Pioneering. The VISION i wheeled paver earns praise in Fort Myers, Florida. The VÖGELE Magazine on Paving Applications Issue 08

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1 Hot-on-hot and hot-to-hot // Two InLine Pave trains rehabilitate runways in record time The best of both worlds // SUPER is ideal for projects big and small Taking off // SUPER displays top performance in new airport construction The VÖGELE Magazine on Paving Applications Issue 08 The VISION i wheeled paver earns praise in Fort Myers, Florida Pioneering

2 2 // Contents RoadNews 08 4 Complete program for America The global leader in road pavers has the perfect machines for all paving applications 28 Parking lot repaved in Mississauga The SUPER unites the power of a large machine with the maneuverability of a compact paver 8 Approach road rehabilitation in Fort Myers The VISION i paver sets new standards 34 Runways resurfaced in record time Hot-on-hot paving with two InLine Pave trains 18 Expansion of Fort Lauderdale-Hollywood International Airport The future of grade and slope control is digital! The Navitronic Plus non-contacting 3D control system saves time and money Center Pages: Tips & Tricks from Practical Applications Proper use of VÖGELE pavers on all mix designs

3 Editorial // 3 The perfect paver for every paving situation There is plenty to do the USA has the largest network of roadways in the world, 4,038,913 miles in total. Add to that all the airports, parking lots, race tracks, walkways, cycling paths, farm tracks and more. New roads constantly are being built and existing ones rehabilitated. Smoothness and rideability no longer are the only goals in this context. The contracting authorities are demanding shorter construction times on the one hand, and more durable roads on the other. Therefore, for road construction professionals, the focus increasingly is on the cost-efficiency of projects. And this is precisely where VÖGELE enters the picture. We not only have the broadest range of products on the market, VÖGELE pavers, screeds and material feeders are also all designed for versatility. The individual models can be used for a wide range of different applications. VÖGELE material feeders, for instance, have a conveyor concept that transports coarse material just as easily as asphalt. VÖGELE pavers and screeds are highly flexible: One and the same machine can be used for different layers, paving widths and layer thicknesses. VÖGELE grade and slope control technology also adheres to the principle of versatility: The Navitronic Plus 3D control system has an open port to which common 3D positioning systems from other manufacturers can be connected. With versatile products like these, VÖGELE provides the basis for greater cost-efficiency in road construction. Be inspired and enjoy reading this issue! Brodie Hutchins Roland Schug Vice President, Vice President, Dealer Development Marketing WIRTGEN America Inc., USA VÖGELE AG, Germany Imprint RoadNews for new roads the VÖGELE Magazine on Paving Applications Editorial Address: Joseph-Vögele-Str. 1, Ludwigshafen, Germany, Telephone +49 (0) , Fax +49 (0) , roadnews@voegele.info, Website Editors: Roland Schug, Anja Sehr, Martin Hilken Technical support: Jan Hakenes, Cees Haasnoot, Laikram Nars Narsingh 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 4 // main topic Complete Program for Road Construction World market leader VÖGELE offers the widest range of products. PRACTICAL APPLICATION 1 Fort Myers, Florida

5 the perfect Machine for every paving requirement // 5 Professionals PRACTICAL APPLICATION 2 Fort Lauderdale, Florida PRACTICAL APPLICATION 3 Mississauga, Canada

6 6 // main topic The SUPER gives you the stability of a large machine, and the maneuverability of a small paver at the same time. David Tittley, Quality Paving Ltd. Multi-lane highways, airports, municipal roads, winding roads and parking lots, new construction or ultra-durable resurfacing jobs: VÖGELE has the right machine and the right screed in its range for every paving job from ultra-compact small pavers to large pavers and material feeders, from paving widths of 1 ft. 8 in. to 52 ft. 6 in. This versatility has a purpose, because the daily challenges facing professionals in road construction are highly diverse. No two projects are alike. That calls for both knowledge and experience. Since 1929, we at VÖGELE have been concentrating on the development, engineering, production and servicing of road pavers, screeds and material feeders. And that calls for flexibility, too. We adapt 100% to the demands and common practices of our different markets. And everyone benefits: Construction companies, paver and screed operators, and material feeder drivers around the world. At VÖGELE, we focus on people VÖGELE road pavers set standards in many areas: Technology, but also cost-efficiency, eco-friendliness, operating friendliness and occupational safety. VÖGELE has developed a globally unique operating concept to ensure that paver and screed operators can use its highly complex technology simply, competently and safely. Once a person has mastered the ErgoPlus operating concept, he can operate any VÖGELE paver equipped with it. Drivers and screed operators have their pavers effortlessly under control at all times. Man and machine form a team. No matter what the project: A VÖGELE can handle it. On the following pages, you can read up on different construction projects involving a variety of requirements and find out just how these requirements were met using different solutions from VÖGELE.

