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Paving surface seal on dumping ground for refuse is
not a simple job. Due to the steep slope, the paver normally works in a
horizontal direction around the refuse heap while a heavy winched vehicle
secures the paver. German contractor Kirchhoff paved the asphalt seal in
vertical strips from the bottom upwards, with no time-consuming and costly
securing of the paver. The standard-design Super 1900 of standard design was
combined with an AB 500 screed in the TP2 version, and managed the steep
slope all on its own.
In the United States, two models of Europavers are
sold by Joseph Vögele AG, not to be confused with Vögele America Inc., a
Chambersburg, Pennsylvania, manufacturer of U.S.-designed and built pavers,
which also is owned by Wirtgen Group. These are the Super 1900 and the Super
2100, which are manufactured in tracked and wheeled models, but in the U.S.
have been purchased only as track machines to date.
They utilize three screed models: a fixed,
mechanical screed (not hydraulically extendable) the SB 300; and
hydraulically extendable screeds with tamper bar and pressure bars, the AB
500 and AB 600. With bolt-on extensions, the maximum paving width of the SB
300 is over 52 feet, good for airport work; the maximum extendable width of
the AB 600 is just under 30 feet. However, paving of that width is not done
in the United States, which usually is no wider than 18 feet.
Yet another Vögele model, the Super 1800 SF, is used
in the U.S. not to place hot-mix asphalt, but modified to place NovaChip
open-graded friction course exclusively.
A shift to asphalt paving
Although the Europavers were first used for base
work, as special asphalt mixes like SMA are specified, and as smoothness and
density bonuses are offered, contractors are discovering the benefits of
Europavers in placing today’s specialty mixes.
“Clearly there is a shift happening,” ABG Titan’s
Hutchins said. “A growing number of contractors are using the Titan pavers
principally for asphalt. They were designed to place asphalt at very high
levels of compaction, and contractors are beginning to utilize this
technology. They are able to use these machines on stiff mixes like SMA to
achieve density and rideability much, much easier than they could with
conventional American pavers.”
After years of looking beyond the American market,
Joseph Vögele AG now is marketing its machines in the U.S. “The Super 1900
and 2100 machines are of interest to American contractors who are looking
for more consistent densities, and higher levels of smoothness,” said Stu
Murray, president of Wirtgen America Inc., Nashville-based distributor of
Joseph Vögele machines.
“If the contractor just wants to go out and pave —
and hope he gets paid for most of it — his mindset will never lead him to a
European paver,” Murray said. “But a contractor who has faced the density
specifications that states have been rigidly enforcing, the smoothness
requirements that highway owners are insisting on, plus related penalties
for not achieving one or the other, may be interested in such a machine.”
These big Europavers have awakened the interest of
quality-conscious contractors, Murray told Better Roads. “It’s simple:
American pavers have been the same mechanical ‘mousetrap’ for 50 years, and
that’s especially true for the screed technology,” he said. “All of the
paver tractors worldwide fundamentally are material transfer devices.
Material is dumped from truck to hopper, it is conveyed from the front of
the hopper to the back of the paver where it’s sometimes metered or
otherwise flow-regulated. The material is dumped onto two augers, one which
takes it to the right and one to the left. Every single paver on Planet
Earth is built like that.”
The differences between pavers today lie in the
screeds, he said. “Screeds follow a basic design,” he added. “They have some
kind of vibration system and preliminary strike-off and screed plate.
They’re anywhere from 18- to 30-inches wide. And they’re heated, and perform
like a large iron which is towed by the tractor, and floats in relation to
the tractor. There is a higher level of technology and thinking that goes
into a screed designed today than persisted over the last 50 years.”
Interest spurred by tour
The new interest in European pavers in America for
asphalt paving is a natural outcome of a landmark trip to Europe to study
European asphalt paving techniques. This 1990 tour was the first
contemporary International Scanning Tour undertaken by the Federal Highway
Administration, and was co-sponsored by the American Association of State
Highway & Transportation Officials, the National Asphalt Pavement
Association, the then-ongoing Strategic Highway Research Program, the
Asphalt Institute, and the Transportation Research Board.
“The objective was to exchange ideas and experience
with highway agencies and the construction industry in Europe on design,
production, and placement of asphalt pavements,” said then-Federal Highway
Administrator Tom Larson. “We were particularly interested in the design of
asphalt wearing courses, the use of asphalt modifiers and the benefits they
offer to improve the durability of asphalt pavements — as well as recycling
— both hot and cold. In addition, we were interested in contracting
practices that would be innovative in the United States and cooperative
public/private activities, not only in design and financing, but in research
into new materials, methods, and machines.”
