Guntert & Zimmerman

Construction ProfilesSpring 2009

Acme Paving at McCarran Airport <COVER>

Concrete Paving in The Wettest Place on Earth p. 5

Equipment Delivery

to the East Coast

p. 9

No Gambling at the Las Vegas

Airport

1

Runway 25L/7R, the busiest runway at McCarran Airport in Las

Vegas, has recently underwent a $75 million reconstruction.

The 25L/7R reconstruction was one of the largest airport paving

projects under construction in the USA. The project required

extensive planning efforts due to a hefty liquidating damage

clause in the contract of $500,000 per day. This liquidating

damage clause is purported to be the largest in the history of

paving.

Asphalt milling of the existing runway began on November 3,

2008 and was completed just 16 days later, producing more

than 300,000 tons of recyclable AC millings. Las Vegas Paving,

the prime contractor on the project, subcontracted the paving

operation to ACME Concrete Paving, Inc (Spokane, WA). Upon

milling completion ACME rapidly mobilized 2 RexCon Dual

Drum 12 cubic yard (9.17 cubic meter) concrete plants, 2 G&Z

pavers (S850 and S1500), 2 G&Z belt placers (PS1200 and ISF-

150), and a G&Z texture/cure machine (TC1500). Concrete

paving began on November 19, 2008 with production rates

sometimes exceeding 7,000 cubic yards (5,351 cubic meters) per

day. Paving dimensions on the 18” thick runway were 10,525’ x

150’ wide and 11,000’ x 100’ wide on the parallel taxiway.

A unique setup at the plant-site allowed stockpiling to occur at

night during minimal traffic hours. A single drive over grizzly

with large receiving hopper permitted tandem and triple belly

dump trailer delivery, dumping onto a simple reversible belt that

allowed feeding to either batch plant. The sand and two coarse

aggregates were stockpiled using radial stackers. Individual

stockpiles were kept small to minimize stockpile loss with timely

deliveries by aggregate producer and prime contractor, Las

Vegas Paving. Also unique to this job was ACME’s utilization of

Kawasaki loaders, water trucks, and light plants supplied by Las

Vegas Paving all of which greatly reduced mobilization costs for

Acme Paving coming all the way from Spokane, WA.

This job was well underway during the 2009 World of Concrete

and allowed frequent visits by interested World of Concrete

attendees. Even though the project limits were directly adjacent

to the east west runway, security was handled by erecting a fence

encircling the entire project site which made for easy access to

this high profile job.

The pours on the runway were paved at 37.5’ (11.43 m) lanes with

the G&Z S1500 fed by the new PS1200 Placer/Spreader from the

right side and the older G&Z ISF-150 feeder from the left side.

The taxiway pours were paved at 33’-4” (10.15) wide with Acme’s

new G&Z S850. The PS1200 which was purchased specifically

for this project was delivered to ACME in 2009. The PS1200 was

designed with the ability to leave the tractor at 37’-6” (11.43 m)

while rapidly changing strike-off widths to 33’-4” (10.15 m) using

a specifically designed set of strike off support arms.

The ability of the G&Z equipment to rotate tracks 90 degrees

enabled quick moves to the next pour and minimized hand

pours on cross taxiways where ACME utilized a pair of Multi-

Quip roller screeds. Acme also cited the effectiveness of the

S850 to pave “stringless” on the closure passes. Elevation was

sensed by “locking to grade” where the elevation sensors took

their grade reference off the crawler track yokes. Alignment was

accurately sensed for both the front and rear crawler tracks in the

“front steer only” mode requiring only the front steering sensor

referencing off the inside of the previously poured concrete.

Acme also made good use of the S850’s Computerized Crown

Control feature which allows automatic transitions in and out

of crown. The runways were paved at a consistent 1.25% crown,

but the taxiways were paved with a 1.25% variable crown. The

pavers ability to automatically adjust to the specification saved

a lot of time.

PS1200 Equipment ChoiceG&Z engineers and service personnel learned a great deal about the capacity of the PS1200 while it was being pushed to its outside limits on this project. With important lessons learned and much knowledge gained through the experience, the PS1200 placer/spreader proved to be an ideal machine in this application for the following reasons:

1. Spreading Capability up to 40 ft.: Heavy duty tractor frame capable of spreading widths from 18 to 40 ft.

2. Transportable in a Single Load without a Crane (patented): The PS1200 is self loading in a matter of a few hours.

3. Rapid Belt Relocation (patented): The tractor is universal with only the relocation of the strike-off / spreader plow required which can be accomplished in under 1.5 hours without a crane.

