SPRAY INJECTION PATCHING MACHINE GUIDE 2015
CONTENTS
Spray Injection Patching Explained
2
Host Vehicle Recommendations 3 Spray Injection Patching Machine Options
4
Standard Velocity Machine Specification
5
Machine and Chassis Configuration
6
Why Choose the Velocity Patching Machine
7-8
Safety Features 9 Quality and Testing 9 Servicing and Inspection Plan – Auxiliary Engine Machine
10
Worldwide Breakdown and Global Spare Parts Cover
10
Manufacturing Facility 11 Machine Enquiries 11 Customer Testimonials 12
Spray Injection Patching Explained Spray injection patching is a rapid patching technique suitable for use on rural and urban roads, using cold emulsion asphalt, which is placed under pressure into the void depression in the road surface. The void is first blasted with compressed air to clean the surface and remove any debris, then the surface of the void is sprayed and coated with bitumen emulsion. Finally the asphalt is sprayed into the void, self-compacting from the bottom up, requiring no additional compaction. Benefits • Low carbon footprint compared to using hotmix asphalt. • No waste generated. • No excavation so no damage caused to the lower layers. • Fast installation so minimal disruption to road users - reduced traffic management costs. • Can receive traffic immediately. • Can save up to 80% cost compared to conventional repairs. • Higher daily outputs compared to conventional asphalts. • No noise, no dust, no hand arm vibration issues. Important Considerations • Good bond achieved with existing substrate. • Mobile equipment mounted on motorised vehicle. • Efficient 2-man operation. The process is suitable for repairing the following: • Potholes - preventative, programmed and emergency. • Pre-surface dressing patching. • Edge deterioration, haunching. • Sealing and extending the life of worn conventional repairs. • Depressions, cracking and crazing.
Host Vehicle Recommendations The Velocity Patching Machine needs to be installed on a host vehicle. Velocity can work with customers to select and supply the optimum vehicle for our process. The type and size of vehicle required will depend on the model of patching unit selected, the vehicle manufacturer and also any road network legislation pertaining to gross vehicle weight. The choice of host vehicle is an important decision as it will impact on the reliability of your patching machine. The following points should be considered before purchasing: • • •
Initial cost and lead time of the chassis The aftersales maintenance, servicing and breakdown cover available The reliability and durability of the truck chassis
Another important point to consider is whether you would like the patching equipment to be permanently fixed to the chassis or demountable. The advantage of demountable equipment is that customers have the ability to free up the chassis, enabling one chassis to be used with multiple pieces of equipment. If this route is something you favour, additional planning is required when ordering the chassis. The following is a typical UK specification chassis for a 5m^3 Patching unit. Volvo is our preferred chassis supplier because of the after-sales service offered, although the initial cost of the chassis can be more expensive than other suppliers. In our experience, a cheaper chassis can prove to be more expensive and problematic in the long term.
EXAMPLE RECOMMENDED HOST VEHICLE SPECIFICATION Chassis Volvo FL Version Euro 5 (G) Body Type Road Surfacer Taxation Class HGV Suspension
Road friendly to suit GVW
Revenue Weight 18,000kg Gross Cylinder Capacity 7146 Fuel Heavy Oil No. of Seats 3 Wheel Plan
2 Axle Rigid Body
Wheel Base 4700mm Recommended Transmission Automatic (Allison) Recommended Tyres
Rated to suit GVW
Final Drive
Low ration to suit crawling
Vehicle Category N3
Spray Injection Patching Machine Options We build our machines based on hopper capacity. The following sizes are available as standard: • 1.5m³ • 5m³ • 7.5m³ Machines can be built either permanently fixed to the chassis, supplied as export (machinery only), demountable (able to be simply removed from a chassis and stored on legs) or trailer mounted. Other options can be designed specifically for customer requirements. Here are our most popular machines; VPM1.5AE permanently mounted on 7.5t chassis
VPM5.0AE permanently mounted on an 18t chassis
VPM7.5AE permanently mounted on 26t chassis
Standard Velocity Machine Specification The patching machine can be supplied either integrated onto the customer chassis or where delivery of the chassis to the UK is not feasible, supplied part assembled in a shipping container. Upon reaching the destination the machine can be fully assembled and integrated onto the customer chassis by our commissioning team. Alternatively commissioning instructions can be supplied to customers. Each patching unit is supplied fully tested and signed off before it leaves the Velocity manufacturing facility. Velocity are able to produce variations of the standard machine for larger or smaller payloads upon request.
