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Focus on Asphalt Pavers

Focus on Asphalt Pavers

September 10, 2008  By Administrator

Focus on Asphalt Pavers


14Pavement maintenance made easier with new paver

A new truck-mounted slurry seal and micro surfacing paver is now available from Bergkamp Inc. that is claimed to be one of the most advanced pavers of its type on the market.


According to Bergkamp, slurry seal and micro surfacing are among the most efficient methods of preventive maintenance for highways, roads and parking lots. The main difference between slurry seal and micro surfacing is that slurry seal uses a standard emulsion which requires evaporation to occur and sets in several hours. Micro surfacing uses a polymer modified emulsion that produces a chemical reaction to force the moisture out and can set in less than an hour so traffic can return quickly.

The M310 allows operators to easily calibrate the machine, monitor production rates and quickly make adjustments during production. The unit is equipped with Bergkamp’s Electronic Mix Control and Diagnostic System (EMCAD) that displays current and average material ratios, total material used and material rates. It also can produce on-demand reports to track production for individual sections of the job, or the entire job, via an onboard printer. Operators can evaluate these printouts and make the necessary adjustments to improve the machine’s efficiency.
According to the manufacturer, calibration procedures on the M310 are simple with no manual calculations required. The system ties material ratios of aggregates, asphalt emulsion, water, additive and fines together with an electronic signal and automatically maintains the ratios with feedback loops.

The M310 carries a 7.7 m3 of aggregate, 2270 litres of both asphalt emulsion and water and 303 litres of additive. The operator interface has joystick controls and slides to either side for
improved visibility for the operator. Both the engine and pugmill run quietly. The onboard 99 hp Cummins diesel engine is positioned at the front of the unit in an enclosed compartment that further reduces noise for the driver and crew. The pugmill slides out for easier cleaning – the bottom bowl stays in the paver while the excess material falls out of the bottom for faster clean up. The fines feeder is positioned low so it is easily accessible for loading. All liquid tanks are removable for maintenance.

Aggregate is delivered to the pugmill by a 609 mm wide belt-over-chain conveyor while the steep hopper walls minimize bridging. A Roper gear pump, three-way valve and inline strainer allow trouble-free loading of asphalt emulsion onto the truck. New material can be loaded at full rate without affecting the production settings, states Bergkamp.

New BOMAG paver offers power and capacity

15The new BF6615 self-propelled asphalt paver from BOMAG has been engineered for larger, high-production commercial paving projects. Weighing in at 9300 kg, the BF6615 features a 99-hp Cummins water-cooled diesel engine that is turbocharged for consistent power at all altitudes. The engine’s ECO-mode feature saves fuel and reduces noise by automatically lowering rpm’s during stops and pauses.  At the same time, an exclusive load-sensing hydraulic system lowers fuel costs by delivering power only when needed.

The new design, UNIMAT 2 full-width floating screed has a standard 2.44 m to 4.57 m paving width. The screed is electrically heated, eliminating the need to change propane bottles in the middle of a large project. Dual vibrators provide 2,500 vibrations per minute.

The paver’s 8.1-tonne hopper capacity on the BF6615 allows high-production paving to continue between trucks. Even with its power saving system, the new paver can push asphalt feeder trucks while maintaining working speeds up to 55 m/min.

The BF6615 also features a crawler style track drive system undercarriage with standard bolt-on polyurethane track pads.  Eight sealed rollers per side carry the weight of the machine, while bolt-on rock guards installed on the inside and outside of each track drive prevent asphalt from loading up on the chains.  Each of the track drives is bolted to a cross member frame structure and can be removed individually for maintenance.  The entire undercarriage structure can be removed as well.

The screed on the BF6615 features two abrasion-resistant, extendable, reversible and independent hydraulic augers.  Evenly distributing a uniform layer of asphalt across the mat, the two augers extend with the screed extensions, providing consistent material control at all paving widths and minimizing the need for hand labour. 

Screed extensions can be adjusted for a two-inch crown or invert. Screed wear plates are 9.5 mm thickness abrasion-resistant 400 Brinell hardened steel. Designed to withstand harsh job-site conditions, screed plates are bolted on for easy replacement.