7 the perfect Machine for every paving requirement // 7 This machine was developed and designed by people like me. John Foreman, APAC-Southeast, Inc. The stringless steering was one of the main selling points over the competition. Justin D. Cooper, Archer Western

8 8 // Site Report // Highway Class This ma and designe

9 Residential access road rehabilitated with the VISION i // 9 chine was developed d by people like me. Screed operator John Foreman, talking about the VISION i, which excelled in Fort Myers, Florida. PRACTICAL APPLICATION 1 Fort Myers, Florida

10 10 // site Report // Highway Class One team, one opinion: The VÖGELE VISION i is one of the most versatile 10-ft. pavers on the market. USA // Fort Myers, Florida Canada USA New York Inner-city road works, such as the pavement rehabilitation of Henderson Avenue in Fort Myers, Florida, always put high demands on both man and machine. On the one hand, the project must be completed in the shortest possible time and the road reopened to traffic. On the other hand, high quality work is expected all around, by developers and naturally the paving crew itself. Knowing at the end of the day that they did a great job fills the members of a crew with pride. But pride can also sharpen a critical eye, for example with regard to the machines you work with. Atlantic Ocean Pacific Ocean Mexico Fort Myers Job Site Details Rehabilitation of an access road in Fort Myers, Florida Total length: 2,000 ft. Width: 22 ft. Paving Details Paving width: 22 ft. Layer thickness: surface course 1.25 in. Material Surface course: S (Surface) 3 Equipment VISION i with VF 600 Extending Screed WIRTGEN W 150 Cold Milling Machine Screed operator John Foreman for APAC-Southeast, Ltd. has worked with virtually everything on construction sites that has crawler tracks or wheels, so he knows exactly what he is talking about when he praises a paver by saying, This machine was developed and designed by people like me. He was referring to the VÖGELE VISION i, which was used in Fort Myers in combination with a VÖGELE VF 600 Extending Screed. Among other things, Foreman was addressing the versatility that makes the 10-ft. wheeled paver an extremely economical investment for any business. The VISION machine can be used virtually anywhere, from inner-city job sites, like here on Henderson Avenue in Fort Myers, Florida, to highway applications. Two additional advantages are its small turning radius and its transfer speed of 12 mph. They enable the VISION paver to maneuver easily in small spaces and travel quickly from one section of a job site to another. The fact that the VISION i even runs very quietly is another advantage pointed out by Corey Wall, WIRTGEN America District Sales Manager, who served as consultant on the job: The machine runs so quietly that local residents hardly realized we were working out here. The generator, the wheeled undercarriage and other components of the VISION i have been noise-optimized. And that is a major plus for noise-sensitive jobs in residential areas, says Corey Wall.

11 Residential access road rehabilitated with the VISION i // 11 On the quiet: The noise-optimized VISION i is ideal for jobs in noise-sensitive locations, such as residential areas.

