road news 23

RoadNews for new roads

Maximum evenness // New surfacing for “Vehicle Dynamic Assessment Pad” of Continental, USA

Pavement rehabilitation in Germany // Clean roadworks with VÖGELE SprayJet Technology

Perfect precompaction // VÖGELE paver enlarges container terminal in Manila, Philippines

New mobile feeder with pivoting conveyor from the VÖGELE PowerFeeder generation

Power and Versatility:The Feeder MT 3000-2 Offset

The VÖGELE Magazine on Paving Applications Issue 23 // September 2011

Editorial

2

Top performance on every job site // With machines, technology and service from VÖGELE

VÖGELE have elevated mobile feeder technology to a higher

level with their new PowerFeeder generation. The MT 3000-2

was presented in RoadNews No. 21. This issue now highlights

the new MT 3000-2 Offset, the mobile feeder featuring a

pivoting conveyor. With its outstanding performance and

easy operation, the machine proves its value on various

job sites – a revolutionary innovation with a wide range of

potential uses.

SprayJet technology from VÖGELE also allows paving

teams to carry out roadworks quickly and efficiently.

In our expert interview, Dipl.-Ing. Volker Schäfer from the

German Association for Road and Transportation Research

explains the advantages of thin asphalt overlays paved

“hot on hot” on spray seal (DSH-V), a paving method

ideally handled by the VÖGELE spray paver. The importance

of this technology is set to further grow in future, as more

and more roads are in need of pavement rehabilitation to

be carried out cost-efficiently with long-lasting results.

This issue also includes a supplementary brochure

documenting the WIRTGEN Group’s 50th anniversary.

Reinhard Wirtgen founded a haulage company for the

transport of construction materials in 1961. Meanwhile, the

one-man firm has grown into a corporate group operating

worldwide and employing some 5,000 people. The brochure

tells the story of how the WIRTGEN Group with its four

core brands of WIRTGEN, HAMM, KLEEMANN and VÖGELE

succeeded in becoming the global market leader for mobile

road construction machinery: with innovative solutions,

recognized processes and a full range of modern products

meeting the highest standards.

With VÖGELE, you are perfectly prepared for every job.

Roland Schug

Contents

Contents // RoadNews 23

3

Top Feature ..............................................................................................................................................................................

Versatile VÖGELE feeder with pivoting conveyor // Boost performance with the MT 3000-2 Offset 4

Site Reports ..............................................................................................................................................................................

German group of companies replaces all their pavers // Perfectly equipped for every task with the new VÖGELE fleet 22

Sound basis for further growth // VÖGELE paver enlarges container terminal in Manila, Philippines 40

VÖGELE paver rehabilitates Continental's “Vehicle Dynamic Assessment Pad” in the USA // Perfect evenness

and maximum compaction 44

Expert Interview ..................................................................................................................................................................

Perfected spray paver operation gains ground // Economical, eco-friendly, noise-reducing:

Paving thin overlay is a convincing option 32

Technology ...............................................................................................................................................................................

Light balloons for pavers and feeders // VÖGELE make the night shine brightly 20

Efficient paving of surface course with the VÖGELE spray paver // Prime pavement quality and low consumption 30

Calibration made easy // Step by step guide to perfect spraying of emulsion 38

Photo Report ...........................................................................................................................................................................

Two SUPER 1900-2 rehabilitate motorway section in Istanbul, Turkey // Overnight paving job on the Bosporus 28

VÖGELE News ........................................................................................................................................................................

“Heroes of the Road” // News on our microsite for heroes 16

Tips & Tricks ...........................................................................................................................................................................

A handy option from VÖGELE // Articulated limiting plates for auger tunnel Centre Pages

Imprint RoadNews for new roads – the VÖGELE Magazine on Paving Applications | Editorial Address: Joseph-Vögele-Str. 1, 67075 Ludwigshafen,

Germany, Telephone +49 (0) 621 8105 – 392, Fax +49 (0) 621 8105 – 469, E-Mail [email protected], Website www.voegele.info

Editors: Roland Schug, Anja Sehr, Martin Hilken | Translations: Maria Weckesser | Agency: bilekjaeger, Stuttgart | Reproduction of

articles is permitted after written consent. We disclaim liability for editorial submissions which have not been requested. Trademarks and

registered trademarks are the property of the owners.

4

Boost Performance with the MT 3000-2 Offset

Versatile VÖGELE feeder with pivoting conveyor.

Top Feature

VÖGELE optimize the supply of mix on every job site with their new PowerFeeder generation. After presenting the MT 3000-2 in RoadNews 21, this issue now highlights the advantages of the MT 3000-2 Offset.

5

VÖGELE PowerFeeder MT 3000-2 Offset

OFFSETTECHNOLOGY

Feeding pavers non-stop and without direct contact provides for first-class pavement quality.

Thanks to the sophisticated conveyor concept, even large feed lorries are unloaded within 60 seconds.

Conveyor can be pivoted 55° to the right or left, as well as 23° upwards. Mix can be discharged up to 3.5m to the right or left beside the mobile feeder and at heights ranging from 0.8m to 3.7m.

ErgoPlus® installed for safe and easy operation by one or two persons.

A modern laser-based distance control system ensures that the MT 3000-2 Offset always maintains exactly the right distance from the paver.

Technical Highlights of the PowerFeeder MT 3000-2 Offset

6

Top Feature

OFFSETTECHNOLOGY

7


Karl Keller, Mechanical Engineering Department

F. Kirchhoff Strassenbau GmbH & Co. KG

“It is impressive to see how cleanly the mix is transferred to the paver. Hardly a single grain is lost by the feeder.”

The innovative pivoting conveyor forms the centrepiece of VÖGELE Offset

Technology. The 1.1m wide conveyor can be pivoted through 55° to both

the right and the left, as well as 23° upwards, opening up a whole variety

of potential uses. As a result, the mix at the end of the conveyor can be

discharged up to 3.5m to the right or left beside the mobile feeder and at

heights ranging from 0.8m to 3.7m. This makes the machine ideal, for

example, for feeding pavers from the side, as well as for backfilling trenches

or the spaces between safety barriers on motorways or long-distance roads.

The feeder is also recommended for roadworks on hard shoulders.

Not only asphalt, but also gravel, water-bound base course mix, recycled

material and topsoil are delivered right there where they are needed, with

spot-on accuracy. Segregation of the mix is prevented at all times during the

conveying process by the 30° troughed shape of the conveyor. What’s more, the

conveyor is particularly lasting as the endless belts are industrially produced

without seams.

Intelligent automatic tensioning also contributes significantly to the conveyor

belt’s durability: it is only tensioned to the maximum extent when absolutely

necessary. In such cases, the belt tension increases until the drive power is

transmitted 100%. Belt tension is reduced if a lower conveying capacity suffices.

As a result, the belt is only tightly tensioned for short periods, extending its

service life considerably.

Innovative pivoting conveyor

8

Top Feature

9


A non-stop, non-contacting transfer of mix, such as is achieved by the feeder,

is a decisive factor for perfect paving quality. Not only, but above all, on

large-scale projects when large quantities of mix need to be transferred to one

or more pavers as quickly as possible.