The BF6615 features dual operating positions for control from either side of the paver. The engine is positioned low in the machine, giving the operator outstanding visibility from either side. Engine shroud is standard for heat and noise reduction.  Fail-safe brakes are also standard.

Both the augers and dual hydraulic slat conveyors offer full automatic control with manual override. This allows the operator to precisely control the amount of material being sent to the screed if paving wider or thicker on one side or the other.

The BF6615 is compact with a transport length of 4.57 m. and a height is 1.87 m. For simple cleanup, the BF6615 features a hydraulically lifting bed and has all major components located outside the hopper.  A standard fume extraction system helps reduce asphalt odour. 

Other standard equipment includes urethane track pads, a high engine water temperature/low engine oil pressure automatic shutdown, wash down spray system, swivel mounted bumper rollers and power depth adjustment controls for variable mat thickness.  Optional equipment includes a swivel-mounted tow-type hydraulic truck hitch, working lights, ditch plates, simple Moba automatic joint matcher and Topcon screed automation system.

Caterpillar launches new paver
15The AP655D is the latest addition to Caterpillar’s line of asphalt pavers. According to the manufacturer, it has been designed for improved performance, operator comfort, ease-of-use, mobility, and reliability on assignments ranging from routine commercial jobs to demanding highway operations.

The AP655D features dual operating stations with the Advisor Monitoring System (AMS), tilting consoles, exclusive Mobil-trac undercarriage or steel track undercarriage, high capacity cooling
system, belt or hydraulic driven generator system and Caterpillar’s unique material handling system with independent auger and conveyor controls. Power is supplied by a 174 hp Cat C6.6 turbocharged, 6-cylinder diesel engine. The deck-mounted cooling system provides cool intake air in order to maximize fuel efficiency and minimize emissions. A variable speed fan draws ambient air across the engine compartment and through the radiator. The exhaust air exits toward the hopper providing a cool engine compartment and working environment for the crew.
The AP655D includes dual swing-out operator stations with tilting consoles. The stations offer four different positions for good visibility to the operator’s surroundings. The stations can be positioned beyond the machine frame for greater visibility when precise paving control is required.

An Advisor Monitoring System located on the left operator station provides an interactive interface to assist the operator. The system includes project planning calculators, start-up checklists, engine operating parameters and many other features to assist the operator. The system also lists fault codes for machine functions, making troubleshooting quick and easy.
The Mobil-trac™ undercarriage offers increased traction when operating on unstable bases or on grades, low ground pressure and high flotation. High travel speeds give the AP655D Mobil-trac the ability to be quickly repositioned at job sites or driven to the next site. The Mobil-trac can be purchased with either the raised tread-bar belt or the smooth belt. The smooth belt offers less disturbance of the base materials. The AP655D can also be purchased with a steel track undercarriage. The steel track undercarriage incorporates special quad-roller rear bogies, Cat D3 track rails, and automatic tensioning to deliver a smooth ride. The steel track undercarriage is available as a more economical alternative to the Mobil-trac.

The paver utilizes three steering modes, including PAVE, TRAVEL and MANOEUVRE. The MANOEUVRE mode is unique to Caterpillar. This mode permits the tracks to counter-rotate, allowing the machine to turn within its own footprint. This unique feature provides quick mobility in commercial applications when moving to a new starting point.

The independent material handling system provides precise mix delivery. The gateless material handling system promotes hands-free operation by providing features such as ratio control dials, and independent control of each auger and each conveyor. The independent operation reduces component wear and minimizes the potential for mix segregation. Reversible augers and conveyors assist the crew by reducing handwork and clean-up. The reversible augers are able to pull asphalt back into the main screed area when retracting the extenders while the reversible conveyors pull asphalt back into the tunnels, resulting in limited spillage.

The foldable front hopper apron offers a power folding option. The apron folds rearward providing good material flow while reducing clean-out effort and time, according to the manufacturer.

The high capacity generator provides power for the electric screed heat, auxiliary lights and job site tools. The tractor-mounted generator provides 25 kW of power at 60 Hz for the electric screed heat and the auxiliary power panel.

The AP655D can be equipped with the AS3251C screed with rear-mounted extenders or with the AS2252C screed with front-mounted extenders. These screeds provide fast warm-up, simple operation and reliability. The AS3251C vibratory screed features hydraulically-driven, rear-mounted extenders. Heavy-duty support tubes stabilize the extender providing even material flow for high quality results on highways and streets as well as commercial applications.