12 12 // site Report // Highway Class For a video on this project, please visit our website at: > News & Media > Mediathek The VISION i sets new standards in every respect! John Webb, Paving Foreman APAC-Southeast, Ltd. With this machine, the future is built-in, says Corey Wall John Webb, Paving Foreman for APAC-Southeast, Ltd. and his team found paver operation and the operator platform to be right in line with future demands. They are VÖGELE s way of proving its ability to accurately translate experiences, demands and requests from people in the field into machine technologies. All of the functions on the VISION i s ErgoPlus operating console are arranged in such a way that the operator can even locate them with his eyes closed if necessary. The operating console can be easily positioned by the operator with just a few adjustments. And the operator platform itself permits ideal all-around visibility of all the critical points on the paver, such as the material hopper, steering guide and screed. Visibility and safety are fundamental requirements for doing a super job, explained Webb, particularly when a construction project is relatively complex, such as the pavement rehabilitation of Henderson Avenue, where cars and thick roadside vegetation occasionally prevented crews from focusing on the essentials. This paver has been perfectly thought out, all the way from the material hopper to the screed, said Corey Wall, District Sales Manager, WIRTGEN America. Together with the conveyor tunnel, the extra-large material hopper has a capacity of 240 sq. ft. This ensures a continual supply of mix for uninterrupted paving. When material is loaded from a truck, the oscillating push-rollers ensure jolt-free feeding, even in downtown areas with a lot of tight bends. The hydraulic hopper front is also worth a second glance. It guarantees that all of the mix is fed to the material conveyance process without manual intervention. The powerful separate hydraulic drives of the conveyors and the augers permit high laydown rates. The height of the augers can be infinitely adjusted by up to 6 in. As a result, the VISION i can spread mix optimally whether thin layers are being paved or layers with varying thicknesses.

13 Residential access road rehabilitated with the VISION i // 13 Great all-around visibility thanks to the VÖGELE ErgoPlus operator platform. The paver operator can also effectively supervise the material feed process.

14 14 // site Report // Highway Class Multitalented! The VÖGELE VF 600 Extending Screed with front-mounted extensions is infinitely variable from 10 ft. to 19 ft. 6 in. and even up to 25 ft. 6 in. with bolt-on extensions.

15 Residential access road rehabilitated with the VISION i // 15 This machine will perform as it should right now for what the future is going to demand of all machines. John Foreman, Screed Operator APAC-Southeast, Inc. A powerful tractor calls for a screed to match The VISION i s team partner was the VÖGELE VF 600 Extending Screed, which is specially designed to meet the demands of US road construction crews. And for good reason: It has an infinitely variable paving width of 10 ft. to 19 ft. 6 in. and even up to 25 ft. 6 in. with bolt-on extensions. This makes the VF 600 right for virtually all applications requiring a high degree of variability, from parking lots to highways. Despite all the innovative machine technology, roadway construction is and always will be a people business. And VÖGELE excelled in this discipline as well. The VISION i was presented to the APAC team during an on-site product demonstration under real practice conditions. It paved 40,000 tons of material for the demo. The result: The management of APAC-Southeast, Ltd. approved the purchase of the VISION i immediately after the demonstration. It is a very fine product. I'm very happy with it, said John Foreman, summarizing his experiences with the VÖGELE VISION i.

16 16 // site Report // Highway Class VF 600 Extending Screed This screed equips VISION pavers for a wide range of paving tasks. Working at high paving speeds with varying paving widths requires a screed that can always be relied on to deliver precise results. The VF 600 from VÖGELE is just such a system. It is suitable for a highly varied range of paving tasks from multi-laned expressways to narrow urban roads. Its variability is also evidenced in the range of possible profiles: Crowns, transverse slopes and berms are set once and then built perfectly from the start to the end of the paving process. The extensions themselves can be moved in or out at two different speeds as required. Pressing the button on the operator s ErgoPlus console very briefly permits particularly precise control, e.g. along an edge. The button must be pressed and held for more rapid extension or retraction. The powerful hydraulic system controls each extension separately, ensuring smooth and precise movement. The fact that the screed can be extended symmetrically on both sides enhances variability on the job.

17 Residential access road rehabilitated with the VISION i // 17 VF 600 Highlights Basic width: 10 ft. Basic paving range: 10 ft. to 19 ft. 6 in. Maximum paving width: 25 ft. 6 in. Compacting system V (vibration) Smooth, robust telescoping system for precise operation at all widths Sloping extension up to 10% Innovative electric screed heating Easy-to-use ErgoPlus operating system Compact design allows for great visibility to all areas Ideal tool for multivariable width applications and mainline paving Capable of many screed profiles with crown and sloping extensions. (Berm is available as an option.)

18 18 // Site Report // Highway Class Placing CTB with VÖG 3D System Navitronic Made possible by non-contacting grade and slope control and high compaction.

