Mobile Screens.

“When employers place an emphasis on education, it gives employees a sense of importance and purpose.

“An investment in the employee is just as important as the investment in equipment,” he continues. “The employee is an intricate part of the entire operation, and can play a major role in the success or failure of the operation. Creating a positive culture creates an employee that cares as much about your success as you do.”

Lippert likes to remind companies they are depending on their employees to keep their operation running smoothly. “If you don’t pay attention to your employee, then you are neglecting your equipment,” he says. “Maintenance is an investment in man and machine. If an employee understands that your success equals his or her success, a quality operation and maintenance plan becomes very simple to implement and follow.”

The importance of daily inspections leaving holes in the belt where material gets caught, pieces torn off the edge of the conveyor belt, and tracks running the length of the belt.

Screens Screens are a vital part of the crushing and screening operation. A standard woven wire mesh has a certain wire diameter, a square woven mesh with a crisscross pattern. As it wears, the openings will become greater. As

Engines & Hydraulics Regular engine maintenance also prevents small operational issues from becoming larger problems.

Operators should ensure all fluids, such as oil, coolant and hydraulics, are full, and should check and clean out any debris near the engine and radiator. Also, stick to the manufacturer recommended maintenance schedule.

Understanding that small imbalances can lead to substantial and expensive problems is the first step to maintain your mobile crushers. System inspections should be completed daily, to make sure all of the major wear parts are properly secured and lubricated.

“By paying proper attention to these areas, such as the liners, crusher anvils and blow bars, and adjusting as needed, the operator can assist the machine to run at peak performance, providing ideal flexibility and efficiency,” says Donaghy. “Otherwise,

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_69-72_SpecialReport_JL.indd 71

71

8/26/15 3:16 PM

SPECIAL REPORT you’ll be paying for it in the future through increased repairs and downtime, resulting in less profit.”

When performing daily inspections on your crusher, there are several areas to examine before use, starting with the bearings. Roller bearings should be inspected daily and replaced as needed. Operators should inspect and clean out the crushing chamber to check for any loose or worn parts. After they should examine the screen cloth for any debris and clean it out as well.

The wear plate of this crusher box has almost completely worn through and must be replaced or the crusher box will be permanently damaged.

Worn grizzly bars require hardfacing to return to optimum condition.

When an operator is inspecting a conveyor, they should assess the belt scrapers and skirting to make sure it does not require any adjustments or repairs. Key conveyor components, such as rollers and bearings, should be thoroughly inspected to ensure they are not loose, damaged or broken, which could cause additional expenses and downtime.

“By keeping your unit serviced, such as greasing the bearings every day, you can receive several years of use before replacing,” says Donaghy. “A crusher typically lasts 15 to 20 years, provided it’s serviced regularly. A wellmaintained crusher gives you several more years of service and profit when it comes time to resell.”

For more information on mobile crusher maintenance or to view more products, visit ForConstructionsPros. com/asphalt.

Material dropped from a height deforms and wears hopper walls.

72 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_69-72_SpecialReport_JL.indd 72

8/26/15 3:16 PM

RECYCLING & CRUSHING PRODUCTS Eagle Crusher UltraMax 1400-45 The 1400-45 high-production, portable crushing plant produces uniform cubical products in hard rock and heavy-duty recycling applications.

• High-volume, primary/secondary crushing plant • Eliminates the need for a dual crusher system • Simultaneously produces 3 cubical spec products • Operates as either an open- or closed-circuit system • 56-in. x 35-in. feed opening Search: 10078194

Gencor Giraffe Recycle System Eagle Hybrid Traxx Impactor Plant The Hybrid Traxx track-mounted impactor plant features diesel electric power for both the impactor and the plant, with hydraulic operation powering the tracks.

• Equipped with Eagle Crusher’s new UltraMax II Impactor • Large under-crusher clearance at 18 in. is designed for concrete and asphalt processing • Independent hydraulic adjustment for primary and secondary curtains reduces wear cost and provides precise product control • 42” x 40’ conveyor fixed at a 10-ft. discharge height allows for direct loading of trucks • Features a sculptured 3-bar, solidsteel rotor backed by the industry’s first 5-year rotor guarantee Search: 10090720

WHAT DOES SEARCH: 10000000 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!