The AS2252C vibratory screed features narrow front-mounted extenders that utilize 229 mm wide screed plates that reduce the need for handwork when changing paving widths.


LeeBoy unveils its largest paver
16VT LeeBoy Inc. has introduced its 9000 asphalt paver, a 14 968 kg machine featuring a manoeuvrable, rubber tire design and a 2.44 electrically-heated screed system. Designed for large commercial, high production paving applications, the 9000 is powered by a 173-ho Caterpillar diesel engine. The engine is transversely mounted, which allows for better ground level access and cooling efficiency. A fume ventilation system vents asphalt vapours away from the operator and screed area. An easily raised hood cover the low profile engine and the side grating can be quickly removed to provide access to the engine compartment.

The 9000 model features dual hydraulic slide-out operator stations for improved fore and aft visibility as well as fully equipped consoles that incorporate CAN Bus system design and digital gauges for monitoring paver functions and diagnostics. Paver steering is accomplished using Plus 1 control architecture with touch pads.

A two-speed motor with single reduction planetary torque hub enables the paver can travel at up to 19.3 km/h and at paving speeds of up to 76.2 m/min. The machine is driven by two large heavy-duty low pressure 19×29.5 tires. The 12×22 solid rubber front tandem steering bogie wheels oscillate to improve mat quality by overriding roadbed irregularities.

The material handling system on the 9000 paver begins with a 10-tonne capacity receiving hopper with heavy-duty, hydraulic radius hopper wings and high strength plastic flashing to prevent material spillage. Dual  457 mm slat bar and roller chain conveyors feed the 406 mm diameter hardened cast steel augers that push asphalt to the screed. The auger assembly can be hydraulically raised and lowered. Standard sonic feed sensors control the augers. The operator has independent left and right hand control of the conveyor system and material flow gates. Manual tunnel extensions are available to keep mix away from the drive tires.
The paver is equipped with a Legend electric screed system that extends hydraulically from 2.44 m to 4.72 m. An onboard 20 kW generator heats the main screed and the front-mounted extensions. The manufacturer’s exclusive heat element replacement system is designed for quick changes.

New pavers from Roadtec

Two new 2.44 m asphalt pavers have been recently introduced by Roadtec, an Astec Company. The RP-170 is a rubber–tired machine that replaces the RP-150 while the new the rubber-tracked RP-175 replaces the RP-155.

Both new models are powered by a Cat C6.6 ACERT Tier 3 diesel engine rated at 174 hp. The engines comply with the latest environmental standards while providing a 12 per cent increase in horsepower over previous models. Fuel capacity of both new pavers has also increased by 40 per cent to 360 litres on the RP-175 and 340 litres on the RP-170, allowing more hours of work before refuelling.

New, hydraulically-driven cooling fans provide a substantial drop in paver noise emissions for a quieter work environment around the paver. The new swing-out seat design and new operator control layouts that were previously introduced on Roadtec’s 3 m models are also standard on these new 2.44 m machines.

Terex introduces paver upgrades
17bAs part of a design enhancement program to boost productivity, the Terex CR662RM RoadMix material transfer vehicle and asphalt paver now features a new variable-pitch in-hopper configuration that is claimed to dramatically increase material throughput. The new pitch spacing, transitioning from 254 mm in the front to 279 mm then to 305 mm in the rear, more aggressively channels material to the rear of the machine for faster truck unloading. The new auger design helps to increase production capabilities to more than 454 tonnes/h. Even with a more aggressive pitch, the constant-diameter augers continue to reblend 100 per cent of the material to combat both material and thermal segregation, according to the manufacturer.
A new conveyor assembly for the CR662RM features a stationary lift conveyor with flights averaging every other pitch – compared to the previous every third pitch – to reduce hydraulic pressure and more quickly channel material from the rear of the tractor to the swivelling conveyor. New hydraulic pressure gauges for the conveyors, mounted at the operator’s station, help to minimize the chance of plugging the system. Hydraulically operated clean-out doors and reversible conveyor flights aid in clearing obstructions.