4. Powerful 60” Roll-In / Roll-Out Concrete Belt: • The belt skip is hinged support by hydraulic cylinder to allow

for haul road elevation variations. • Belt doesn’t require stopping to allow trucks to pass and rolls

in / out under 7 seconds. • The belt also strikes off and spreads the top of the concrete

pile as it rolls in.5. Heavy Duty Strike-Off: Module is strong enough to push concrete

back to the paver and tall enough to contain concrete pile. 6. Powerful Spreader Plow System: After pre-spreading by the

concrete belt, material spreading is accomplished by a powerful hydrostatic wire rope winch driven spreader plow.

• Almost zero maintenance. • Cost to operate is a fraction of the cost to operate an auger. • Spreading action is not impeded by a center auger bearing or

outer gearboxes like an auger system.

2

The G&Z PS1200 Placer/Spreader has been working in the North

American Concrete Paving Market in a number of different

paving applications for over 5 years. Never has it been utilized

in a tougher application than on this project. For this particular

application, the design limits of the G&Z PS1200 were tested

by the 18” thick 37.5’ wide pavement, concrete with an average

slump of 1”. This low slump airport mix was made partially with

manufactured sand which added to the “stiffness” of the mix.

One challenge was the concrete being pre-placed in front of

the PS1200 by another G&Z Placer. This created large piles of

concrete that had to be pushed by the PS1200 while still receiving

and placing concrete. Acme was impressed with the PS1200’s

mobility which saved them a lot of time maneuvering around the

job site as well as on/off the site. Due to the time sensitive nature

of the job, it was necessary that all pieces of equipment used were

highly productive. The PS1200 was designed to operate at a level

of high productivity. Though the conditions were challenging,

the PS1200 met them time and time again.

With this large scale project completed, Acme Paving is quite

satisfied with its purchase of G&Z equipment. Not only did

the G&Z equipment perform well on the job site despite the

challenges allowing Acme to finish two weeks ahead of schedule.

Furthermore, the professionalism and knowledge displayed

by the G&Z service techs during the project added to the value

of the equipment. Even under a rigorous timeline and tough

airport paving conditions, the team at Acme along with the G&Z

equipment and personnel rose to the challenge.

There were a large number of participants on the team that

made this project successful; however, we want to recognize a

few key companies and individuals instrumental in the project’s

success:

Vice President Robert SeghettiVice President Steve ClarkPaving Superintendent Brian WhiteEquipment Manager Steve White

Concrete Removal and Diamond Grooving

Project Manager and Estimator Ryan Mendenhall (grandson of Las Vegas Paving’s founder Bob Mendenhall)

ACME

3

2009 Paving School Recap

This was my second year helping coordinate and also attending, the G&Z annual paving school. Nothing is more worthwhile then the quality time spent with our existing and potential customers during the paving school week. Paving School offers a full three days of time to spend with concrete contractors from all over the country. It provides an excellent forum to listen and learn through the stories and experiences of the professionals that are out on job sites everyday building our roads and airport pavements.

One behalf of Guntert & Zimmerman, I would like to say thank you to everyone who participated in this year’s concrete paving school. The turnout this year was great. We had 68 attendees representing 15 different contractors from around the nation.

I would like to extend a formal thank you to Paul Okamoto and Paul Jaworski for their brilliant addition to our in house experts. The mix design and vibration class received many accolades from our attendees. G&Z hopes to continue to bring experts from our industry to paving school to add to the wealth of knowledge transferred during the week.

Paving School is an excellent value to the attendees. In addition to the knowledge gained through the classes offered, they have several opportunities through the school to network with their peers to gain helpful insights and “tricks of the trade”.

There is much excitement around G&Z these days. We are about to launch our new S600 half width slipform paver which will incorporate several of the same productivity features combined with the ability to achieve smooth ride as provided by the S600’s big brothers - the G&Z S850 and S1500. With the S600 market introduction, we are planning on introducing several new modules and classes about the S600 in G&Z’s paving school next year.

With next year in mind, I hope you will choose to return to paving school again or attend for the first time. As paving school grows, so does the program. In 2010, we hope to offer a robust and redesigned paving school that continues to transfer vital knowledge from different aspects of our industry. Stay tuned for details as the event gets closer.

If you would like to be kept apprised on paving school developments for next year, please e-mail David Lipari at dlipari@guntert.com.