EXPORT MODEL – Machine completed ready to be shipped
TYPICAL UK LAYOUT - Volvo FL, 18t GVW
Machine and Chassis Configuration All machine build requirements are initially discussed with customers and then modelled and assembled using CAD prior to any metal being cut. Load bearing components like the Subframe are tested using FEA to ensure they are able to withstand applied loads. Velocity also evaluate impact on axle loads to ensure built units are within the vehicle manufacturers limits before an order for the host vehicle is placed. The Velocity Patching unit is designed to require very little integration with the host chassis allowing for a simple and quick installation.
Loading Example – Freightliner Chassis, 5m^3 supplied as an Export Model
Fr. Axle
|
Configuration
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R.Axle
|
Total
5966 lbs 2712 kg
Chassis Only
4156 lbs 1889 kg
10122 lbs 4601 kg
8558 lbs 3890 kg
Chassis and Velocity Machine (Unladen)
10175 lbs 4625 kg
18733 lbs 8515 kg
11024 lbs 5011 kg
Chassis and Velocity Machine (Laden)
27948 lbs 12704 kg
38973 lbs 17715 kg
Laden vehicle adds Aggregate Emlusion Water Full Oil and Diesel Tanks Full Tool Boxes
|
Mass 7,500 kg 1,600 kg 100 kg 96 kg 100 kg
Why Choose the Velocity Patching Machine? At Velocity we are committed to working with our customers to meet their individual needs. We manufacture high quality machines that produce superior repairs. We continually develop and test our machines using feedback from our Road Repair Service Fleet. The following are some of the latest features you can expect to find when you order a Velocity machine.
GLASS REINFORCED PLASTIC COMPONENTS The composite materials used to make our hopper and toolboxes result in high durability and decreased weight allowing for a larger payload. For customers this means less down time caused by tavelling back and forth from site when re-filling and higher fuel economy due to carrying less weight.
SUBFRAME MOUNTED COMBINED TANK Our hydraulic and diesel combo tank fastens directly to the subframe and removes the necessity to fasten separate hydraulic and diesel tanks to the chassis resulting in easy integation between Velocity unit and chassis.
MAINTENANCE WALKWAY Our maintenance walkway allows easy access to the engine unit and emulsion tank and also provides a step to safely inspect the capacity of the hopper.
Why Choose the Velocity Patching Machine?
POWERPACK Our engine unit coupled with an upgraded alternator provides power to the heater bands, working lights and all other electrical components making the Velocity unit fully self sufficient. This also provides the power to drive our delivery system and hydraulic system making chassis integration simple and fast.
REAR STEP Light weight and standardized components make up our rear step and the modular design allows for fast and simple repair of any accident damage. The rear step can also be easily upgraded to act as a rear under-run protection decive if necessary.
DELIVERY SYSTEM Extensive research and development including fluid dynamics were used to assist in the design and maximise the efficiency of our delivery system reducing the energy required to propel aggregate and furthermore minimise waste. Our delivery system now produces far less overspill than other patching machines with an application rate of ≼2 m³ per hour even the largest defects are repaired quickly and efficiently.
Safety Features Velocity machines are equipped with the following safety features to help protect machine operators from injury and the equipment from damage: • • • • • • • • •
Operator emergency stop button Delivery bin guard proximity switch Driver operator communication buzzer Driver rear view camera Conspicuity marking and high visibility colour scheme Blower high temperature cut off switch Blower over pressure cut off switch Accessible walkway and grab handles Auxiliary engine instument panel
Quality and Testing All Velocity machinery is built to a high standard incorporating the following quality sytems: • Organisation All machines builds are recorded using our data management system and CAD software. This enables us to plan builds and provide delivery dates prior to an order being placed. Each build is allocated a project manager to ensure the build project runs as smoothly as possible. • Factory Acceptance Test Each machine is subject to a Factory Acceptance Test in which all functions of the machine are tested and signed off by both the build team, quality inspector and project manager. • Endurance Testing Once a machine has been signed off it is then put through an endurance test by running materials through the machine for 25 hours. The Endurance test ensures the machine is worked as if it was out in the field. Once testing is completed the machine is serviced and cleaned ready for collection. • CE Marking Velocity machines are CE marked showing that they comply with all EU directives applying to our equipment. • Shipping and Delivery Velocity pay particular attention to preventing damage through shipping and delivery. If a machine is to be shipped in a container the equipment is fitted to our specially designed base. It is then strapped, secured and shrink wrapped before packing into the container. • Guarantee Velocity provide a 1 year or 1000 hour guarantee (whichever expires first) on all parts excluding service items.