The unique aspect of the CR662RM is that it functions equally well as a material transfer vehicle or as a remix anti-segregation paver. The manufacturer claims that the new in-hopper auger design enables the CR662RM to match or better production rates of conventional slat pavers, while giving the additional benefit of virtually eliminating segregation.

When equipped as a paver, the CR662RM incorporates two, 15245 mm long spread auger sections that deliver material to the left-and right-hand sides of the screed. A new spread auger design employs two independently controlled, variable-speed outboard drive motors, mounted to the tractor’s rear bulkhead. This eliminates the centre gearbox drive and, since the left-and right-hand auger sections back each other up, reduces the occurrences of centerline segregation.

Three screed models are offered to covert the machine into a paver including the diesel or electric Fastach®10, electric VersaScreed 10, and the electric or diesel Stretch 20®.
For use as a material transfer vehicle, the screed and spread augers are removed from the tractor and replaced by the conveyor assembly. The RoadMix MTV is capable of delivering continuous, non-contact and off-set paving capabilities. Asphalt is immediately channelled from the receiving hopper to the rear of the machine, providing reduced handling time and virtually eliminating hot mix temperature loss. Material passes through the stationary 940 mm wide life conveyor to a 762 mm wide swivel conveyor. The second conveyor swings 55 degrees to the left or right of centre and offers a hydraulically variable discharge height from 1.85 m to 2.94 m.
The CR662RM features Terex’s patented Smartrac rubber track drive system. Oscillating bogie wheel assemblies combine with the system’s frictionally drive rubber tracks to automatically apply the correct tension, whether in forward or reverse. The rubber track drive spreads the machine’s 24 495 kg weight over a larger area, resulting in a low ground contact pressure of less than 12 psi.

New electric screed offers more flexibility

Terex Roadbuilding has introduced it new VersaScreed 210 electric screed for paving large parking lots, highways and city streets. The new 3 m screed features hydraulically variable paving widths from 3 m to 5.6 m, 457 mm wider than previous designs. By adding left-and right-hand bolt-on screed extensions, the VersaScreed 210 delivers full-width paving to 6.6 m.
The front-mounted screed extension design of the VersaScreed 210 allows for fast width changes with less shovelling and handwork, states the manufacturer. Its wedge-shaped front extensions automatically shed asphalt when narrowing paving widths, which eliminates asphalt trapping and improves mat quality. On-the-fly angle of attack extension adjustments also help to maintain uniform mat texture. In addition, the new screed incorporates 127 mm diameter vertical and 102 mm diameter horizontal tube supports that prevent screed deflection, even at extended paving widths, to improve mat smoothness.

The reversible 610 mm wide main and 203 mm wide extension screed bottoms are constructed of AR400 Brinell hardened alloy steel for longer service life. Spring-loaded end gates maintain constant contact with the subgrade and are mounted to heavy-duty 19 mm thick end plates for added service reliability.

The electric heating system quickly brings the screed bottoms to paving temperatures. Eliminating smoky start-ups, the 34 kW three-phase generator allows contractors to heat screed bottoms on the way to the job site while offering ample reserve power to run auxiliary equipment such as lights for night paving operations. Two thermostatically-controlled zones automatically maintain minimum set temperatures for both left-and right-hand main screed and extensions.

All screed controls – including crown adjustment, extension slope and extend/retract, and match height – are electric over hydraulic for more reliable operation.


New series pavers from Vögele

Two new 3 m asphalt pavers have been by Vögele America Inc., a member of the Wirtgen Group.

Called the Vision Series, the models include the tracked 5200-2 and the wheeled 5203-2.  They are described by the manufacturer as quieter, cooler and more productive than the company’s predecessor models.

The new series has been completely designed from the ground up to incorporate the latest in paver technology. The slope of the machine and hood have been configured so the operator can see the sides, the hopper and the conveyors in back, without having to move around. The operator’s station swings out from both edges for improved visibility to the sides, behind and into the hopper. In addition, the control console slides from one side of the paver platform to the other, and also swivels and tilts. Streamlined twin exhaust pipes redirects exhaust fumes and heat away from the operator and crew. No exhaust stack is located in front of the operator.
On the wheeled Vision 5203-2, three drive versions are available – one with rear wheel drive, one with optional two-wheel front wheel assist, and a new optional six-wheel drive version.
An optional hydraulic front apron eliminates much of the usual shovelling in front of the paver. As the hopper closes, the front apron rises preventing forward spillage of the asphalt material.
Self-diagnostics are built into the new series. Fluid levels and other inspection points are monitored automatically from a central display panel, eliminating daily manual checking by the crew. Similarly, self-tensioning conveyors on the new pavers have hydraulic cylinders that keep them adjusted.