19 airport expansion with Navitronic Plus and the SUPER // 19 ELE Plus PRACTICAL APPLICATION 2 Fort Lauderdale, Florida

20 20 // Site Report // Highway Class Super pleased! Justin D. Cooper (l.), Project Manager at Archer Western, and Corey Wall (r.), District Sales Manager at WIRTGEN America, are thrilled with the high quality paving. USA // Fort Lauderdale, Florida Canada USA New York For a video on this project, please visit our website at: > News & Media > Mediathek Pacific Ocean Mexico Atlantic Ocean Fort Lauderdale Job Site Details Construction of a new approach road at Fort Lauderdale- Hollywood International Airport, Florida Total length: 8,000 ft. Width: 22 ft. Paving Details Paving width 22 ft. Layer thickness: base course 6 in. Material Base course CTB (cement-treated base) A unique airport expansion project! The new Fort Lauderdale- Hollywood International Airport is a structural challenge, because the new runways are on an artificially constructed overpass over US Route 1 and the FEC Rail Line. The time frame planned for building the runways and approach roads was extremely tight. It would have been impossible to keep to this tight schedule using the conventional grade and slope control method with stringlines. The time-consuming process of setting up the stringlines alone would have dramatically reduced the time available for placing the base course. In solving this challenge, Archer Western gained an edge by recommending the Navitronic Plus 3D system from VÖGELE for grade and slope control. Equipment SUPER with AB 600 TP2 Extending Screed Navitronic Plus

21 airport expansion with Navitronic Plus and the SUPER // 21 VÖGELE Navitronic Plus Highlights True 3D machine control for road pavers. Use of digital planning data for precision control of the paver and screed. Open port for connecting external 3D positioning systems from well-known manufacturers. Control accuracy in the millimeter range. Maximum precision. Economical use on linear job sites, such as highways and country roads, and for large areas, such as airports. Controls layer thickness, transverse slope and screed position. Steers the paver fully automatically.

22 22 // Site Report // Highway Class VÖGELE s Navitronic Plus is a non-contacting 3D system that not only handles grade and slope control, but also controls layer thickness and the paver s direction of motion, all fully automatically and with high precision. These capabilities make it unique in the market. The core component of 3D control technology is the positioning system, which is connected to the Navitronic Plus by an open interface called an open port. Thanks to this open port, users can choose different systems from several manufacturers: Optical systems with a laser total station and prism (e.g. PaveSmart 3D from Leica) or satellite-supported systems with GPS receivers in combination with a laser receiver (e.g. mmgps from Topcon). Justin D. Cooper, Project Manager at Archer Western, confirms: The machine has worked seamlessly with our Leica robotic total station stringless setup. How it works Starting from fixed points, the systems measure the actual position of the paver via a 360 prism and a total station. High-precision sensors on the machine supply additional information on the grade and slope of the screed and its exact position. All of the data collected is transmitted to the positioning system s external computer, where a comparison is made with the stored project data. The computer transmits any deviations to the Navitronic Plus 3D control system in order to initiate correction. In other words, the Navitronic Plus directly intervenes in the steering of the paver via the machine control system. The paver, whose current position is recorded continuously by the laser total station or GPS system, is guided fully automatically along the planned route. The paving crew can check the position of the paver and any deviations from the target line on the display of the 3D control system. Navitronic Plus saves a significant amount of time and money The open port is a key economical advantage of Navitronic Plus, because it enables contractors to use the 3D positioning systems of other machines for the road pavers, too. The additional investment in 3D control therefore is significantly lower for asphalt paving. Another key aspect helps to cut costs: The existing survey data used for earthmoving operations can also be used for road paving. By eliminating time-consuming surveying, large areas in particular can be surfaced much more quickly with Navitronic Plus, which Controls screed position fully automatically leads to considerable savings. With VÖGELE Navitronic Plus, the 6-in. base course paved in strips 22 ft. wide, was built with perfect results in record time. Justin D. Cooper, Project Manager at Archer Western, emphasizes: They needed to work quickly so the other aspects of the job could get done on schedule. Archer Western gained additional time by using a VÖGELE AB 600 TP2 Extending Screed with high compaction system comprising a tamper and two pressure bars, which considerably reduced the amount of final compaction by rollers.