The Gencor Giraffe RAP unit combines a bin and feeder, lump breaker, vibrating screen and scale conveyor into a single easily transportable unit.

• Unique bin design eliminates material bridging, with steep-sided tapered walls, self-relieving throat and welded beater plates on the sides of the bins

ProSizer 2612V from KPI-JCI - AMS The ProSizer 2612V is designed for processing RAP millings.

• Closed circuit mobile plant • Double-deck VariVibe high-frequency screen with horizontal shaft impactor (HSI) crusher • Hydraulic screen angle adjustment and rotary screen tenioning system can meet different RAP application demands • Set-up time of less than 15 minutes Search: 10086296

FT3620 Fold & Go from KPI-JCI - AMS • Rack and pinion adjustments allow the bin gates to be easily raised or lowered to maintain the correct amount of RAP being fed for precise material flow • Exclusive double-drum RAP lump breaker can easily reduce RAP material size without crushing the aggregate and is designed with a self-relieving tire and air bladder drive system • Long, folding and reversible bulkhead can accommodate any plant arrangement and provides for bin loading from either side for optimum versatility on varying jobsites Search: 10091574

Astec Mobile Screens has developed the FT3620 Fold ‘n Go - engineered to run closed-circuit with other Astec FT track machines.

• Can process a variety of aggregate materials • Has the ability to produce three saleable products on a closed circuit and a fourth product on an open circuit • Production capacities as high as 700 tph • Will fit on a lowboy trailer for easy site-to-site transport • Optional blending gates, hydraulic screen angle adjustment, a triple deck screen, and a remote control system Search: 10082124

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_73-74_RecycleProd_JL.indd 73

73

8/26/15 3:17 PM

RECYCLING & CRUSHING PRODUCTS Powerscreen Warrior 2400

Rotochopper B-66 with Asphalt Shingle Grinding Package The Rotochopper B-66 is available with an asphalt shingle grinding package for processing high volumes of asphalt shingle waste, wood waste and other low grade resources.

• Allows fast tooth and screen changes to quickly match feedstock characteristics and finished product needs • Replaceable mount rotor • Specially designed grinding chamber water injection system • Diesel or electric power Search: 10140332

The Powerscreen Warrior 2400 is designed for large scale operators in the quarrying and mining sectors.

• Capable of handling larger feed sizes • Output potential of up to 800 tph • Heavy-duty incline screen with high amplitude triple shaft drive mechanism • Screening, scalping, 2- or 3-way splitting and stockpiling materials • Slide out tail conveyor facility Search: 10223026

Kleemann Mobicat MC 110 R EVO Mobile Jaw Crusher The 99,200-lb. Mobicat MC 110 R EVO mobile jaw crusher is powered by a 324-hp diesel engine and hydraulic crusher drive.

• Inlet opening of 44” x 28”, allowing for a maximum feeding size of 42” x 26” and a feeding height of 26” x 394” • Maximum feed capacity of 300 tph • Primary screening is achieved through a slotted grate in the feeder trough • Hopper walls integrated in the chassis and a fully hydraulic crushing gap adjustment ensure quick set-up times Search: 11272750

ADM Recycle Systems Asphalt Drum Mixers offers four models of portable and stationary recycle systems that allow plants to use milled material in asphalt mixes.

• 15-ton capacity • Continuously welded at the seams • Bins contain angle irons and midsection stiffeners for reinforcement • Steeply sloped sidewalls help prevent material from plugging or bridging • For RAP transfer, includes a heavyduty weigh conveyor that is 2-ft. wide and between 45- and 65-ft. long • Based on plant conditions, up to 50% of mix can contain recycled pavement • Portable units feature heavy-duty I-beam frame on a gooseneck trailer with a fifth-wheel kingpin hitch, single axle and air brakes Search: 10082306

IROCK RDS-20 Mobile Crusher The RDS-20 (rapid deployment system) primary crushing plant combines a closed circuit design, four-bar impactor and heavy-duty components for reliability, increased efficiency and the precision to produce a uniform, cubical product.