With the MT 3000-2 Offset, the highest possible conveying capacity is

guaranteed at all times. For the high-performance PowerFeeder from VÖGELE

takes just 60 seconds to empty a 25-tonne feed lorry. Several machine features

make this possible. For one thing, the feeder’s material hopper can hold up to

8 tonnes of mix. The worm conveyors, proportionally controlled, and large

worm blades (diameter 400mm) provide for homogeneous conveyance of mix

without residues. Thirdly, the conveyor can transfer up to 1,200 tonnes of

material per hour.

This high capacity considerably speeds up the job site logistics and leaves the

lorry drivers more time to manoeuvre. In this way, the entire machine concept

ensures that paving can proceed without interruption, thus avoiding humps

which often appear in the pavement when resuming paving after a stop.

Maximum conveying capacity for non-stop paving OFFSET

TECHNOLOGY

Emptying a 25-tonne feed lorry in 60 seconds flat

60

sec

5550

45

4035

3025

20

15

105

60

sec

5550

45

4035

3025

20

15

105

60

sec

5550

45

4035

3025

20

15

105

60

sec

5550

45

4035

3025

20

15

105

60

sec

5550

45

4035

3025

20

15

105

60

sec

5550

45

4035

3025

20

15

105

60

sec

5550

45

4035

3025

20

15

105

60

sec

5550

45

4035

3025

20

15

105

60

sec

5550

45

4035

3025

20

15

105

0 seconds

The feed lorry manoeuvres up to the feeder.

30 seconds

Thanks to the high-performance feeder concept, more than

half of the 25 tonnes has already been unloaded.

60 seconds

The feeding process is complete. The mix has been distributed

into the feeder’s receiving hopper and the extra material hopper

of the paver.

10

Top Feature

Feeding the paver from the side with the pivoting conveyor is

particularly useful, for instance, when placing mix on a deeply

milled out strip, with no possibility for a feed lorry to manoeuvre.

The conveyor can be controlled with such precision that it is ideal

for backfilling trenches of every kind.

The new PowerFeeder MT 3000-2 Offset from VÖGELE is perfectly

tailored for use when paving “hot to hot” with two pavers.

OFFSETTECHNOLOGY

11


Large roads, such as motorways or trunk roads, are the best known area of use

for mobile feeders. The new PowerFeeder MT 3000-2 Offset from VÖGELE is

perfectly tailored for use when paving “hot to hot” with two pavers. Yet the

offset technology is also ideal for filling the spaces between safety barriers on

motorways or long-distance roads quickly and economically.

In addition, the mobile feeder also demonstrates its strengths when it comes

to surfacing footpaths or cycle paths. With its pivoting conveyor, it can travel

on the main road and conveniently transfer mix to a small or compact paver

on the cycle path. The new VÖGELE PowerFeeder MT 3000-2 Offset is also

used in an InLine Pave® train laying binder and surface courses “hot on hot”

in a single pass. Its pivoting conveyor alternately supplies mix to the paver for

binder course and the paver for surface course by way of a transfer module.

The versatile MT 3000-2 Offset can do far more than these few examples would

indicate – and that pays off, as is confirmed by Daniel Stier, Site Manager for

contractor F. Kirchhoff Strassenbau: “Thanks to the pivoting conveyor, the

machine can be used most effectively.”

A variety of potential uses

Even spaces between safety barriers can be filled quickly and

economically.

On confined sites, where a “normal” supply of the paver with

mix is impossible, material can be transferred from the side.

OFFSETTECHNOLOGY

Top Feature

12

Emergency

Stop

Conveying Process:

Fast / Slow

Pivoting Conveyor:

Raising / Lowering

Safety Switch


Easy-to-use yet sophisticated operating concept

Like all machines of the VÖGELE “dash 2” generation, the MT 3000-2 Offset

comes with the intuitive ErgoPlus® operating system. Fitted with two seats as

standard, the feeder can be operated by one or two persons. On complex job

sites, this allows one operator to concentrate exclusively on the conveying

process transferring mix from the feed lorry to the paver, while the other

operates the conveyor. The conveyor is controlled with high sensitivity via a

newly designed joystick in the armrest of the driver’s seat.

To raise or lower the pivoting conveyor, the operator simply pulls the joystick

back or pushes it forwards. The joystick is turned to execute a lateral movement.

A safety switch prevents displacement of the conveyor due to accidentally

touching the joystick: the afore-mentioned functions can only be executed

when the safety switch is pressed at the same time.

The feeder’s conveying capacity is controlled by two push-buttons on the

joystick. The yellow button sets the standard conveyor speed. This speed

can be briefly overridden by pressing the white button if a particularly high

conveying capacity is required. The conveyor speed is infinitely variable.

Of course, all vital functions of the conveying process can also be controlled

from the operator’s console.

13

Pivoting Conveyor:

Turn

Conveying Process:

Automatic Mode (Main Switch)

Conveying Process:

Manual Mode (Override)

14

Top Feature

// Large capacity

The material hopper holds

up to 8 tonnes of mix.

// Crawler tracks

High tractive effort and precise

control.

// ErgoPlus® operating concept

Safe and easy operation

of machine and conveyor

by one or two persons.

Highlights of the PowerFeeder at a Glance

[ 6 ]

15


OFFSETTECHNOLOGY

// Feeding from the side

The conveyor pivots through

55° to the left or right. As a

result, the conveyor’s discharge

end can be up to 3.5m to the

left or right of the feeder.

// High performance

A 25-tonne feed lorry is emptied

in just 60 seconds.

// Height adjustment

The conveyor can be raised by

up to 23°. This allows the paving

material to be transferred

at heights ranging from 0.8m

to 3.7m.

// Drive

Powerful and economical DEUTZ engine with

ECO mode. The cutting-edge “i” engine for

Europe, the USA and Japan is rated at 160kW and

complies with the exhaust emissions standards

COM 3b and Tier 4i. Engines for all other countries

are rated at 142 kW.

www.voegele-heroes.info16

HeroesRoad

Of the

www.voegele-heroes.info

Heroes of the Road

Our microsite www.voegele-heroes.info is growing constantly: we have uploaded some more new videos of spectacular job sites around the world, plus new interviews with users which provide interesting insights into the everyday life of “Heroes of the Road”. One click is all it takes!

Unlimited PowerThis time, one of our new videos in the “Super Stories” section will whisk you off to an airport rehabilitation job in Iceland. And we will also show you just how much power even the smallest of the VÖGELE pavers can yield. Meanwhile, the compact class – our middle-weight champions – will be flexing their muscles, too.

Take part in building thelongest virtual road in the worldwww.voegele-heroes.info/#/justpaveit

www.voegele-heroes.info/#/ourheroes 17

Heroes and their Comments

Ernst BöniForeman

Pius Schmid AG, Visp, Switzerland

Stefan ReisertForeman

Georg Moll Tief- und Straßenbau GmbH, Gruibingen, Germany

I wouldn't want to miss our SUPER 1803-2.

”

VÖGELE get simply everything right.

New “Heroes of the Road” have come forward. Read the section “Our Heroes” and get the full story behind these and other statements.