Working together, AASHTO, NAPA, and the FHWA
selected a 21-member study group that included six AASHTO and eight industry
representatives, as well as the TRB chair, the president of the Asphalt
Institute, and two SHRP officials. Through cooperation with six government
and industry representatives in Europe, a 14-day study tour of six countries
— Denmark, France, Germany, Italy, Sweden, and the United Kingdom — was
arranged.
“If the participants began with any chauvinistic
ideas about the superiority of United States technology, they quickly
realized we have a lot to learn from Europe about asphalt pavements and
about pavement philosophy in general,” Larson said. “European pavements are
better than ours and it’s no accident.”
Europeans built their pavement foundations better,
he said. They used innovative surfacings such as stone mastic [matrix]
asphalt, and utilized asphalt modifiers to a greater extent, and with better
results, than in the United States. “Government and industry have a closer
relationship — probably closer than would ever be possible in the United
States — that encourages innovation and quality,” he said.
SMA, Superpave, and smoothness
“As a result of this tour, SMA came to the United
States,” Murray said. The trip also spurred development of Superpave as an
American durable asphalt mix. “It was felt with new gradation controls, new
asphalt binders, new fines contents, gap-graded mixes, and cellulose fibers,
Superpave and SMA could provide Americans with durable asphalt mixes that
would perform well over the long haul. But Americans found the new mixes
were difficult to work with. They had to be placed at higher temperatures,
and they were harder to compact and get consistency. And everybody learned
the hard way it was near impossible to get it smooth with conventional
techniques.”
Over time contractors learned to work with hotter
temperatures, get higher frequency rollers, get owning DOTs to permit
different rolling patterns and specs, and developed a concept called the
tender zone which helped achieve correct compaction of Superpave. Still,
smooth pavements that would win bonuses were difficult to attain, Murray
said.
“Highway contractors seeking smoothness and density
bonuses sought equipment that could provide very smooth lifts, because given
the extremely competitive nature of bidding these days, when a contractor
bids a job, at least part of the bonus is bid into his cost,” Murray said.
“He assumes he will get part of the bonus, and figures that into the bid
price to undercut his competitors.”
After long-overlooking the U.S. market for asphalt
paving, German manufacturers ABG Titan and Joseph Vögele AG have entered the
American HMA paving market, with tractors and screeds that have worked for
years placing SMA-type, gap-graded HMA mixes.
Compaction at the screed
“People in Europe learned that if you want maximum
smoothness and consistent density, you have to get it at the screed,” Murray
said. “You can’t get it with five or six, double-drum, high-frequency
rollers that are making eight passes each to get density, but not leaving
the mat smooth, and breaking aggregate while they’re at it.”
Murray says that it takes so much energy to move the
HMA as it exits the truck, while pushing the truck, to place the asphalt at
a uniform depth and width and density and smoothness, that the needed energy
is best applied right at the screed, not after the HMA lies in place.
“For a long time, contractors thought that if
additional energy was needed, they could just bring another roller or two or
three onto the job,” Murray said. “In the last two years a lot of
contractors have come to realize that putting that much energy into a mix 10
to 500 feet behind the paver is inefficient. Now they know why the Europeans
have been developing big, heavy screeds with different energy systems in
them. The ideal point at which to put the energy in the mix is the point
where the mix is being formed and shaped to the right width and depth,
because the material is hot, fluid, and is uncompacted. A screed with high
energy can consolidate it, densify it, and smooth it in one, short process.”
Then the rolling process can change from being a
breakdown-intermediate-finish process, to one which can concentrate on
attaining optimum smoothness. “Now that the energy has been put in the mix
at the screed, the compaction has changed from a breakdown and conditioning
process, to a finishing process,” Murray said. “Now the contractor only has
to bring 90 or 92% density up to 93 or 94%. He only needs two rollers,
without high vpm or weights.”
Of course, there is a trade-off. With the added
mechanics and hydraulics in the compacting screed, such a paver
tractor-screed combination will cost more money. The tractors will be larger
and heavier, with a heavier screed, but the power plant may have less
horsepower than American pavers, principally because of the dramatically
higher cost of fuel in Europe.
And with the added energy being placed in the mat at
the screed, maintenance costs are higher for Eurostyle screeds, as opposed
to American screeds. Other than that, the hoppers, conveyors, wear parts,
augers, hydraulic motors, and pumps are essentially the same quality as
found in the American pavers. “This combination still will be much cheaper
than owning and operating two to three additional compactors,” Murray said.
Electric heat at the screed also has made the
Eurostyle pavers more user-friendly than American pavers. Electrically
heated screeds eliminate the smoking, the blow-torch effect beneath the feet
of the workers, and the environmental mess generated by diesel fuel-heated
screeds. But electric screeds have been used in Europe since 1960. “It’s
old, old technology which is making its way to American-sourced pavers,”
Murray said.