• Able to crush, screen and separate up to three different sizes of materials at a rate of up to 500 tph • 5’ x 16’ double-deck screen • 52” x 17’ initial vibrating feed opening and 56” x 32” crusher feed opening • Hydraset Hopper allows one person to attach and remove the hopper/ feeder unit in one piece • 440-hp Caterpillar C-13 ACERT Tier 3 or optional Tier 4 engine Search: 10812466

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

74 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_73-74_RecycleProd_JL.indd 74

8/26/15 3:17 PM

CLASSIFIED ADVERTISING

Phone: 970-260-2435 • www.aggdesigns.com

Infrared VersatIlIty

THE 4X6 PORTABLE HEATER

Late model Terex E225P Counterflow Drum Mix Plant 5 Bin Cold Feed, Self-Erect Silo, Baghouse, 20,000 G. A/C Tank CMI Impulse II Controls, Complete MCC and Control House

500 Bbl Self-Erect Portable Mineral Filler System Weigh Pod w/ Reverse Weigh; Pneumatic Gate; Load Cells Rotary Vein Feeder, Blower, Pulse Jet Baghouse

Pot Hole • Bird Baths • Ugly Joints Oil Spots • Tire Indentations • High Spots Utility Patches • Low Spots Surface Cracks • Stamped Asphalt Hot Patches • Drainage Repairs

✔ Lightweight ✔ efficient ✔ DurabLe

1-877-4-reHeat

(608) 298-9301 www.asPHaltreHeat.com





   

    











 

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

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_75-81_Classifieds.indd 75

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

Made in the USA

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

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

75

8/26/15 3:18 PM

CLASSIFIED ADVERTISING

ASPHALT PLANTS • Astec 400 tph portable double barrel plant • CMI 400 tph portable counterflow plant • CMI 350 tph portable drum mix plant • Dillman 300 tph portable counterflow plant • Astec 300 tph Double Barrel drum plant • ADM 250 tph portable drum mix plant • Astec 250 tph portable six pack plant • ADM 225 TPH portable counterflow plant • CMI 250 tph portable drum mix plant

• ADM 160 tph portable drum mix plant • Astec 150 tph portable drum mix plant • ADM 110 tph portable drum mix plant • 10,000# asphalt batch plant • Astec 150 ton silo & slat conveyor • Gencor 65,000 CFM Portable baghouse

Please Call For Complete Inventory

Plant for sale? Call Clancy!

Serving the Asphalt Industry for over 40 years

E.T. CLANCY COMPANY 219-879-8231 • 800-348-8553 • Fax: 219-874-2261 Email: sales@etclancy.com • www.etclancy.com

Retirement plan of owner of a 43 year old paving and pavement maintenance company provides a Golden Opportunity for a younger entrepreneur with construction knowledge to expand footprint in the fourstate area (PA, NJ, DE & MD). Owner is an innovative individual who has pioneered the implementation of various innovative ideas and technology in asphalt and concrete pavements and seeks an energetic individual to step in his shoes and take the company to new heights. We have instant Brand Recognition with a stellar reputation in our industry. It is a turn-key operation and the owner is willing to stay on board to facilitate the transition. Individuals with serious goals, provable net worth of at least $5MM and liquidity need inquire.

If seriously interested, please submit your inquiry to: dsingsime@ACBusinessMedia

Wanted: 12x30 Stationary asphalt Control House ➤ Late model in good condition. Able to be mounted on concrete block or poured walls ➤ 360 degree view preferred

Reply to:

Mark Sweeting Wolf paving/ plant Manager

➤ 1600 amp MCC 262-269-8473 marks@wolfpaving.com

Servicing OLD & NEW Batching Systems since 1984 Batching Loadout Truck Scales Okidata 320 Printers www.BatchingControls.com 603-566-4330

Time is running out!