Our heroes

”

”

”

HeroesRoad

Of the

www.voegele-heroes.info/#/ourheroes18

Ben Lakerveld and Fons Cornelissen have been working as a team for 40 years. They have worked with pavers and screeds from VÖGELE for almost all their working lives. In an interview with RoadNews, they explain just what makes them swear by VÖGELE.

Ben Lakerveld (left)56 years old, paver operator Fons Cornelissen (right)55 years old, screed operator

A team for 40 yearsDura Vermeer Infrastructuur,Hoofddorp, Netherlands

Heroes of the Road

Screeds from VÖGELE are Simply the Best.,,

,,

19

Heroes for 40 Years

RoadNews: Mr Lakerveld, Mr Cornelissen, you have been working with VÖGELE for 40 years now. Is everyone in your company a VÖGELE fan?

Ben Lakerveld:We are indeed fans. These machines are absolutely reliable and you can do a magnificent job with them. And VÖGELE’s screeds – whether fixed or extending – are simply the best around.

RoadNews: How have the VÖGELE machines changed in the course of 40 years and what has remained the same?

Fons Cornelissen:The biggest changes have mainly occurred in the last six years. The ErgoPlus® operating system was a great leap forward. And the modern wheeled pavers are also fantastic. What has not changed is the machines' reliability and the fact that VÖGELE listen to what the paver and screed operators have to say.

RoadNews: You two have not only been in the business for decades, but have also been working together for many, many years. How do you get along after working together for such a long time?

Ben Lakerveld:We are so tuned in to one another at work that it sometimes takes no more than a look to know what the other is thinking. If a spot of bother crops up, it usually blows over within quarter of an hour. I think we’ll miss one another when we retire.

RoadNews: Which is your favourite VÖGELE machine?

Fons Cornelissen:There’s no contest: the SUPER 1800-2 with ErgoPlus®.

1976 // Ben Lakerveld and Fons Cornelissen, under way with the VÖGELE 200 on the ring road at Lelystad near Amsterdam.

1978 // In the port of Amsterdam with a VÖGELE 170 – at the time, the first such machine with extending screed in the Netherlands.

1975 // Four men and their paver: the team from Dura Vermeer Infra-structuur and the VÖGELE 200 on the A 35 motorway near Enschede.

20

01 //

Technology

VÖGELE Make the Night Shine Brightly

Lighting for night-time job sites.

An increasing number of construction projects are being carried out at night. VÖGELE’s light balloons provide optimum working light in the dark with almost no shadow.

A growing number of road construction projects are being

conducted at night in order to minimize nuisance to traffic.

After all, blocked lanes cause less chaos at night than

during the daytime. But this makes the right lighting of

the night-time job site all the more important. The light

balloons are the best candidates for this particular job.

They can be mounted on all pavers of the 2.5m and 3m

classes as well as on both “dash 2” generation feeders.

As optional accessories, they make the ideal addition to

the halogen lamps permanently installed in the hardtops

of the machines.

High-powered “moons”

When switched on, the balloons look almost like moons

floating above the machines. But the soft white light

performs excellently in practice: each balloon has a power

output of as much as 2 kW. That equates to around 2.7 h.p.,

about the same output as a chain saw. This amount of

power ensures optimum visibility without impairing the

21

02 // 01 // The holders for the support poles can be mounted in next to no time.

02 // On night job sites, the light balloons don’t just ensure good working conditions. They also make a major contribution to accident prevention.

Light Balloons for Pavers and Feeders

performance of the tractor unit. And that’s not the only

advantage: in the close-up range between 0 and 5m of the

balloon, the light is even and homogenous. This guarantees

ideal lighting conditions, particularly when working with

extending screeds. At the same time, the light is scattered

in such a way that it hardly casts any shadows and does

not dazzle. This is not only important to the quality of the

work, but is a major factor in accident prevention.

Simple mounting

Mounting is as simple as can be. The holders for one or two

support poles are mounted to the hardtop or guard rail of

the machine. The balloons are supplied with electricity by

the generator for screed heating. They are simply plugged

into the socket after installation. The balloon then quickly

inflates and provides strong light for the long hours of the

night.

Light Balloon

Diameter 110cm

Weight 8kg

Type of lamp Halogen

Output 2kW

Optimum working height 2.5 – 5m

Average inflation time < 1 min.

Time until full illuminance immediate

Illuminated range (with 25 lx) 1.500m2

Illuminance under balloon (height of 5m) 310 lx

Maximum windspeed 100km/h

22

Site Report

Perfectly Equipped for Every Task with the New VÖGELE Fleet

German group of companies replace entire paver fleet.

23

.......

.......

.......

.......

A Première for the New VÖGELE Fleet

A video on this construction project

can be found on the Web at:

www.voegele.info

> News & Media > Mediathek

24

Gewässer: Helvetica Neue 46 Light Italic 6pt

Nachbarländer: Helvetica Neue 46 Light Italic 5pt

Land: Helvetica Neue 65 Medium 5pt

Hauptstadt: Helvetica Neue 65 Medium 4ptKreis: 0,85 mm Ø gefüllt ohne Kontur

Städte: Helvetica Neue 45 Light 4ptKreis: 0,75 mm Ø Kontur 0,5pt

Job Site Details

Construction of new roundabout with cycle path

in Versmold, Germany

Length of section: roundabout and

200m of cycle path

Width of section: 2 – 10m

Paving Details

Pave Width roundabout 4 – 10m

cycle path 2 – 3m

Layer Thickness

Base course: roundabout 14 – 18cm

cycle path 8cm

Binder course: 8cm

Wearing course: roundabout 4cm

cycle path 2.5cm

Material

Base course: roundabout AC 32 T S (50/70)

cycle path AC 22 T N (70/100)

Binder course: AC 22 B S (25/55-55)

Wearing course: roundabout SMA 11 S (25/55-55)

cycle path AC 5 D N (70/100)

Equipment

SUPER 1603-2 with AB 500-2 TV Extending Screed

SUPER 1300-2 with AB 340 TV Extending Screed

Competition on the road construction market is fierce.

The pressure on time and costs is rising while customers’

budgets are shrinking. For this reason, contractors not only

need a fleet of high calibre machines, but also the services

to match. That is why Gröschler GmbH now rely exclusively

on pavers made by VÖGELE.

Gröschler GmbH is a group of four construction companies

in northern Germany. The jobs Gröschler undertake for their

customers range from narrow cycle paths to wide motorways.

To assure their ability to offer this wide range of roadworks

reliably and achieve consistently perfect results, Gröschler have

replaced their entire fleet of pavers with VÖGELE machines.

No fewer than six VÖGELE pavers now work for Gröschler:

the tracked SUPER 1300-2, SUPER 1600-2, SUPER 1800-2

and SUPER 1900-2 pavers, as well as the two wheeled pavers

SUPER 1603-2 and SUPER 1803-2. And the very first job was

plain sailing all the way.

Excellent manoeuvrability and high steering stability

The job took the Gröschler team, headed up by Harald Ott,

to Versmold, a little over 30km west of Bielefeld. A major

location for the food processing industry, Versmold is currently

suffering the effects of heavy truck and car traffic. A bypass is

under construction now and as part of this project Gröschler

was to build a roundabout with the new SUPER 1603-2 before

surfacing the associated cycle path with a SUPER 1300-2.