Quality and Testing The following service plan is offered by Velocity: • •
Machine to be serviced every 250 hours. Machine to be inspected every 6 weeks pending workload.
Velocity will provide up to 3 services per year 250 hour service and general machine inspection 12 month full service and general machine inspection 250 Hour service to include: Inspect machine and report findings and recommendations to customer Replace engine oil Replace engine oil filter Replace fuel filter Replace blower air filter Replace aux engine filters x2 inner and outer 12 month service to include everything listed in a 250 hour service plus the additional items below: Replace hydraulic oil filter Replace coolant Remove and clean radiator Replace blower oil Replace compressor oil Additional Benefits of the Plan Training carried out with Operators to educate them on maintaining the equipment between services. 24/7 phone support and fault diagnostics. Velocity to keep a record of vehicle repairs, parts replaced, inspections and service sheets.
Worldwide Breakdown and Global Spare Parts Cover Velocity machines are backed up by a strong supply network of parts and team of maintenance engineers around the UK. We carry most spare parts in stock and can source all other parts quickly minimising down time. Our team of knowledgeable engineers are always on hand to offer advice over the phone or call onsite to fix any problems if required. • • • • •
Engineers available on call out Spare components carried by all engineers Engineers available throughout the UK at short notice Most components stocked at Velocity HQ All other replacement items can be sourced quickly
Manufacturing Facility Our manufacturing facility based in Sunderland, Tyne and Wear, UK is where we build all new machines and maintain our road repair service fleet. We also operate a spare parts store containing an extensive range of replacement parts. Our manufacturing facility is certified under the following British Standards: • • •
ISO 9001 Quality ISO 14001 Environmental ISO 18001 Health and Safety
Machine Enquiries VELOCITY UK LTD Tel : 0191 565 4400 Fax : 0191 564 1096 info@velocitypatching.com Please contact Velocity to arrange any of the following: • • • •
Manufacturing facility visit View a machine operating Talk through a machine specification Information on the injection patching process
Testimonials Mark Swindells Area Manager, Cheshire East Highways “2012 was our first time working with Velocity but it was a very positive experience, so much so that we started our 2013 Velocity programme in the first weeks of January. We combined our local knowledge with Velocity’s expertise to successfully carry out a significant programme of repairs. “Velocity does what it says on the tin. They make permanent pothole repairs very successfully. What really impressed me about them was when I met the team manning the vehicles, it was clear that their operatives were very experienced and knowledgeable in their field. That meant we could rely on them to get on with their task with limited supervision. I would certainly recommend them.” Steve Rivers Highway District Manager, Kent County Council “Our Highways team has been using Velocity’s process across the county for a number of years. Over this time, a greater understanding of the process and its benefits has allowed it to be targeted to work effectively, to provide long term and durable repairs to the rural road network. “This type of repair can be carried out quickly, reducing disruption to traffic and I believe it is a valuable addition to our toolkit.” David Blackburn Recycling Manager, Dorset Highways “We first trialled Velocity technology in 2009. That very quickly turned into a more permanent use of the technology. It was immediately clear that their technology could save us so much money compared to conventional hot repairs that we could not afford to ignore it. “We have a wide range of tools in the box when it comes to road repairs, but for a rural county like ours Velocity are the absolutely perfect solution in terms of good value for money and a long-lasting solution to potholes. “Until we took on Velocity’s expertise, the backlog of defects was overwhelming. Thanks to Velocity, we’ve never had a backlog for years. “Carrying out a repair in a matter of minutes minimises traffic disruptions so Velocity also help with public perception, while I have to say that the carbon savings compared to conventional methods are immense, so the environment is a winner too. Velocity is a real winner for us.”
VELOCITY UK LTD Hendon/Woodbine Street Sunderland Tyne & Wear SR1 2NL Tel : 0191 565 4400 Fax : 0191 564 1096