Don’t miss out on advertising in the next issue of ASPHALT CONTRACTOR. Contact Denise Singsime for more information 1-800-538-5544 ext. 1245 dsingsime@acbusinessmedia.com

LIME ADDITIVE Used Crafco Model 200 routers starting at $6,000.00.

Pugmill Systems manufactures top-quality portable and stationary pugmills for lime additives, soil cement, and stabilized base.

100-1500 TPH. Durable, low maintenance design.

Router

Used Crafco SS melters and EZ pour melters starting at $15,000.00.

In Stock: New 500 and 750 Pugmills Conveyors, Belt Feeders

Call toll free at 1-888-922-3630

PUGMILL SYSTEMS, INC.

NHMS • P.O. Box 5315 • Akron, Ohio 44334

(931) 388-0626 COLUMBIA, TN www.pugmillsystems.com

email: nhmsltd@gmail.com Additional used equipment available.

All sales include onsite training.

Manufacturers of Davis Pugmills

76 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_75-81_Classifieds.indd 76

8/26/15 3:18 PM

CLASSIFIED ADVERTISING

Asphalt Shingle Grinding Service, LLC

It’s More Than Fine...

It’s Just Right!

Recycled Asphalt Shingles

(RAS/RAP) Production Sales Manufacturers Waste Tear-Offs Nationwide Mobile Grinding Asphalt & Concrete Crushing

ONE PASS PROCESSING 100% Passing 3/8 95% Passing #4 90% Passing #8 Average Sieve Analysis

877-679-5708 ShingleGrinding.com September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_75-81_Classifieds.indd 77

77

8/26/15 3:18 PM

CLASSIFIED ADVERTISING

RAP-14619 2001 CMI RA-218P Portable Baghouse

• • • •

45,380 CFM 504 Bags 5,0:1 A/C Ratio 9,072 SQ FT Cloth Area

RAP-14612 GENCOR 400TPH - TWO DRUM PLANT – COMPLETE – EQUIPMENT MODEL YEAR NOMINAL 1990

• 100 x 40 CF dryer saddle chain driven • Rotary mixer for Recycle entry

• Cedarapids Baghouse rated at 70,000 cfm w/ KO box

RAP-14067 88 X 35 PORTABLE CEDARAPIDS DRUM MIX PLANT

• 2 - 200-ton Silos to silo center • 88’ x 28” Gencor Drag Slat Conveyor • Cedarpids Portable Control House

• 490 Exhaust Fan w 150hp motor • Bags and Cages in Good Condition RAP-14242 CMI PORTABLE PARALLEL-FLOW DRUM PLANT

• 375 TPH • 7’ CMI PVM Drum w/9’6 Expanded Ends • (2) Portable AC Tanks • Self-Erect Silo w/ Drag Slat

• Portable Recycle System • Portable 5-Bin Cold Feed System (10 x 14 Openings) • Portable Control House & MCC w/ Impulse Controls

RAP-14455 2002 GENCOR SILO SYSTEM

• (2) 300-ton Silos • 400 TPH Main Drag Slat • Truck Scales

RAP-14435 CEDARAPIDS INCLINED RECYCLE BIN W/ FEEDER

NEW 1.5 MBTU HOT OIL HEATER

• Rated at 1,500,000 BTU/ hour output • Gasses make two passes over helical coils • Shell fabricated of

1/4” steel plate • Bolt on end plate for access to coil • 4” insulation on shell and 6” insulation on ends

RAP-14381 ASTEC PORTABLE 4-BIN COLD FEED

• 10’ x 13’6 Top Bin Openings • Bin Vibrators on Three Bins

• Collecting Conveyor • Tandem Axle Portability

• Nominal 6ft Drum Mixer • Nomnal 35k CFM • Cold Feed with Scale Baghouse Conveyor • Elevator with Load Out • AC Tanks Silo • Control House

RAP-13915 ASTEC 60K CFM BAGHOUSE

• RBH-58:DB 98-007 • Horizontal Cyclone • Skid Mounted Arrangement

• 10,843 sq ft - 5.5 to 1 = 60,000 cfm

78 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_75-81_Classifieds.indd 78

8/26/15 3:18 PM

CLASSIFIED ADVERTISING

contact us today!