For the roundabout, the SUPER 1603-2 was equipped with an

AB 500-2 Extending Screed in TV version. The paver placed

base course, binder course and wearing course in widths

varying from 4 to 10m. The machine’s small turning radius

of just 6.5m (outside) made it easy to manoeuvre and allowed

the team to build the roundabout effortlessly and with absolute

accuracy.

Site Report

Versmold

Berlin

North Sea

Germany

France

Switzerland Austria

Poland

Czech Republic

Belgium

Nether-lands

Germany

T i p s & T r i c k s f r o m p r a c T i c a l a p p l i c aT i o n s

articulated limiting plates for the auger Tunnel for a perfect Head of mix in front of screed

andré felchner, Head of applications Technology at VÖGElE, Germany, provides “Tips & Tricks from practical

applications”. He is an expert in both practical applications and paver technology and conveys his knowledge

also in VÖGElE training courses and workshops to paving teams from all over the world.

17

A uniform head of mix in front of the screed is crucial to achieving premium paving quality. Articulated limiting plates for the auger tunnel offered by VÖGELE are a handy option here. Even when working in varying pave widths, they constantly ensure an optimum head of mix in front of the screed – no conversion required!

roadnews 23

Varying pave widths are easily

tackled with extending screeds.

in order to ensure a flow of

mix towards the screed which

is both variable and accurate,

articulated limiting plates are

recommended for the auger

tunnel. They help ensure

a continuous flow of mix.

“Articulated limiting plates for the auger tunnel”

offered as a VÖGELE option.


17roadnews 23

potential problems when paving without limiting plates for the auger Tunnel

7 conveyors and augers are perfectly matched and transport the mix in front of the screed. Despite this,

however, the mix may not be delivered correctly when working in varying pave widths. as illustrated

here, undesired accumulations of mix may build up in front of the screed.

3 articulated limiting plates for the auger tunnel guide the mix.

3 They prevent the mix from segregating.

3 They avoid premature cooling of the mix.

3 They adjust automatically in line with the pave width.

3 There is no need for conversion.

solution: The right Head of mix in front of the screed at all Times


17roadnews 23

How does it work?

uEven at very small pave widths, the mix

is optimally guided.

When the pave width of the extending screed is

increased, the articulated limiting plate moves

forwards under the pressure of the mix.

When the pave width of the extending screed is

reduced during the paving process, the side plate

pushes the articulated limiting plate for the auger

tunnel inwards.

uEven at larger pave widths, the mix

is optimally guided.


17roadnews 23

uThe kits for SUPER 1900-2,

SUPER 2100-2 and

SUPER 3000-2 have red marks.

articulated limiting plates for the auger tunnel are available as standard for the small sUpEr 700

and sUpEr 800 pavers, as well as for the compact sUpEr 1100-2, sUpEr 1103-2, sUpEr 1300-2 and

sUpEr 1303-2 pavers. needless to say, every other VÖGElE paver can easily be equipped with these

plates, too. make sure, however, that the correct kit is used.

uA specially developed kit is also

available for SUPER 1600-2,

SUPER 1603-2, SUPER 1800-2

and SUPER 1803-2.

result: a perfect pavement at all times

The right articulated limiting plate for Each paver’s auger Tunnel

no matter whether the pave width increases or

decreases, the articulated limiting plates for the

auger tunnel always provide for perfect paving.

25

04 //

01 //

02 //

03 //

Harald Ott, Head of Paving Team

Gröschler GmbH


01 // The SUPER 1603-2’s small turning radius of just 6.5m (outside) results in excellent manoeuvrability on confined job sites.

02 // The wheeled paver provided for a perfect curvature of the roundabout.

03 // For grade and slope control on the roundabout, the kerb served as a reference for a multi-cell sonic sensor.

04 // The SUPER 1300-2 surfaced the cycle path with high precision.

“Changing over to VÖGELE technology was child's play.”

26

The compact tracked SUPER 1300-2 also worked with absolute

precision, surfacing the cycle path with an AB 340 Extending

Screed in TV version in widths of 2 to 3m. Both pavers were

fitted with multi-cell sonic sensors for grade and slope control.

The requirements in terms of surface accuracy were strict, but

the results left nothing to be desired: a deviation of no more

than 4mm was permitted in both longitudinal and transverse

directions over a distance of 4m – a demand which was easily

met by both pavers.

Training in the “CTT” made the change easier

For Gröschler’s paving teams, the first days of working with

the new machines were pretty exciting. But their nervousness

was unfounded, for they had received two days of theoretical

and practical training on operation of the new pavers in

the “Centre for Training and Technology” (CTT) at the

VÖGELE headquarters. The fact that all pavers of the “dash 2”

generation are equipped with ErgoPlus®, the intuitive system

for paver operation, once again proved to be a major advantage.

Anyone who has learned to use the system once can easily work

with any machine of this generation. “Paving, driving and

operation are all much easier with VÖGELE machines than

with any other make,” says screed operator Udo Tegenkamp.

All Gröschler’s paving teams got to grips with their new pavers during a two-day training held at the “Centre for Training

and Technology” (CTT) on the VÖGELE premises.

And even after the machines had been delivered, a VÖGELE

service technician remained on hand to advise and assist the

teams. This not only included instruction on the Gröschler

premises in Gütersloh, but also close supervision during the

first jobs on site. The team was able to concentrate entirely on

the paving job. “We have now been working with the machines

for three weeks,” said Harald Ott in Versmold, “and we are

getting on wonderfully well with ErgoPlus®.”

Intensive talks carry the day

Gröschler’s management had conducted intensive talks with

VÖGELE for several months before deciding to make the change.

The great trust and confidence established during many years

of reliable support by Regional Sales Manager Rolf Limberg

of WIRTGEN Windhagen provided a sound basis. During the

negotiations, not only did VÖGELE’s products find favour,

but also the services they provide (refer to the article on the right).

Markus Dorgerloh, Managing Director of Gröschler GmbH,

explained why opting for VÖGELE was an easy decision for the

management: “VÖGELE satisfy customers in terms of technical

performance while responding flexibly to their needs as well.

This gives you the feeling that you’re in good hands.”

Site Report

27

„This overall package convinced us that VÖGELE are the right partner for us.“

Markus Dorgerloh, Managing Director

Gröschler GmbH

Whenever a new paver leaves the VÖGELE factory, it is not

just packed with outstanding technology. Along with the

machine, VÖGELE also supply a comprehensive services

package to guarantee top performance throughout the

machine’s service life.

For VÖGELE, quality means more than just building excellent

machines. In the “World of Quality”, every effort is also made

to ensure that contractors can make optimum use of their

pavers, screeds and feeders at all times.

Even experienced professionals sometimes need support

during their daily work. VÖGELE’s customers can rest assured

that they will not be deserted in their hour of need, when

faced with special tasks. This support begins at the preparatory

stage, when the paving team arrives at the “Centre for Training

and Technology” on the VÖGELE premises. If required,

VÖGELE experts are also available on the job site to provide

help and advice when customers operate their new machines

for the first time. And it’s not just people who are sent to the

aid of VÖGELE’s customers: first-class components and parts

are supplied via “Parts and More”, the WIRTGEN Group’s

useful tool.