Both the 5200-2 and the 5203-2 pavers have independently operated hopper wings. One side can be dumped, or the other, or both at the same time. Vögele has also eliminated the flow gates and implemented independent conveyor and auger drives. Each conveyor is driven separately and independently from the auger. Augers and conveyors are reversible. The tracked 5200-2 features a mechanically-lowered strike-off plow in front of the rubber tracks that prevents the machine from going over a hump of material, or getting asphalt mix in the tracks. The long crawler tracks are fitted with wide 457 mm pads for maximum tractive effort and navigation. Misalignment of the rubber track has been eliminated due to the zero clearance between track rollers and the rubber tracks.

A separate drive and electronic control is provided for each crawler track for better stability and improved steering accuracy.  Engine power is translated into pave speed with loss of power as the drive units are integrated in to the crawler track drive wheels.

Both pavers are powered by a six-cylinder Cummins Tier 3 diesel engine that delivers 240 hp at 2000 rpm. Different speed ranges are selected at the push of a button. The options are MIN, ECO Mode and MAX. At 1800 rpm, ECO Mode provides low noise level and less fuel consumption, sufficient, says the manufacturer, for most paving operations.
The 11.7-tonne capacity material hopper has two cylinders per side to provide smooth operation. The slope inner design improves the mix flow to avoid segregation.  Large truck push rollers can be set to three different positions for shock-free docking of trucks. Proportional control and continuous monitoring of conveyors and augers ensure a constant head of mix in front of the screed. Proportional control allows the conveyors and augers to deliver exactly the amount of mix actually required. Because separate drive and material monitoring is installed for each conveyor and each auger, mix material can be spread in the auger tunnel when conveyors are not running.

Three electric screeds are available for the new pavers including the Carlson EZ-III 1017 and EZ-IV 1019 with front-mounted extensions and the HR 500 E rear-mounted screed. No diesel-heated screeds are available.
With ErgoPlus controls at the screed, paver functions are logically arranged and clustered in groups reflecting the needs of the paving site. Direct access to the paver is achieved via push buttons. Reversal of auger rotation, for example, can be easily done by the screed operator at the touch of a button.

Weiler Products
New windrow elevator has remixing capabilities

21Weiler Products has introduced its new 250 hp E1250 self-propelled material transfer vehicle for continuous, non-contact asphalt paving projects. The optional power remix transition hopper remixes both size and temperature segregated particles to help achieve smoothness bonus, according to the manufacturer. The E1250 also allows offset paving over barriers, string lines or other obstacles that make it difficult to position trucks in the front of the paver for inline paving.
The E1250 was designed and built with a low centre of gravity and a tight turning radius. Weighing 22 000 kg, the MTV is 3.5 m high and 13.7 m long. It has a maximum transport speed of 15.4 km/h and a variable working speed of 0-3.7 km/h.  The hydrostatic drive train eliminates the need for a gear box and gives the operator two-speeds for on-the-fly shifting from working speed to transport speed. It also features drop out floors in the elevator, remix hopper and conveyor to facilitate maintenance.

The operator’s station has tilt-wheel steering and ergonomically positioned controls for improved productivity. The operator can operate the unit from either side of the machine by simply lifting a spring-loaded pin.

According to the manufacturer, the remix hopper incorporates two interlaced 406 mm diameter segmented augers for better remixing capabilities since the augers are not completely covered. There is only 50 mm to 127 mm of material in the hopper at any given time which permits both side-to-side and top-to-bottom mixing. The 1524 mm wide elevator is driven by two direct drive, high torque motors giving the elevator a capacity of 907 tonnes/h. The 762 mm wide conveyor is driven by another direct drive, high torque motor for a 544 tonnes/h loadout capacity.

Optional equipment includes a 9 kW generator, a hydraulic truck hitch, a rotating LED beacon, a conveyor light package, an 11.7-tonne capacity hopper insert and a 4.5-tonne hopper insert extension.

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