800-826-0223

www.stansteel.com

STANSTEEL Asphalt Plant Products

)BVDL MPEFM &4** DPNCJOBUJPO 0JM GBT #VrOFS t )FBvZ EVtZ TUBUJPOBrZ GrBNF BOE MFHT tP HrBEF t R"1 FntrZ CPMMBS t )FBvZ EVtZ tXJO ErJvF NPtPST BOE reduDFST t TSVOOJPO tZQF ErJvF BTTFNCMZ JO eYDFMMFnU DPOEJUJPO t -BtFS NPEFM LOPDLPVU tZQF QrJNBrZ DPMMFDtPS XJUI JnterDonneDUJOH EVDtXorL CFtXFFO %SVN BOE LOPDLPVU CoY JT JODMVEFd.

GTB-5026WS Hotmix Storage Silo #JUVNB 4UPS¥ TUBUJPOBSZ IPU NJY TUPSBHF TJMP %FMVYF TJMP JT GVMMZ JOTVMBUFE TLJSUFE BOE JODMVEFT BOUJ TFHSFHBUJPO CBUDIFS NJY XBTUF CZQBTT DIVUF MPX BOE NJE MFWFM CJOEJDBUPST IPU PJM IFBU PO UIF DPOF BOE HBUFT BOE B TRVBSF UPQ BDDFTT EFDL XJUI IBOESBJMT " IFBWZ EVUZ TVQQPSU TUSVDUVSF NBOVGBDUVSFE GSPN XJEF DF BSFB

GTB-5035 IWS CMI 85,000 ACFM Portable Baghouse t MountFE &YIBVTU FBO PO GPPTFOFDL FRVJQQFE XJUI TXJO )1 NPtPST eYIBVTU EBNQFS t SUBDL tFTUJOH QMBtforN BOE BDDFTT MBEEFS t tPUBM #BHT CBHFT t InerUJBM DVTU CPMMFDtPS t )PQQFS NPVnted tXJO EVTU DPMMFDUJPO BVHFST XJUI DrPTT BVHFS t TrJQMF "YMF $IBTTJT XJUI JOTUBMMBUJPO TVQQPrU MFHT tP HrBEF t FVMM QFrJNFtFS TBfetZ IBOErBJMT BrPVOE toQ.

GTB-5090I CMI 65,000 CFM Nominal Pulsejet Baghouse $.* MPEFM "1- QVMTFKFU CBHIPVTe. TIF CBHIPVTF TFDUJPO JODMVEFT tPQ MPBEJOH /PNeY CBHT BOE DBHFT XJUI venturJFT BOE B GVMMZ FODMPTFE CBH DMFBOJOH TyTtFN TIF EVTU IPQQFS TFDUJPO JT PG B TJOHMF “V” UrPVHI t TIF CBHIPVTF IBT ” EJBNFtFS Y ’ OPNJOBM MFOHUI CBHT fPS B tPUBM PG fU¤ PG CBH DMPUI t #BHIPVTF JT rBtFE BU $F. OPNJOBM BU B DPOTFrvBUJvF BJr to DMPUI rBUJP t #BDLXBrE JODMJOFE eYIBVTU GBO XJUI

GTB B MBUF NPEFM )BVDL &4** .#56 #VSOFS BOE #MPXFS 5IF %SVN 4IFMM JT B OPNJOBM w EJBNFUFS Y MPOH BOE JT NPVOUFE PO B IFBWZ CFBN GSBNF FRVJQQFE XJUI B USJQMF BYMF TVTQFOTJPO t 1PSUBCMF 'PVS #JO $PME GFFE TZTUFN t w CFMU XJEUI Y OPNJOBM MPOH 7JSHJO "HHSFHBUF 'FFE $POWFZPS 'FFEJOH UIF ESVN t 1PSUBCMF 1VMTFKFU #BHIPVTF XJUI NPVOUFE ,OPDLPVU #PY 1SJNBSZ t 1PSUBCMF %VBM #JO 3"1 4ZTUFN t "TUFD XJEF Y MPOH TUBUJPOBSZ $POUSPM )PVTF XJUI .PUPS 4UBSUFST #SFBLFST "TUFD 1. 1MBOU 0QFSBUJOH $POUSPMT BOE )BVDL #VSOFS $POUSPMT t 1PSUBCMF TFMG FSFDUJOH MJNF EVTU TZTUFN NPVOUFE )FBUFD )PU 0JM )FBUFS t 4UBUJPOBSZ 5SJQMF 4JMP 4ZTUFN