This service is based on a worldwide network of sales and

service companies, as well as dealers. It ensures that VÖGELE

can meet all their customers’ wishes quickly and reliably,

anywhere in the world. In this way, VÖGELE combine the

strength of a global player with the customer proximity of

a family-run company.

A service range that speaks for itself. “This overall package

convinced us that VÖGELE is the right partner for us,” said

Markus Dorgerloh, Managing Director of Gröschler GmbH,

when the six new VÖGELE pavers were handed over to his

company.

Excellent All-Round Support with Technology and Service by VÖGELE

“World of Quality” makes VÖGELE a strong partner for road construction contractors.


28

Photo Report

A new binder course and surface course

of stone mastic asphalt (SMA) were paved

on an 11km stretch of the motorway.

Data were transmitted

to NIVELTRONIC Plus®,

the System for Automated Grade

and Slope Control, by a variable

mechanical grade sensor.

Overnight Paving Job on the BosporusRight in the heart of Istanbul, between the Mahmutbey customs point and

the “Avcılar” bridge, two SUPER 1900-2 pavers rehabilitated a section of the “TEM”,

the Trans-European Motorway.

29

Job Site DetailsRehabilitation of the “TEM”

(Trans-European Motorway)

in Istanbul, Turkey

Length of section: 11km

Paving Details

Layer thickness:

Binder course 4cm

Surface course 4cm

Material

Wearing course:

Stone mastic asphalt (SMA)

Equipment

2 SUPER 1900-2

SUPER 1900-2 in Istanbul

Roadworks were only possible

between 10.30 in the evening

and 6 in the morning.

All in all, some 67,000 tonnes

of mix were paved.

Technology

Prime Pavement Quality and Low Consumption

Efficient paving of surface course with the spray paver from VÖGELE.

SprayJet technology from VÖGELE allows economical paving of high-quality surfacings – in the form of thin asphalt overlays making economical use of resources. When spraying bitumen emulsion, too, only the quantity actually required is applied, no more and no less.

[ 1 ]

[ 2 ] [ 3 ]

[ 4 ] [ 5 ]

[ 6 ]

SPRAYJET

TECHNOLOGY

30

The AB 500-2 and AB 600-2

Extending Screeds handle

maximum pave widths of 6m.

They come in the versions

TV (with tamper and vibrators)

or TP1 (with tamper and

1 pressure bar) for compaction.

[ 1 ] Extending Screeds

The frequency of the spray pulses

is adjusted automatically

as a function of the selected rate

of spread, pave speed and pave

width. This achieves a uniform

film of emulsion.

The sophisticated spray technology

of the SprayJet Module allows

the emulsion to be applied evenly

and to achieve full coverage of

the existing surface. The rate of

spread can be selected accurately

between 0.2 and 1.6kg/m2.

Due to the low spray pressure of

3 bar (maximum) for the emulsion,

the formation of spray mist

is avoided.

Spray Technology[ 2 ] Spray Nozzles[ 3 ]

SUPER 1800-2 with SprayJet Module

The standard emulsion tank,

insulated against loss of heat,

holds 2,000 litres. In order

to reliably keep the bitumen

emulsion at the ideal temperature

for spraying, a heating unit

(2 x 7kW) is installed. At a low

emulsion level, the heating unit

is switched off automatically

to avoid burning.

The SprayJet module stands out

through easy control and uses

self-explanatory symbols.

The useful, automatic

“Start of Job” and “End of Job”

functions activate and deactivate

the spray bars at precisely

the specified points.

250 mm

120° 120°

Standard Emulsion Tank[ 4 ] ErgoPlus®[ 5 ]

For contracts requiring very large

rates of spread, an extra emulsion

tank is available holding

5,000 litres. With this extra tank,

a total of 7,000 litres of bitumen

emulsion can be carried on board

the paver.

Extra Emulsion Tank[ 6 ]

31

Economical, Eco-friendly, Noise-reducing: Paving Thin Overlay is a Convincing Option

Perfected spray paver design gains ground

Expert Interview

32

SPRAYJET

TECHNOLOGY

Rehabilitating road pavements by paving thin asphalt

overlays “hot on hot” on spray seal (DSH-V) is becoming

increasingly widespread. A powerful spray paver is needed

for these jobs, such as the SUPER 1800-2 with SprayJet

Module from VÖGELE. Dipl.-Ing. Volker Schäfer explains

how the DSH-V method works and which points must be

noted when using a spray paver.

RoadNews: Mr Schäfer, how important is this method for

“pavement preservation” today and how is this likely to

develop in future?

Volker Schäfer: The method’s growth potential is a long

way from being exhausted – quite the contrary, in fact.

Its significance for additionally reducing noise in particular is

not being given nearly enough emphasis. Another advantage

of this method is that it is a technically mature means of

controlling noise which has now also been firmly anchored

in our technical guidelines. With the exception of paving

porous asphalt (OPA), other noise abatement methods are still

in their infancy: we do not know just how long the life span

of the respective pavements actually is. In the case of DSH-V,

however, we have been observing all of its properties over the

last 20 years and we can, therefore, reliably plan the application

of this type of surfacing. Since this is important to the client,

the importance of this method will continue to increase.

RoadNews: Which points must be observed if a thin asphalt

overlay is to be successfully paved “hot on hot” on spray seal?

Which skills are needed and what must the machine be

capable of?

Volker Schäfer: The team must have received special training

to work with the spray paver. After all, they are not just paving

asphalt, but are also applying a spray seal of bitumen emulsion

at the same time. Some additional technical know-how is

needed in order to handle the emulsion correctly. The logistics

of a spray paving job are naturally also a little different, as the

work proceeds at 3 to 5 times the pave speed of conventional

asphalt paving. The spray paver’s operating concept should

be easy to learn and easy to understand. Because everything

happens fairly fast, the machine must also respond quickly.

That is basically all that is needed.

RoadNews: What are the advantages of the DSH-V method?

Volker Schäfer: Due to the composition of the asphalt

mix, the texture is finer and more open-graded than that of

conventional asphalt pavements. This enhances the road’s

non-skid and noise abatement properties. Although noise is


33

What is DSH-V?

DSH-V is a method for paving thin asphalt overlay

“hot on hot” on spray seal. It is a quick, clean and

economical paving method for rehabilitating asphalt

pavements and for restoring a road's non-skid properties.

At the same time, it improves the surface quality of the

road, for instance by reducing the level of noise.

The method has been successfully used and further

developed in Germany since 1991.

Thin asphalt overlays paved “hot on hot” on spray seal

comprise a binder course to seal the base and an asphalt

surface course which is paved in the same pass. For the

binder course, a polymer modified emulsion of the type

C67BP5-DSH-V is normally used, containing 67% of

bitumen. The bitumen emulsion is applied by a paver with

integrated spray assembly and heated emulsion tank.

The method has both economic and ecological advantages:

paving thin overlays reduces the amount of costly surface

course mix needed for the job. That not only saves money,

but also resources. As spraying bitumen emulsion and

paving asphalt take place in a single pass, the roadworks

are quickly completed, thus also cutting costs and reducing

the duration of road closures. Finally, the high-precision

VÖGELE SprayJet Technology minimizes the formation of

spray mist and applies exactly the specified quantity of

bitumen emulsion, no more and no less.