Good luck in this years’ paving season. With the infusion of stimulus money towards road projects, it will no doubt be a busy season. Thanks again for your attendance and participation. We look forward to seeing more of your team next year!

- Ron Meskis, National Sales Manager

4

Concrete Paving in

The Wettest Place On

Earth

5

As we all know it takes a coordinated effort of man, materials,

and equipment to construct a concrete roadway under a tight

smoothness specification. Now, toss in the element of weather

but not just any weather, the wettest conditions found anywhere

on earth.

The Assam region of India is known for an average rainfall of

approximately 1270 cm (500 in). The world’s highest recorded

rainfall which occurred in Cherrapunji (Assam) was 2290 cm (75

ft) of rain which fell in one 6 month period (Cherrapunji is about

180 km [112 mi] from the jobsite). These annual monsoons

typically begin in March and continue through the end of

September. It is so wet in this region of the world that “Google”

claims this to be the “wettest place on earth!” This doesn’t leave

a very big window to construct a quality concrete pavement.

It is under these extreme conditions

that Patel KNR (JV) is paving concrete

on a straightening and widening

project of the National Highway (NH-

37) in the Assam region of India. The

project is located between Guwahati,

the state capital and Dharamtul,

thereby connecting the upper and

lower parts of Assam.

The project consists of a four lane reconstruction of the roadway

for a total concrete paving length of 41 km (25.5 mi). The project

also includes a 16 km (10 mi) stretch of new construction known

as the Nagaon Bypass. The concrete paving work is scheduled

to be completed by March 2009 with the total cost of the project

at approximately Rs 238,72,47,500 (USD 46,050,004.75).

The project is being constructed using a Guntert & Zimmerman

S850 with Compact Dowel Bar Inserter (CDBI) at a paving width

of 8.75 m (28.7 ft) and at a thickness of 310 mm (12 in.).

Transverse joints are sawn every 4.5 m (14.7 ft) with load transfer

dowels (32 mm x 500 mm [1.25 in x 19.6 in] located mid-depth in

the slab) across these joints. The typical spacing of the dowels

is 300 mm (11.8 in.) with exceptions of 200 mm (7.8 in) and 150

mm (5.9 in) on centers at the median and shoulder respectively.

The longitudinal joint is tied with a 16 mm x 640 mm (.6 in x 25

in) tie bar spaced on 600 mm (23.6 in) spacing.

There was a significant amount of planning on the concrete

batching operation that occurred prior to the first slab being

placed. It was decided to erect two batch plants (Ajex Feori &

Penta 3000 TS), both of which could produce 120 cubic meters

of concrete per hour (157 cubic yards per hour) with the use of

a twin shaft mixer.

Once the batch plants were erected a series of batch trials were

carried out to check the accuracy and uniformity of the batching

& mixing process. Additionally, slump tests were performed at

20, 30, 45, and 60 second mix times

to verify what mixing time achieved

a specified slump of 20-25 mm

(.78-.86 in) at the paver.

The target paving speed was 1.0 meter

per minute (3.2 feet per minute),

while ignoring any concrete waste

translating to an average of 162 cubic meters per hour (211.8

cubic yards per hour) delivered to the paver. This concrete

production amounts to approximately 70% of the combined

rated output from both plants.

The batch size on each plant is 3 cubic meters ( 3.9 cubic yards)

with a plan for discharging 3 batches per truck to achieve the

target truck load of 9 cubic meters.

Both batch plants were located at Patel KNR (JV)’s site offices

which are 3 km (1.8 mi) beyond the Eastern limit of the contract.

The first section of pavement constructed was at the opposite

(Western) end of the contract on a 7.7 km (4.7 mi) portion of

the NH-37 that is being re-constructed. The average haul to

this section was 22.8 km (14 mi) and the route is through the

town of Nagaon.

Average annual rainfall of over 1,270 cm (500 in.)

6

A trial paving section was completed prior to full scale

production, with two objectives in mind. The first was to

verify that all the needed resources (tools and labor) were

deployed to the job site prior to full production. Secondly, the

test was conducted to demonstrate to the engineer Patel KNR

(JV)’s abilities to construct an 8.75 m ( 28.7 ft) wide pavement

with the G&Z S850 and CDBI while achieving all the required

specifications relating to strength, smoothness, straightness of

edges, texturing, curing, saw cutting, etc.