GTB-5032 Astec Stationary Double Barrel t 4JY CJO DPME GFFE TZTUFN t 4DBMQJOH TDSFFO t 1VMTFKFU CBHIPVTF t "TQIBMU UBOLT t -JRVJE "$ .FUFSJOH 4ZTUFN t 5XJO CJO 3"1 TZTUFN t UPO TJMP TZTUFN t -JNF EVTU TJMP XJUI XFJHI QPE t 4UBSUJOH HFBS CSFBLFS QBOFMT BOE PQFSBUJOH DPOUSPMT

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

Scan this code with your smart phone for thousands of used equipment listings Bituma® is a trademark of Gencor® Industries, Inc. and Stansteel is not related to or licensed by Gencor®.

www.stansteelused.com

79 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_75-81_Classifieds.indd 79

8/26/15 3:18 PM

CLASSIFIED ADVERTISING

Astec Relocatable 300TPH Double Barrel Plant ®

®

NEW LISTING IN GOOD CONDITION. AVAILABLE NOW. LOCATED IN LUMBERTON, NC. contact Astec sales

423.867.4210 ext.1245

VIEW ONLINE # 820

astecused.com ASTEC, INC.

an Astec Industries Company 4101 JEROME AVENUE • CHATTANOOGA, TN 37407 USA • 423.867.4210 • FAX 423.867.4636 • www.astecinc.com

DRYER/DRUM SPECIALISTS “Serving the rock and asphalt industries since 1985” WE ARE SECOND TO NONE IN SERVICE AND SATISFACTION ALIGNMENT

Just as your vehicles need proper alignment, so does your dryer.

Nearly all external dryer problems are caused by trunnion and frame misalignment. Long-term mis-alignment causes damage resulting in downtime and costly repairs. Even units that seemingly float properly can in reality be drastically out of alignment.

SIGNS OF MIS-ALIGNMENT

✔ Metal flakes from tires or trunnions ✔ Trunnion mis-location and trunnion bearing failure ✔ Poor wear/contact on tires and trunnions ✔ High drive motor amperage ✔ Excessive vibration ✔ Thrust roller and bearing damage ✔ Tire pad and keeper wear ✔ Lack of proper floatation Evans & Daniels uses precision laser and sighting techniques to restore your unit to proper alignment settings.

RESURFACING

Evans & Daniels uses highly specialized grinding equipment that can fit into the tightest of spaces. We resurface tires, trunnions, thrust rollers and tire thrust faces.

We don’t require cranes, lifting assistance, or steel framework. In most cases, we can grind during regular production conditions.

COMMON WEAR PATTERNS ✔ Tapers ✔ Washboard ✔ Concave / Convex ✔ Shoulders ✔ Lumps / Divots / Cracks ✔ Rollover

TIRE & TRUNNION RESURFACING — TRUNNION ALIGNMENT — PREVENTIVE MAINTENANCE

www.evansanddaniels.com — 570-779-1982 80 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_75-81_Classifieds.indd 80

8/26/15 3:18 PM

CLASSIFIED ADVERTISING

IT PAYS

TO ADVERTISE

Contact Denise for info: 1-800-538-5544 dsingsime@acbusinessmedia.com

FOR SALE

✔ Portable Standard

Havens 50-ton Silo & 500 tph Slat ✔ Portable Boeing 70-ton Silo & 500 tph Slat ✔ Twin City 76,000 cfm Baghouse Fan (hi efficiency) Clark Loney 888-220-1277 • Fax 707-929-0569 Email: clark@asphaltequipment.us www.asphaltequipment.us

InnOvATIOn...