Source: Gütegemeinschaft für Dünne Schichten im Heißeinbau auf Versiegelung e.V. // www.dsh-v.de

this method so good! With a spray paver, you can work on an

inner-city road one day and on a heavily frequented motorway

the next, all with the same machine. The Southern Bavarian

Motorway Authorities in Germany are already applying the

DSH-V method instead of conventional asphalt paving, not

only for pavement rehabilitation jobs but for reconstruction,

too. And they are using it at all locations where local residents

are clamouring for noise reduction measures, but where a

porous asphalt surfacing is not yet called for.

RoadNews: What can you tell us about the C67BP5-DSH-V

bitumen emulsion?

Volker Schäfer: The bitumen emulsion C67BP5-DSH-V

contains 67% of bitumen and 33% of water. Its viscosity is,

therefore, very good in comparison to more highly concentrated

bitumen emulsions with a 70% bitumen content or more. The

emulsion is much more fluid, easier to handle and to spray, but

is not so thin and therefore more “stable” than a 60% bitumen

emulsion. Even though we're only talking about a few percent

here, this makes a world of difference. The bitumen emulsion

contains polymer modified bitumen as binder to improve the

elasticity and ensure a strong bond.

RoadNews: The bitumen emulsion has to “break” in order

to produce the desired adhesion. What does that mean?

Volker Schäfer: To produce a bitumen emulsion, the bitumen is

finely shredded and mixed with water. Seen under a microscope,

bitumen emulsion is hence made up of small, medium-sized

and larger globules of bitumen which are suspended in water,

so to speak. The water contains an emulsifying agent which

encloses the bitumen globules like a film so that they repell one

another instead of bonding. In this state, the bitumen emulsion

can be stored stably and can hence be transported to its place

of use at room temperature. Normally, the breaking process

only begins when the bitumen emulsion comes into contact

with raw rock, as occurs, for instance, during surface treatment.

The bitumen and the water separate again, the globules bond

together and the adhesive effect is obtained. But breaking can

also be triggered by incorrect handling.

RoadNews: Some people wonder what actually happens

during spray paving. First the bitumen emulsion is sprayed

on the surface, to be followed immediately by the hot asphalt.

Where and when can water escape from the bitumen emulsion?

Does it escape during this short time after spraying or only

once the asphalt overlay has been paved and the water evaporates

through the porous composition of the asphalt?

Expert Interview

34

Volker Schäfer is a recognized expert in the field of asphalt

road construction and a specialist on the topics of structural

preservation and noise-reducing asphalts as well as asphalt

pavements for very high loads. He works as a consultant on all

matters related to asphalt and sett paving methods and their

implementation in accordance with construction contracts.

He has been a publicly appointed and sworn expert on asphalt

paving in road construction since 2003. Since it was first

founded in 2005, Volker Schäfer has been a lecturer for the

further education programme entitled “Asphalt Technology

for the Specialist Fields of Asphalt Preparation and Asphalt

Paving as well as Practical Implementation in Accordance with

Construction Contracts”. He is also very active in the “Asphalt

Paving Methods” work group of the German Association

for Road and Transportation Research (FGSV). In 1991,

Volker Schäfer was one of the founding members of the

technical committee dealing with “Maintenance Technology”,

which he has headed for the past three years.

Personal Details // Volker Schäfer

not reduced to quite the same extent as with porous asphalt,

the reduction is still significantly greater than with classical

dense asphalt surfacings. Initially, the focus was on optimizing

the durability of the road and improving its non-skid

properties. Noise abatement was more or less a secondary

aspect of the development, though it has now become one of

its principle uses.

RoadNews: In your opinion, will the DSH-V method

essentially be used in municipal areas or is it equally suitable

for use on motorways and national roads?

Volker Schäfer: Noise is produced wherever there is a lot of

traffic and/or vehicles travelling at high speeds. Not all job

sites meet the basic prerequisites for paving porous asphalt as

a noise reduction measure. But the DSH-V method can be used

to durably reduce noise levels very quickly on existing roads

without requiring major structural changes. That is the great

advantage of this method. That is also why it can be used not

only on inner-city roads with heavy traffic, but also in residential

areas, on national roads and even on motorways. A little more

care is needed when working on inner-city roads with their

kerbstones, but that is no problem. And that is what makes

Volker Schäfer: The classical dogma is that bitumen

emulsion must be sprayed, have broken and the water have

evaporated before being overlaid with asphalt. But everything

is very different with the DSH-V method. Initially, a large

amount of bitumen emulsion is sprayed, about three times as

much as is normally used to build a pavement in layers. This

means that 2½ times the amount of water must evaporate.

Breaking effectively does not take place between spraying the

emulsion and paving the asphalt, the time frame is simply

too short. Instead, the hot asphalt is laid immediately. In

combination with the porous composition, the energy emitted

by the hot asphalt causes most of the water to evaporate

upwards immediately. A small amount of the moisture can

also escape into the voids of the asphalt layers below.

RoadNews: Can you describe the special mix used for this

method?

Volker Schäfer: The mix used in 90% of all cases is a DSH-V 5

asphalt because it can be used everywhere, from motorways

to roads in residential areas. However, DSH-V 8 mix can also


be used. DSH-V 5 is an asphalt with an aggregate grading curve

somewhere between stone mastic asphalt (SMA) and asphaltic

concrete. It has a higher voids content than conventional

asphalt, since the sprayed bitumen emulsion seals the pavement

from below. In other words, binder is artificially accumulated

at the bottom during the paving process. The asphalt mix itself

only contains the quantity of binder required to ensure that

there is no need to spread chippings over the surface of

the DSH-V overlay, as would be the case with any other

roller-compacted asphalt. The non-skid property is obtained

from the outset.

RoadNews: How important do you consider the use of a

feeder to be in this process? What effect does it have on the

process?

Volker Schäfer: Three factors in particular support the use

of a feeder when paving thin asphalt overlay “hot on hot” on

spray seal. Firstly, as already mentioned, the pave speed

is very high when working with this method. At such

speeds, the mobile feeder can greatly simplify the fairly

35

Expert Interview

36

Volker Schäfer: It could, but speed must not be obtained at

the expense of quality. The important point is that the basic

conditions for paving are met. And this also applies to such

methods as DSH-V. The great virtue of DSH-V is that the

finished overlay does not require a long cooling time and can

hence be driven over shortly after paving. Planning must focus

on quality as early as during the construction of the road, and

not just when it needs rehabilitating. In my view, compact

asphalt pavements with a 2cm surface course should have a

service life of 20 years – and even more for the compact, thick

asphalt binder courses with very low voids content. All we

then have to do after 20 years is mill off the remaining thin

surface course and overlay it with a thin asphalt surfacing

paved “hot on hot” on a spray seal. In the end you have a

low-maintenance road that lasts for at least 30 years.