A critical element to successful slipform paving in India is good

technical field support for the contractor. Allen Buildwell (G&Z’s

representative in India) and G&Z supplied many technicians

over a period of months. The duties of these technicians

included assisting with operation of the Penta batch plant and

the assembly of the G&Z equipment as well as its operation

during the course of the project. Prior to the first installation

of concrete, Allen Buildwell and G&Z provided training to the

Patel KNR (JV) personnel in the safe operation of the S850 Paver,

CDBI, and texture cure machine.

The project to date has been an astounding success. The

engineer on the project representing the state is pleased with

the overall quality and smoothness that is being produced by the

Patel KNR (JV) team with the help of the G&Z equipment.

According to Mr. Panindra Reddy of Patel KNR (JV), “We are

overjoyed at the performance of the G&Z equipment. For

as big as this equipment is, it was relatively ready-to-go after

being unloaded.” Additionally, “The Allen Buildwell and G&Z

personnel were critical components to the success of this project.

They were helpful from every aspect of concrete paving from

pre-planning, mix design analysis, equipment set-up, operation,

and trouble shooting. In my opinion, I would pave with no other

machine with such confidence.”

The philosophy at G&Z is to design and manufacture paving equipment that best addresses the needs of the contractor and results in higher productivity and better quality pavements. Though the up-front costs will be higher, it is an easy case to prove that any extra initial investment will be quickly recaptured in what the contractor gains in productivity due to:

1. Dramatically reduced time to load, set-up, tear down, and change widths versus the competitors

2. Patented 90 degree and counter-rotation steering. This allows for easy maneuverability around the site and for loading onto a transport vehicle.

3. Narrow profile design so the paver can work as close as possible to obstacles.

4. Reduced hand pours at headers because of the machines capability to back onto previous days pour and begin right at the header.

G&Z S850 quickly paving away from the previous days concrete slab.

7

PAVING AUSTRALIA’S EAST COAST PACIFIC HIGHWAYG&Z RECENTLY COMMISSIONED A S1500 PAVER, ONE PS1200 PLACERSPREADER AND TWO TC1500 TEXTURE CURE MACHINES ALONG WITH TWO CONCRETE PLANTS IN COLLABORATION WITH THEIR CUSTOMER THEISS PTY LTD IN AUSTRALIA. THEY HAVE JUST BEGUN TO USETHE EQUIPMENT AND HAVE BEEN THRILLED WITH THEIR GOOD FUNCTIONAND END PRODUCT RESULTS. MORE NEWS TO COME IN G&Z’S WINTER 2009CONSTRUCTION PROFILES MAGAZINE AS THESE MACHINES CONTINUETO BE PUT TO THE TEST.

TC1500

SCP-6

S1500

PS1200

Increased productivity and opportunity for contractors to earn

smoothness bonuses have long been the key criteria driving

the design philosophy at Guntert & Zimmerman (G&Z).

Quite often, the significant cost saving details get overlooked

because contractors don’t always have the time to delineate

these savings when analyzing equipment value. More often

than not, the primary consideration in making an equipment

purchase is initial price and not the total cost of ownership over

the equipment’s life.

G&Z is usually not the lowest initial cost machine being

considered in a buying decision. However, the G&Z machine

generally contains features the competition just doesn’t offer.

A G&Z machine is extremely well constructed and engineered

for precision and versatility. These machines are high value

equipment with a rapid return on initial investment as well as

retaining value for a longer length of time. Enhanced mobility

and other features make G&Z more efficient which allows for

increased productivity due to less downtime between pours

and between job sites.

For a contractor to successfully construct high quality concrete

pavements attention to the details is a necessity. This requires

attention to the concrete materials, the equipment, and people

executing in the field. Therefore, it is not uncommon for

contractors to share that same focus for quality and detail as G&Z.

Bringing G&Z Excellence to the

East Coast

9

It was these same set of values that brought G&Z and Golden

Triangle together as a team in the Pennsylvania concrete paving

market. Chuck Niederriter, C.O.O. for Golden Triangle, and Ron

Guntert had been speaking for years prior to Golden Triangle’s

first purchase of a new S850 slipform paver in 2008.

Prior to Golden Triangle purchasing the G&Z S850, Chuck

Niederriter was concerned because the pavers they owned were

not able to achieve profileograph results to meet Pennsylvania’s

tight International Road Index (IRI) smoothness specifications.

Additionally, when evaluating equipment, Niederriter recognized

the value in the S850’s solid structure, transportability, and other

productivity features.