23 Tips & Tricks From Practical Applications Proper Use of VÖGELE Pavers on All Mix Designs The right paving material is available for every application. Mix properties range from extreme longevity to the highest possible flexibility. To fulfill the varied requirements of a job, the mix composition must be carefully selected. What is more, the composition also influences how a mix is placed with the paver. VÖGELE pavers are equipped with automatic functions and options that help to achieve a perfect result with any and all types of material. 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 also conveys his knowledge to paving teams from all over the world in VÖGELE training courses and workshops. Overview of the most common asphalt mixes: 1. Stone Mastic Asphalt (SMA) Aggregate with a high percentage of fractured surface mixed with a higher bitumen content. Filler and polymers are used to reduce drain down and increase strength. Surface courses made of stone mastic asphalt display high wear resistance and stability. It is used primarily for highway construction. 2. Asphalt Surface Mix Well graded aggregate mix, with void content that varies depending on where its being used. After paving and final compaction, asphaltic concrete achieves a high density and is characterized by stability and excellent absorption of shear forces. When used for surface courses, the high content of coarse aggregate provides for good interlocking, resulting in good grip. 3. Asphalt Binder Mix Well graded aggregate mixed with bitumen. Maximum aggregate size varies based on location and thickness of the binder layer. 4. Asphalt Base Mix A mixture of larger aggregate mixed with bitumen. Lay-down temperature is usually lower than base and surface course. Asphalt binder courses are paved under the surface course to absorb the shear forces caused by traffic. The base course serves to absorb the vertical forces caused by traffic.

24 Tips & Tricks From Practical Applications What influence does the mix composition have on the material s properties? What can be done to compensate for any differences? Different Load Bearing Capacity The mix properties have an impact on the floating behavior of the screed. When paving a mix of high load bearing capacity, the counterforces exerted on the screed are higher than with a material of low load bearing capacity. Given identical settings for the paver functions, different results may be obtained. In such cases the VÖGELE Screed Assist feature allows today s heavier screeds to provide excellent results for all mix designs and applications. Automatic Functions Help to Resume Work After an Interruption in Paving Additional features on the VÖGELE pavers are automatically engaged to further enhance the quality of the pavement regardless of the type of mix design used. They can be best explained using the example of an everyday situation. If, for instance, paving must be interrupted due to a lack of mix, just set the joystick on the paver operator s console to P position (parking brake symbol as in a car). The paver stops, as do the conveyors, augers and compacting systems. The Screed Hold function ist activated automatically at the same time. It ensures that the screed does not settle on the pavement. As soon as the joystick is pushed back to F position (forward), the line (B) opens immediately and the Screed Float function is restored. line below (B) is blocked by a non-return valve with the Screed Hold function activated. The screed is held in position by the paver s hydraulics.

25 Tips & Tricks From Practical Applications Different Temperatures for Paving The composition of the mix also influences the temperature recommended for paving. The temperature in turn, has a significant impact on the compactability of the mix and the floating behavior of vibratory screeds. Asphalt Mixes and Paving Temperatures Stone Mastic Asphalt: F (approx.) On all ErgoPlus consoles, the vibratory compacting systems can easily be adjusted to suit prevailing requirements. This allows operators to quickly increase compactive effort if it is too low. Asphalt Surface Mix: Asphalt Binder Mix: Asphalt Base Mix: F (approx.) F (approx.) F (approx.) Screed Freeze Function Even after a brief interruption in paving, the mix in front of the screed may have cooled and may be harder to strike off. Therefore, when resuming work, the screed must be prevented from floating up. Manually decreasing the strike off would be one way to cope with the situation. Another way is Screed Freeze, a very useful automatic function installed in all VÖGELE pavers. When working in Automatic Mode and with the machine geared for paving, this function kicks in automatically (when preselected in the screen) as soon as the joystick on the paver operator s console is set to F position. Screed Freeze applies pressure to the piston side (line A) of the screed lift/lower cylinders for a distance of 1 ft. 8 in. The screed is prevented from floating up or sinking down and therefore will not create humps in the pavement. When resuming work, pressure is applied to the screed via line (A) on the hydraulic cylinder. Screed Hold and Screed Freeze are active at the same time for a defined period or distance. The screed then returns to the Screed Float Mode. A