Roland Schug, Marketing Director at VÖGELE,

welcomed Volker Schäfer (right) to the VÖGELE factory

in Ludwigshafen, Germany.

complex site logistics. It is no longer possible for the feed

lorry to bump the paver. This prevents any unevenness in the

asphalt surfacing. Secondly, the mobile feeder guarantees an

uninterrupted supply of mix to the paver. This vastly improves

the quality of the pavement. And thirdly: if a mobile feeder is

used, an extra emulsion tank can be installed on the VÖGELE

spray paver, with the result that bitumen emulsion is replenished

less often. This also speeds up the paving process.

RoadNews: Long job sites and the associated traffic tailbacks

are a recurrent topic in Germany. With the DSH-V method,

pavement rehabilitation projects can be undertaken quickly

and in high quality, with shorter construction times. Could

this become a decisive factor for customers?

What happens when bitumen emulsion breaks?

[ 1 ] [ 2 ] [ 3 ]

[ 4 ]


37

Prepared base: milled surface or freshly laid binder

course.

Hot bitumen emulsion at a temperature between

70 and 80 °C is applied by the spray paver.

Paving a thin asphalt overlay according to the DSH-V

method. The bitumen emulsion “breaks” immediately

as the hot asphalt causes the water to evaporate,

leaving a firmly adhering film of bitumen.

Any water still remaining in the emulsion evaporates

through the “open pores” of the asphalt overlay.

[ 1 ]

[ 2 ]

[ 3 ]

[ 4 ]

38

[ 1 ]

[ 2 ]

[ 3 ]

[ 4 ]

SPRAYJET

TECHNOLOGY

Technology

Step by Step Guide to Perfect Spraying

Calibration made easy.

To ensure that the SUPER 1800-2 with SprayJet Module produces a perfect pavement, the nozzles of the spray module must be precisely calibrated before work starts. RoadNews explains how:

Step 1 // Preparations Time required for the preparations: approx. 25 minutes.

Set the pump speed to approx.

250 litres/min. via the buttons

on the spray module. Let the

emulsion circulate for about

20 – 25 minutes.

Set the selection switch on

the spray module to position 3

“Circulation”.

Select “Ignition On” on

the VÖGELE paver operator’s

console. Switch on the spray

module (green button).

Start engine when the

operator’s console and spray

module are ready.

Open the red rotary valve in

front of the pressure gauge and

the three ball valves of the

respective spray bar. Open the

return line, then the bypass.

Set the grey ball valves next to

the emulsion pump to “Spray”.

The emulsion must be at the

correct temperature!

The spray ramps must feel hot

before calibration can continue!

Total time required: 35 minutes.

Caution! Caution!

[ 2 ]

[ 1 ]

39

[ 7 ]

[ 8 ]

[ 6 ]

[ 3 ]

[ 4 ]

[ 5 ]

Place the container under

spray nozzle 1 (outermost

nozzle on the left-hand

spray bar).

Weigh a suitable container

and zero the scales.


Step 2 // Calibration Time required for calibration: 5 – 10 minutes.

Weigh the amount of sprayed

emulsion and multiply by 3

to calculate the weight per

minute. Example:

0.9kg/20 sec. x 3 = 2.7kg/min.

Enter the calculated value,

e.g. 2.7kg/min., under “Quantity

sprayed by one nozzle” in the

“Parameters” menu of the spray

module.

Activate “Calibrate nozzles”

on the touch screen.

The emulsion pump starts up.

Set the selector switch in the

“Service” menu to position “6”.

On the touch screen of the

spray module, press the

“open-end wrench” button

(bottom right). The service

menu for the spray module

is now displayed.

First press the “Key” button

at the bottom left.

Select “Calibrate nozzles”.

The system reaches the set

nominal pressure (e.g. 3 bar)

after about 20 seconds.

Nozzle 1 opens and sprays

emulsion into the container

for exactly 20 seconds.

Calibration is now complete!

Caution!

40

VÖGELE Paver Enlarges Container Terminal in Manila, Philippines

Strong basis for further growth.

Shipping traffic has already reached a high level on the world’s oceans and it will continue to grow. As globalization of the world economy increases, more and more goods are transported around the world – predominantly in container ships. To cope with this boom, port operators throughout the world are investing in new infrastructure. This was also the case at the largest container terminal in Manila. The company awarded the contract for the “MICT Berth 6” project was much impressed with the high laydown rate and high precompaction achieved by the SUPER 1600-2.

Site Report

41

The Philippine capital Manila is home to over a million people

and an international logistics centre for goods of every kind.

According to the operator of the “Manila International Container

Terminal” or MICT for short, the largest and most modern

in the city, 1.5 million 20-foot containers are handled here

every year. Storage space was now running out. International

Container Terminal Services, Inc. (ICTSI) which operates the terminal

therefore decided to enlarge the 152,000m² landing area

known as “Berth 6” by around 30,000m². The requirements

to be met by this new area were high: after completion, it had

to withstand weights of up to 6 tonnes per square metre. A very

strong base was needed to shoulder such loads.

Two layers create a strong base

This is where the VÖGELE paver came into play: contractor

EEI Corporation opted for a SUPER 1600-2 with AB 500-2 TV

Extending Screed to do the job. EEI had already been impressed

with VÖGELE pavers during an airport project and were

convinced these machines could achieve a perfect and durable

paving result here, too. In order to build a solid foundation

for the new terminal, a particularly thick base was planned

and placed in two layers. For the first layer, 87,400 tonnes of

water-bound base course mix were laid by the SUPER 1600-2

in widths from 4.5 to 5m. The paver managed to handle the

specified layer thickness of 30cm with effortless ease – another

reason why EEI had taken their decision in favour of VÖGELE

technology: “Compared with other brands, the VÖGELE

pavers easily make 10cm more in terms of layer thickness,”

said Senior Site Supervisor Jerry O. Agtoto. For the second

layer, 28cm thick and only slightly thinner than the first one,

some 34,900 tonnes of water-bound base course material were

placed. Two mobile mixing plants on the job site provided for

an uninterrupted supply of mix to the paver.

Placing Water-Bound Base with SUPER 1600-2

Job Site DetailsEnlargement of container terminal “MICT Berth 6”

in Manila, Philippines

Job site area: some 30,000m2

Paving Details

Pave width: 4.5 – 5m

Layer thickness: 1st layer 30cm

2nd layer 28cm

Material

Water-bound base course mix

Equipment

SUPER 1600-2 with AB 500-2 TV Extending Screed

HAMM HD 110 Tandem Roller

ManilaLaos

Philippines

Malaysia

Indian OceanVietnam

Philippines

The SUPER 1600-2 once again demonstrated its abilities.

30 cm

01 //

42

02 //

01 // The base course was paved in two layers,

each almost 30cm thick. All in all, the SUPER 1600-2

laid 167,800 tonnes of water-bound base course mix

in Manila.

02 // Instead of paving an asphalt surfacing, contractor EEI laid paving setts, an alternative allowing low-cost replacement in case of need.

03 // The ErgoPlus® operating system made operation

of the SUPER 1600-2 with NIVELTRONIC Plus®

very easy.