Chuck Niederriter had been a regular attendee at the ConExpo

show held in Las Vegas every three years. He, along with several

other team members from Golden Triangle, spent a number

of hours “kicking the tires” of an S850 on display at the 2008

ConExpo. With a healthy paving backlog going into the 2008

season and impressed by what they saw, Golden Triangle

ordered a new G&Z S850 and took delivery of it in October

2008.

Taking possession of a new piece of “iron” is always exciting

to a concrete contractor, and this delivery was especially so.

After unloading their new S850 with the help of G&Z service

technicians, Golden Triangle did some minor assembly of the

machine, set the elevation and grade control, and began paving.

Niederitter was amazed at how quickly the paver was ready for

paving after being delivered. “This is the first time our mechanics

and equipment technicians haven’t been all over the paver

making adjustments before and after the first load of concrete

arrived. Not only did the machine start-up go smoothly, but

we were able to achieve the needed IRI numbers from that first

pour forward.”

The first project the S850 was used on by Golden Triangle was

near New Alexandria, PA, which consisted of a $35 million

reconstruction of SR22 having 4 lanes of concrete pavement

plus a turning lane. The 12 inch thick concrete was poured at

24 feet wide with the G&Z S850. After this project is completed

early this summer, Golden Triangle will transition to another

project located on the east end of this project which is valued

at $20 million and consists of a 2 mile reconstruct with the

same pavement section as the 4 mile section they are presently

constructing.

Golden Triangle experienced first hand on this project the ease

of transport of the S850. They expect to be moving the S850 back

and forth between the SR22 project as well as a couple of other

PA Turnpike projects near Brownsville, also known as the New

Mon-Fayette Corridor, in order to meet the tight schedules on

these projects. One of the reasons they chose the G&Z S850 was

for its ability to make transport quick and easy.

In addition to the ease of transport and other cost saving features

of the S850 paver, Golden Triangle was very impressed with the

level of service they received from G&Z’s Service Department.

“The G&Z serviceman, Scott Mallory, did a great job teaching

everyone from the finisher to the project manager on how to

get the best results out of the paver. He was knowledgeable

about not only the paver, but ALL aspects of the paving process,”

praised Niederriter.

“This is the first time our mechanics and equipment technicians haven’t been all over the paver making adjustments before and after the first load of concrete arrived. Not only did the machine start-up go smoothly, but we were able to achieve the needed IRI numbers from that first pour forward.”

-Chuck Niederriter, C.O.O. for Golden Triangle

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Manufactured under one or more of the following U.S. or Foreign Patents: 4,433,936; 4,483,584; 0051885; 6,390,727; 6,390,726; 6,176,643B1; 5,135.333 and 117323 and Patents Pending. Some items shown may be optional. Guntert & Zimmerman Const. Div., Inc. will custom build any machine or accessory to suit your particular job requirement. G&Z reserves the right to make improvements in design, material, and/or changes in specifications at any time without notice and without incurring any obligation related to such changes. Brochure No. 400P099

Guntert & Zimmerman Const. Div., Inc.222 E. Fourth St. Ripon, CA 95366 U.S.A.Phone 209-599-0066 Fax 209-599-2021Toll Free 800-733-2912 Email gz@guntert.com Web www.guntert.com

Construction Profiles is published by Guntert & Zimmerman to inform readers of applied construction technology utilizing Guntert & Zimmerman equipment. All rights reserved. The contents of this publication may not be reproduced either in whole or in part without the consent of Guntert & Zimmerman. Printed in U.S.A.

NARROW PROFILEPAVING KIT

Narrow profile paving gives contractors the ability to pave close to barrier wall, lane additions, and reconstructions without the need to shut down an additional lane of traffic. This configuration is often used in tight confines as in city, county, and industrial applications.

Zero or minumum clearance paving has been done from time to time over the past 20 years. However, limitations exist including inability to achieve smooth ride and pave with a dowel bar inserter. G&Z’s current slipform pavers with DBI can achieve zero band smoothness specification while paving with a minimum clearance of 32 inches.

G&Z recognizes the need for narrow profile paving without sacrificing smoothness. G&Z offers a Narrow Profile Paving Kit which is now available on the G&Z S850 Slipform Paver with Dowel Bar Inserter to accommodate paving with less than 25 inches of clearance. This allows the S850 to pave next to an active lane of traffic. The Narrow Profile Paving Kit is available as a retrofit or at time of order.

G&Z Delivers New Technology to Keep Our Customers Competitive