26 Tips & Tricks From Practical Applications Different Layer Thicknesses The asphalt materials described above are intended for different applications. The composition of a material must fulfill the specific requirements of a given application. The main difference between the asphalt mixes is their maximum grain sizes. As a general rule, the maximum grain size should not exceed one-third of the layer thickness. The table below gives an overview of the layer thicknesses recommended for asphalt materials. Layer Thickness for the Different Asphalt Mixes Stone Mastic Asphalt: in. (approx.) Asphalt Surface Mix: in. (approx.) Asphalt Binder Mix: in. (approx.) The layer thickness selected for a job primarily depends on several factors: The weight of the screed, the screed planing angle, the paving speed and the settings for the vibratory compacting systems. The parameters should be set such that a defined relationship between them is evident (see table below). Asphalt Base Mix: 3 6 in. (approx.) The use of vibrators varies significantly across North America mainly because most vibration systems are ineffective. VÖGELE s unique vibrating systems however are very effective. Compacting System Settings Type of Pavement Layer Surface Course Binder Course Base Course Pave Speed Vibrator Speed ft./min. revs/min ,000 1,500 1,500 2,000 2,000 3,000 TIP! For a consistent paving result, try to maintain constant parameter settings while paving.

27 airport expansion with Navitronic Plus and the SUPER // 23 Grade and slope control: Controls layer thickness and transverse slope Controls the paver s direction of travel fully automatically Highlights of Navitronic from VÖGELE For tracked pavers: Navitronic Plus For wheeled pavers: Navitronic Basic True 3D machine control for road pavers ü ü Use of digital planning data for precision control of the paver and screed ü ü Control accuracy in the millimeter range ü ü Maximum precision ü ü Economical use on linear job sites (highways, state and country roads) and large areas Open port for connecting external 3D positioning systems from well-known manufacturers ü ü ü ü Navitronic provides: Conventional grade and slope control, i.e. controls layer thickness and transverse slope ü ü Fully automatic control of the screed's position ü ü Fully automatic steering of the paver ü Guided steering of the paver ü

28 24 // Site Report // Highway Class AB 600 TP2 The standard in high compaction The right tractor for the screed High compaction is the prerequisite for perfect build-up of the layers, and thus also for a final result that is true to line and level. In the case of varying layer thicknesses, high compaction technology achieves different depths at constant pressure of the pressure bars. The advantage: Guaranteed uniform compaction. VÖGELE screeds set standards when it comes to compaction. Sophisticated technology combined with the latest materials ensures the high-performance and reliability of the VÖGELE high compaction systems. The extending screed used in Fort Lauderdale was equipped with a tamper and two pressure bars. The tamper intensively pre-compacts the material. The rpm and tamper stroke length can be precisely and easily adjusted according to the material volume, mix type and layer thickness. The pressure bars, driven by pulsed-flow hydraulics, are the heart of VÖGELE high compaction technology. A pulse generator generates high-frequency pressure pulses that keep the pressure bars in contact with the pavement at all times. The greater the layer thickness, and the harder the material is to compact, the higher the pressure on the pressure bars must be! With the AB 600 TP2, this pressure is infinitely variable between 581 psi and 1,744 psi. In conjunction with this challenge and screed, Archer Western chose a Highway Class VÖGELE paver: The SUPER The machine concept is designed in such a way that the paver can competently, reliably, efficiently and effortlessly master even the We have been very impressed with the densities that have been achieved in the CTB as the material passes under the machine. With the tamper and pressure bars running, we are able to achieve 98% compaction of the CTB material prior to rolling operations. Justin D. Cooper, Project Manager Archer Western

29 airport expansion with Navitronic Plus and the SUPER // 25 biggest construction projects. Its tremendous laydown rate goes as high as 1,200t/h. With a maximum paving width of 42 ft. 8 in., it is the ideal large paver for seamlessly paving airport runways, highways and expansive traffic areas. The layer thickness ranges up to 15 in. The powerful paver is driven by a high horsepower, 6-cylinder diesel engine with 244 h.p. The crawler unit ensures absolutely smooth running. The electronically controlled, separate drives in the sprockets of both crawler tracks support constant straight running and precision steering in turns. Super compaction! The AB 600 TP2 Extending Screed achieved CTB compaction of 98%.