Paving Fabric Installation Machines Telescoping 1’-18’ Grizzly 600T & 1’-15.5’ Cub 300T 6 Patents Install Fabrics & Grids Virtually Wrinkle Free Mounts for Endloaders, Buckets & Oil Trucks Cuts Labor Costs & Speeds installation Time Roll Pullers™ for Truck Unloading - 3" & 4" cores

When Normal is not good enough.

GAC® for 36 years "The World’s Best" www.gacco.com m@gacco.com • 619-222-5111

› Cold Feed Bin Weigh Loss-Scale Controller - For RAS or every bin on plant - Minimizes material calibrations - Keeps bins running accurately by weight

PUMP PACKING

› Filler and Dust Continuous Weigh Scale - Maintenance free scale replaces Weigh Pod

Stop your pumps from leaking!

› Oil Tank Level Gauge with Hi-Low Alarms - Don't run out, run over, fall in, fall over

Pre-cut packing sets proven within the Asphalt Industry.

Viking®, Roper, Rotan, etc.

Call Scott at 1-800-231-4209 www.rainsflo.com

› EZ-Temp Continuous Temperature - Back lit indicator for Roller Operators - When to get on and when to get off › Plant Operation Web-Based Training - Voted as preferred method of training - Stop and Start from internet computer - 100% of participants refer it to others - Improve safety, production, quality, costs

ADVERTISERS’ INDEX Aggregate Designs Corp.

75

Almix

9

Asphalt Drum Mixers Inc.

26-27, 67

Asphalt Reheat Systems LLC

75

Astec Inc.

13, 42-43, 52-53, 80

BITCO Insurance Companies

46

Carlson Paving Products Inc.

83

Cimline

32

Clarence Richards

81

C. M. Consulting

68

NAPA

63

Dillman

4-5

National Highway Maintenance System Ltd, L.L.C.

76

Eager Beaver Trailers

7

NPE

47

E. D. Etnyre & Co.

65

Process Heating Company

31

E. T. Clancy Company

76

Pugmill Systems Inc.

76

Evans & Daniels Inc.

80

Recycling & Processing

77

Fast Measure By KTP Enterprises

75

Reliable Asphalt Products

78

Freightliner

16 – 17

Road Widener

48

Gencor Industries Inc.

3, 59

Roadtec an Astec Industries Company

11, 84

General Combustion

15

Rotochopper Inc.

41

Heatec Inc.

2

Sakai

25

Innophos

30

Sealmaster

29

Kenco Engineering

49

Stansteel

23, 79

K-M International

28, 68

Systems Equipment Corp.

33

KPI-JCI

35

Tarmac International Inc.

56

LeeBoy

61

Volvo Construction Equipment

21

Libra Systems Corp.

24

Weiler

51

Meeker

37

Wirtgen America

57

www.clarencerichard.com 952-939-6000

September 2015 • www.ForConstructionPros.com/Asphalt • Asphalt Contractor

ACON0915_75-81_Classifieds.indd 81

81

8/26/15 3:18 PM

THE LAST EXIT

Asphalt is Getting

New Ink

One Australian company is repurposing toner ink for use in asphalt mix design Sydney’s first street was laid with TonerPave on September 16, 2014.

By Jessica Stoikes, Associate Editor

D

id you know that the ink in your printer is considered one of the most expensive liquids in the world? If you were to fill up your standard 15-gallon gas tank with printer ink, it would cost you almost $75,000. Ouch.

Once your printer runs out of ink, consumers (hopefully) recycle the cartridges, which leaves millions of them forgotten in landfills. Inside those cartridges, it’s estimated that there is still 13% of unused ink just sitting there going to waste.

Enter the asphalt industry, king of recycling, to make good use of those old cartridges. This time, it’s an Australian company, Downer Group, who has been working to re-purpose this leftover toner powder for use in asphalt mixes.