More on high-density screeds
ABG markets four versions of its high-density
vibratory screeds. The fixed-width VDT 120 paves 9-frrt, 10-inches wide, and
the VDT 121 paves 8-feet, 2-inches wide. The VDT-V 78 is hydraulically
extendable from 8 feet, 2 inches to 16 feet, 5 inches, and the VDT-V 88
extends from 9 feet, 10 inches to 19 feet, 8 inches.
All four models feature ABG Titan’s dual vibrating
tamper bars which, combined with their massive weight, allow the paver to
achieve high degrees of compaction at the screed and, ultimately, notable
smoothness. A VDT 120 used with an ABG Titan 525 paver produced 92%
compaction at the screed recently in an SMA stone matrix asphalt project in
Virginia.
ABG’s high-density screeds are available for Titan
models 325 EPM, 326, 423, 8820, and 525, and also can be used on predecessor
models of those machines. The high-density screeds are also recommended by
ABG for paving roller-compacted concrete. “The benefit of the ABG
double-tamper is in the fact that all of the compaction and proportioning is
in front of the screed plate, as opposed to our competitors, which have
rear-mounted pressure bars,” Hutchins said.
German-sourced Vögele pavers combine a tamper and
one or two pressure bars to bring about a high degree of compaction at the
screed. But even that is old technology, Murray maintained; Romans used
tamper bars hand held — to build their long-lasting roads.
More recently, Vögele High Compaction Technology is
based on pressure bar(s) driven by pulsed flow hydraulics. These pressure
bars bring about high compaction of different construction materials. These
screeds are profoundly heavier than their American counterparts. Most will
weigh 1,500 to 2,000 pounds more than a comparable American screed, although
that weight may be spread out over a wider screed plate.
The tamper provides optimum precompaction of the
mix, Vögele said. Driven by an eccentric shaft, the tamper bar packs the mix
under the screed. Compaction by the tamper is followed by vibrating screed
plates.
At the rear, one or two pressure bars provide high
performance compaction at the screed. The pressure and frequency of the
pressure bars is adjustable, based on the thickness and type of mix being
placed. “All things being equal, a Vögele screed can achieve 88 to 90%
density immediately behind the screed,” Murray told Better Roads. “A typical
American paver with typical American screed and vibration on the same job
and mix will get between 75 and 78% density. The difference between 78 and
90 is the additional energy that’s available in the screed.”
SMA and the Europaver
Driving the acceptance of the big Europavers is the
growing popularity of stone matrix asphalt in the United States. SMA is a
gap-graded (low medium-sized aggregate and fines) hot-mix asphalt design
which brings together robust, coarse aggregate and as much as 6 to 8% liquid
asphalt. Its lack of medium-sized aggregate — and fines percentage less than
15% of the aggregate weight — results in a strong mix with a rut-resistant,
stone-on-stone structure which develops internal friction and resistance to
shear.
But because the gap-graded SMA emphasizes large
aggregate, the low-penetration grade asphalt conventionally used can drain
out of the coarse aggregate structure. To keep the asphalt in place,
cellulose fibers or other asphalt modifier are added at the plant to keep
the binder in place. SMA is derived from the German term splittmastixasphalt,
which was changed in the U.S. to stone matrix asphalt. The terms mean much
the same thing.
SMA poses production challenges. Not all plants are
set up to make SMA, and not all the aggregate suppliers are prepared to
produce the stone necessary for SMA. In a recent Virginia DOT application,
aggregates from 70 miles away were brought in for the mix. The liquid
asphalt for this SMA mix was a PG 76-22, a polymer modified asphalt.
Cellulose fibers were introduced to the drum while the SMA was mixed, and
coarse aggregates represented about 80% of the mix by weight. Liquid asphalt
was about 6.8% and the remainder was fine aggregates — a combination of
mineral filler and dust — and cellulose fibers.
On this project, U.S. 17 in the vicinity of
Fredericksburg, Virginia, a Vögele Super 2100 was used to place the SMA. “We
really feel that paver is an excellent paver to place ride routes,” said Ron
Burton, Stafford plant manager, Virginia Paving division of Lane
Construction. “When we first got the paver in for a demo we took it out on a
primary road where we used it to put down a 12.5-mm D mix, which has a
non-modified PG 70-22 liquid asphalt. Behind the screed we were getting
98%-plus density. It was almost at the point that we felt we might be
getting too much density on the mix, so later we dialed-back the pressure
bar settings.”
For that test, Virginia paved half the road with a
standard paver and half with the Super 2100. Virginia Paving conducts its
own ride smoothness testing with its own rideability van, and it did a
comparison on the two pavements. “There was a noticeable difference,” Burton
said. “We would not use the Vögele everywhere, but when we have ride routes
— projects on which we will be penalized or bonused according to the
smoothness of ride we achieve — that’s the type of paver to put out there.”
“For SMA we’re getting compaction at the screed in
the mid-to-upper 80s,” Burton said. “We have a good feel that what we’re
getting behind the screed will allow us to get density with the rollers
without having to literally beat the mix up, which has happened in the past.