Site Report

SUPER 1600-2 ideal for medium and large paving projects

EEI made their decision in favour of the SUPER 1600-2 for

good reason. On this contract, the paver once again furnished

proof of being a perfect performer on medium to large

construction projects, such as that in Manila. Its travel speed

of up to 4.5km/h allows the paver to move easily and quickly

from one project to another – also an important criterion for

EEI when selecting the paver. Maximum precision and accurate

paving true to line and level were achieved by two variable

mechanical grade sensors, each of them fitted with a 2m ski.

In combination with VÖGELE NIVELTRONIC Plus®, the

System for Automated Grade and Slope Control integrated into

the ErgoPlus® operating system, a perfect pavement of high

evenness was guaranteed.

Strong basis for extra storage space

This way, the paving team had created a sound, strong base for

the project’s next stages. On the water-bound base, the men

placed some 70,000 tonnes of lean-mixed concrete, 20cm

thick. This was followed by a 2cm bed of sand in which they

laid paving setts. All in all, an 80cm package of paved material

now supports the heavy containers and the terminal operators

ICTSI are optimally prepared for the boom times ahead.

For EEI, too, the project was more than satisfactory. In addition

to the absolutely reliable machine technology, the team

also praised the support provided by the WIRTGEN Group’s

Philippine branch and the VÖGELE team. “The service provided

for road construction machines is the best in the country.”

03 //

43

Placing Water-Bound Base with SUPER 1600-2

“Compared with other brands, VÖGELE pavers easily make 10cm more in terms of layer thickness.”

Left: Luisito Manago, General Manager

(WIRTGEN Philippines)

Middle: Jerry O. Agtoto, Senior Site

Supervisor (EEI)

Right: Harald Reufels, Sales Manager

Asia and Pacific (VÖGELE)

Senior Site Supervisor Jerry O. Agtoto

(EEI, middle) was highly satisfied:

44

Perfect Evenness and Maximum Compaction

VÖGELE paver rehabilitates “Vehicle Dynamic Assessment Pad” of Continental Tire the Americas, LLC. in the USA.

Site Report

A video on this construction project

can be found on the Web at:

www.voegele.info

> News & Media > Mediathek

45

01 //

03 //

02 //

Vehicle Dynamic Assessment Pad

Pavement Rehabilitation with SUPER 2100-2

01 // The SUPER 2100-2 took over pavement rehabilitation of the square “Vehicle Dynamic Assessment Pad”.

02 // Chris Cornell (right), Business Development Officer

at Reece Albert, Inc., with VÖGELE's Marketing Director

Roland Schug.

03 // Conti tyres demonstrate their road grip on artificially flooded roads: this course’s pavement was also rehabilitated by Reece Albert Inc. with the help of VÖGELE technology.

46

A SUPER 2100-2 replaced the asphalt pavement of the

“Vehicle Dynamic Assessment Pad” (VDA Pad) at the Conti

Proving Grounds in Uvalde, Texas (USA). To ensure totally

reliable results in tyre tests, the evenness of the pavement

had to meet extremely exacting standards. Selecting a high

compaction screed for the paving work helped produce

a top-quality pavement.

Selected drivers can really put their foot down in Uvalde,

Texas. A little over 110km from the Mexican border, this is

the home of the Uvalde Proving Grounds of tyre manufacturer

Continental Tire the Americas, LLC. Conti’s 2,023 hectare site

includes 11 different courses for testing its tyres in the toughest

conditions: a high-speed oval, various asphalt, cement, gravel

and mud courses, rocky terrain and numerous special test

courses. The climate is ideal for testing purposes, with mild to

warm temperatures prevailing year-round in the region.

Conti prefers to produce its own bad weather – to be precise,

the tyre manufacturer uses, among other things, its “Vehicle

Dynamic Assessment Pad” measuring 60.000m² whose asphalt

pavement has now been rehabilitated by a SUPER 2100-2.

The pad has a 1% slope and can be flooded with water to

a depth between 1.3 and 2.8mm. To yield useful findings on

tyre behaviour in wet weather, however, the surface must be

absolutely flawless and meet the highest standards as regards

evenness and resistance to deformation, for the film of water

must have a uniform depth over the entire area with no

breaks. Quite a challenge for contractor Reece Albert, Inc., but

one which they mastered effortlessly with technology from

VÖGELE. After all, the company had already worked on the

Conti Proving Grounds with its SUPER 2100-2 several times

in the past.

Maximum precompaction by the paver

The existing pavement was first of all removed to a depth

of about 12.5cm. Once a spray seal had been applied, the

Job Site Details

Rehabilitation of the “Vehicle Dynamic Assessment Pad”

at the Uvalde Proving Grounds, USA

Length of section: 244m

Width of section: 244m

Paving Details

Pave width: 4.5m

Layer thickness: binder course 4.5cm

wearing course 2.5cm

Material

Special mix in accordance

with the client's specifications

Equipment

SUPER 2100-2

with AB 600-2 Extending Screed in TP2 Version

HAMM Tandem Roller HD+ 120

Site Report

USA

Uvalde

New York

Canada

USA

Mexico

Atlantic OceanPacific Ocean

47

The paver was fitted with a Big MultiPlex Ski

for grade and slope control.

SUPER 2100-2 with an AB 600-2 Extending Screed laid 4.5cm

binder course over a pave width of 4.5m, followed by a wearing

course, 2.5cm thick, over the same width. To ensure that the mix

could be compacted to the particularly high degree of 92 – 97%

demanded by Conti, the AB 600-2 came in the TP2 version

with tamper and two pressure bars. Using high compaction

technology with pressure bars driven by pulsed-flow hydraulics,

the VÖGELE screed yields the highest degree of precompaction

achievable by a paver. This, in turn, lays the basis for durable

asphalt pavements resistant to deformation. In Uvalde, the

pavement density was tested whenever 500 tonnes of asphalt

had been compacted – and met all the specified requirements.

Maximum evenness required

For this job, evenness was another prime concern for Conti:

a deviation of no more than 3mm was permitted over a

distance of 3m, in both longitudinal and transverse directions.

To meet with such stringent requirements, other factors, such

as air temperature and the temperature of the mix, too, had to

be taken into account. As to machine technology, contractor

Reece Albert, Inc. also opted for highest precision, selecting

NIVELTRONIC Plus®, the VÖGELE System for Automated

Grade and Slope Control. In order to monitor the paving

process and ensure a perfect result, the paver was fitted with

a Big MultiPlex Ski on the right-hand side to scan the base

onto which to lay the asphalt. On the left-hand side, an US ski

scanned the already paved strip. In this way, the paving crew

was able to ensure that even the slightest deviation from the

exacting requirements was instantly detected and corrected.

German technology makes the grade

The result was a tour de force in all respects. Chris Cornell,

Business Development Officer at Reece Albert, Inc., was

delighted with the German equipment: “The evenness we

achieved with VÖGELE High Compaction Technology, in

particular, was beyond anything we’ve achieved in the past.”

Thanks to this precision, Conti can once again count on highly

accurate test results.

Pavement Rehabilitation with SUPER 2100-2

EN 2

2142

69

Motorway, Taiwan.

RoadNews on the Web

Your feedback on RoadNews would be much appreciated. Suggestions are welcome. Please write to us at [email protected]

All RoadNews editions as well as latest information about VÖGELE products and technologies are available

on the Web. Visit us at: www.voegele.info

road news 23

Documents