How it works The material inside your toner cartridges is actually a small plastic powder material that is melted down when printed on to paper. When the waste toner is recycled,

its low melting point makes it an effective glue in asphalt. This can reduce the use of oil-based bitumen.

TonerPave is the result of this process and it’s made by adding MTP (Modified Toner Polymer) to asphalt. The toner is blended with recycled oil and is 40% more energy efficient than the manufacturing of standard bitumen, with a relative saving of 270kg of CO2 emissions per ton.

Every ton of toner-based product used in asphalt mix replaces 600kg of bitumen and 400kg of fine aggregates, such as sand and soil. Almost 100 toner cartridges are needed to make 1 ton of asphalt.

TonerPave put to the test “We have these toner cartridges and the challenge is to do something with them,” says Peter Tamblyn, marketing manager at Close the Loop, the company that owns TonerPave. “This is the only commercially viable waste toner solution on the planet, it’s a good thing.”

Currently, TonerPave is being extracted from cartridges in Melbourne and then transferred to Sydney where it’s being

blended and placed as tests on roadways.

The City of Sydney’s construction services manager, Andrew Christie, said the product must prove as resilient as regular asphalt and have the same 30-year lifespan. “In two or three years we should have an indication if it is a good alternative to traditional asphalt. Hopefully we can start to use it across Australia,” he says.

At $150 per ton, the mix costs the same as standard asphalt, but Christie expects this to drop as the product matures. Raw materials represent a small portion of road resurfacing costs, he said, which is mainly taken up by machinery and staffing.

However, this is the first time TonerPave has been combined with warm mix asphalt, which has been in use in Sydney since 2010. Warm mix asphalt is heated at temperatures lower than regular asphalt and saves the city 24,000kg of CO2 emissions each year.

Christie says 30% of this new mix is also comprised of recycled asphalt, significantly higher than the industry requirement of at least 10%.

The measure is part of the City of Sydney’s target to reduce its greenhouse gas emissions by 70% by 2030. It was the first local council in Australia to be certified carbon neutral under the National Carbon Offset Standard.

All of Australia’s waste toner powder could theoretically one day be used in asphalt mix, Tamblyn says, but many people throw their toner out rather than recycle it.

“If we could get our hands on all of Australia’s waste toner we would happily use it,” he says.

"The rest of the world is looking at this,” Tamblyn finishes. The company is beginning to investigate importing toner waste from overseas markets.

82 Asphalt Contractor • www.ForConstructionPros.com/Asphalt • September 2015

ACON0915_82-84_LastExit_LJ.indd 82

8/26/15 3:19 PM

Carlson Astec Information CARLSON PAVING PRODUCTS, INC. an Astec Industries Company UI "7&/6& &"45 t 5"$0." 8" 64" t 1) t DBSMTPOQBWJOHQSPEVDUT DPN Search: 10072346 Search: 10071910

ACON0915_82-84_LastExit_LJ.indd 83

8/26/15 3:19 PM

INNOVATIVE SOLUTIONS & SUPPORT

BOOST YOUR SUCCESS

ROADTEC COLD PLANNERS PROVIDE EASY OPERATION, VERSATILITY, AND INNOVATIVE FEATURES. ACE™ Grade and Slope Control system automates the elevation of your machine in the most precise and user friendly way possible. New graphic displays allow the crew to easily select, calibrate, and control sensors with minimal time and effort.

Roadtec’s FXS® dust extraction system increases safety and operator comfort by pulling dust from the primary conveyor and ejecting the particles into a dump truck beside the secondary conveyor.

Guardian™ Telematics allows owners and service technicians to remotely monitor machine activity and production in real time. Roadtec service technicians can make machine adjustments remotely, giving you quick and simple troubleshooting with immediate benefits.

BOOST YOUR SUCCESS TODAY VISIT ROADTEC.COM

© 2015 ROADTEC. INC. ALL RIGHTS RESERVED

1.800.272.7100

+1.423.265.0600

Search: 10074458

ACON0915_82-84_LastExit_LJ.indd 84

8/26/15 3:19 PM