You have to get SMA density down with the paver, and then get the remaining
density while rolling it out nice and smooth to get your rideability.”
Europavers boost smoothness
Yet another niche application for which the
Europavers seem particularly suited is the repaving of motor speedways,
either with SMA, or other bituminous mix. Invariably, an aged asphalt
surface is cold-milled, and is replaced with a supersmooth asphalt driving
surface placed with a Europaver.
Contractor Sunmount Corp. bought an ABG Titan 511 to
place road base in the mid-1990s, but since has used it and a newer Titan
525 to pave noted race tracks such as the Texas Motor Speedway in the
Dallas-Fort Worth Metroplex, and the Atlanta Motor Speedway. The firm
recently completed its sixth race track paving job using the Titans, it was
reported.
And in late summer 2004, the Indianapolis Motor
Speedway was reconstructed using SMA following cold milling and track
drainage improvements. Vigorous compaction at the screed was paramount for
application of the SMA pavement, selected by the track and its consultant
for its durability, strength, and impermeability under the punishment of
professional race cars and tires, and weathering.
The screed of the Vögele Super 2100 was achieving 89
to 90% compaction as the material exited, followed by breakdown rolling in
static mode, then unique oscillation compaction to 95.5% density, and finish
rolling in static mode.
Smoothness requirements at Indy go way beyond
standard highway benchmarks. “Our smoothness is hard to define, using the
standard California Profilograph, even with zero blanking band,” said Kevin
Forbes, P.E., director of engineering, Indianapolis Motor Speedway. “Our
issue is with deviations which occur over 100 feet, which are significant to
race car drivers. The typical Profilograph measures every 30 feet, so it
won’t even pick our standard up.”
That’s not meant to demean what state DOTs do,
Forbes said. “We don’t want to take anything away from state highways
because they are very well constructed,” he said. “But it’s a different
application of forces, and it’s different speeds. It becomes very, very
critical that we give the drivers the smoothest, flattest, most predictable
surface we can. If the drivers know the surface underneath them is very
uniform, very reliable, and very consistent, that will allow them to pull
out all the stops in terms of their ability to drive their race car.”
To ensure a smooth base for the SMA, the track was
cold milled by a machine with 14-foot-wide drum. After a ramp-up period,
later in the project the track was getting 92% density immediately behind
the screed.
The Europaver was specified for its better handling
of the SMA, Forbes said. “The three keys to density of SMA in our mind here
are temperature, temperature, temperature. Getting that initial high density
with elevated mix temperatures is a very good thing in case we have issues
with mat temperature later on. And getting 89 to 90% density at the screed
means that the heat we have in the mat will be retained for a much longer
time. It means we will have more flexibility in rolling patterns behind the
paver.” And those patterns are essential to a smooth mat.
Are Europavers slower?
Eurostyle pavers have a reputation for paving more
slowly than American contractors will tolerate, and that’s thought to be a
reason that it has taken so long for them to catch on for HMA work. The
truth is they will pave as fast as an American machine, but in Europe, many
elements combine for a slower job.
“Europeans have a saying about Americans,” ABG
Titan’s Hutchins said. “They say Americans drive slow and pave fast, where
in Europe they pave slow and drive fast. That hits the nail on the head;
application and specs drive the speed of the job.”
“European streets tend to be narrower than American
streets,” Wirtgen’s Murray said, “and asphalt plants in Europe produce at
about 150 tons per hour and will be a batch plant. Job to job, asphalt lifts
there are considerably thicker than U.S. placements. So if you are paving in
downtown Munich, and you have a 150-tons-per-hour plant feeding a paver
laying asphalt 3-inches thick, the paver is naturally going to go slower,
only because of the circumstances surrounding the project.”
Similarly, due to the added available energy at the
screed, it is easy for a swift-moving paver to move faster than the screed
can transfer that energy into the mix. With intense compaction at the
screed, it behooves the operator to go more slowly to make sure the
at-screed compaction is done right. “To be able to get accuracy to grade
with the screed tamping is much easier when the paver moves slowly,”
Hutchins said.
Conversely in America, a corresponding job would be
a wider roadway, an inch and a half thick lift, and a 400-tons-per-hour drum
plant feeding the paver. “Those pavers will move faster,” Murray said. “We
have had German-sourced pavers in Wyoming being fed by a 600-tons-per-hour
plant, and they paved very successfully. It’s a matter of balance.”
But the best of both worlds may soon be upon the
industry. At Conexpo-Con/Agg 2005, Vögele America Inc. will exhibit a
high-horsepower, American-sourced 2219 T tractor, with an AB 600 T2 screed.
“Because Americans like fast, high-horsepower American tractors, we will
give them that, but with a high-energy German screed attached,” Murray said. |