the vision 5203-2i wheeled paver earns praise in fort...

The VÖGELE Magazine on Paving Applications Issue 08

Pioneering

“Hot-on-hot and hot-to-hot” // Two InLine Pave trains rehabilitate runways in record time

The best of both worlds // SUPER 1300-2 is ideal for projects big and small

Taking off // SUPER 2100-2 displays top performance in new airport construction

The VISION 5203-2i wheeled paver earns praise in Fort Myers, Florida

2 // Contents Roadnews 08

4

Complete program for America

The global leader in road pavers has the

perfect machines for all paving applications

8

Approach road rehabilitation

in Fort Myers

The VISION 5203-2i paver sets new

standards

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

28

Parking lot repaved in Mississauga

The SUPER 1300-2 unites the power of a

large machine with the maneuverability

of a compact paver

34

Runways resurfaced in record time

“Hot-on-hot” paving with two

InLine Pave trains

Center Pages: Tips & Tricks

from Practical Applications

Proper use of VÖGELE pavers on

all mix designs

The perfect paver for every paving situationThere 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

Editorial // 3

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 | 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.

Complete Program for Road Construction ProfessionalsWorld market leader VÖGELE offers the widest range of products.

APPLICATION 1 Fort Myers, Florida

PRACTICAL

4 // main topiC

Complete Program for Road Construction ProfessionalsWorld market leader VÖGELE offers the widest range of products.

APPLICATION 3Mississauga, Canada

PRACTICALAPPLICATION 2

Fort Lauderdale, Florida

PRACTICAL

the peRfeCt maChine foR eveRy paving RequiRement // 5

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. •

“The SUPER 1300-2 gives you the stability of a large machine, and the maneuverability

of a small paver at the same time.”

David Tittley, Quality Paving Ltd.

6 // main topiC

“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

the peRfeCt maChine foR eveRy paving RequiRement // 7

“This ma chine was developed and designe d by people like me.”

8 // site RepoRt // highway Class

“This ma chine was developed and designe d by people like me.”

Screed operator John Foreman, talking about the VISION 5203-2i, which excelled in Fort Myers, Florida.

APPLICATION 1Fort Myers, Florida

PRACTICAL

Residential aCCess Road Rehabilitated with the vision 5203-2i // 9

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.

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 5203-2i, 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 5203-2i 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 5203-2i have been noise-optimized.

And that is a major plus for noise-sensitive jobs in residential areas,”

says Corey Wall.


One team, one opinion:

The VÖGELE VISION 5203-2i is one of the most

versatile 10-ft. pavers on the market.

USA // Fort Myers, Florida

USA

Mexico

New York

Canada

Pacific OceanAtlantic Ocean

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 5203-2i with VF 600 Extending Screed

WIRTGEN W 150 Cold Milling Machine


On the quiet: The noise-optimized

VISION 5203-2i is ideal

for jobs in noise-sensitive locations,

such as residential areas.

“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 5203-2i’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 5203-2i can spread

mix optimally whether thin layers are being paved or layers with

varying thicknesses.

John Webb, Paving Foreman

APAC-Southeast, Ltd.

“The VISION 5203-2i sets new standards in every respect!”

12 // site RepoRt // HigHway Class

For a video on this project, please visit our website at: www.voegele.info> News & Media > Mediathek

Great all-around visibility

thanks to the VÖGELE ErgoPlus operator platform.

The paver operator can also

effectively supervise the material feed process.


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.


John Foreman, Screed Operator

APAC-Southeast, Inc.

“This machine will perform as it should right now for what the future is going to demand of all machines.”

A powerful tractor calls for a screed to match

The VISION 5203-2i’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 5203-2i 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 5203-2i 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 5203-2i. •

Residential access Road Rehabilitated with the Vision 5203-2i // 15

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

VF 600 Extending Screed 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.


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

Capable of many screed profiles with crown and sloping extensions. (Berm is available as an option.)

VF 600 Highlights

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


Placing CTB with VÖG ELE 3D System Navitronic Plus Made possible by non-contacting grade and slope control and high compaction.


APPLICATION 2Fort Lauderdale, Florida

PRACTICAL

Placing CTB with VÖG ELE 3D System Navitronic Plus Made possible by non-contacting grade and slope control and high compaction.

aiRpoRt expansion with navitRoniC plus and the supeR 2100-2 // 19

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.

USA

Mexico

New York

Canada

Pacific OceanAtlantic Ocean

Fort Lauderdale

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.

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)

Equipment

SUPER 2100-2 with AB 600 TP2 Extending Screed

Navitronic Plus

USA // Fort Lauderdale, Florida

For a video on this project, please visit our website at:

www.voegele.info> News & Media > Mediathek

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.

VÖGELE Navitronic Plus – Highlights


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.

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

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.

Controls screed position

fully automatically


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

Proper Use of VÖGELE Pavers on All Mix Designs

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:

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.

3. asphalt Binder mix

Well graded aggregate mixed with bitumen.

maximum aggregate size varies based on location

and thickness of the binder layer.

asphalt binder courses are paved under the

surface course to absorb the shear forces caused

by traffic.

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.

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.

4. asphalt Base mix

a mixture of larger aggregate mixed with bitumen.

lay-down temperature is usually lower than base

and surface course.

The base course serves to absorb the vertical

forces caused by traffic.


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.

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

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.

Automatic Functions Help to Resume Work After an Interruption in Paving


Different Temperatures for Paving

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.

The composition of the mix also influences the temperature

recommended for paving.

asphalt mixes and paving Temperatures

Stone Mastic Asphalt: 300 – 360 °F (approx.)

Asphalt Surface Mix: 275 – 360°F (approx.)

Asphalt Binder Mix: 250 – 360 °F (approx.)

Asphalt Base Mix: 250 – 360 °F (approx.)

“Screed Freeze” Function

• 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.

The temperature in turn, has a significant impact on the

compactability of the mix and the floating behavior of vibratory

screeds.

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.

A


Different Layer Thicknesses

layer Thickness for the Different asphalt mixes

Stone Mastic Asphalt: 1 – 2.5 in. (approx.)

Asphalt Surface Mix: 0.5 – 2 in. (approx.)

Asphalt Binder Mix: 2.5 – 4 in. (approx.)

Asphalt Base Mix: 3 – 6 in. (approx.)

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.

pave speed

Vibrator speed

ft./min.

revs/min.

Compacting System Settings

TIP! For a consistent paving result, try to maintain constant parameter settings while paving.

20 – 50 15 – 30 10 – 30

1,000 – 1,500 1,500 – 2,000 2,000 – 3,000

Type of pavement layer

Surface Course Binder Course Base Course

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).

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.

Controls the paver’s direction

of travel fully automatically

Grade and slope control:

Controls layer thickness

and transverse slope

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

ü ü

Open port for connecting external 3D positioning systems from well-known manufacturers

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


AB 600 TP2 – The standard in high compaction

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.

“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.”

The right tractor for the screed

In conjunction with this challenge and screed, Archer Western

chose a Highway Class VÖGELE paver: The SUPER 2100-2.

The machine concept is designed in such a way that the paver can

competently, reliably, efficiently and effortlessly master even the

Justin D. Cooper, Project Manager

Archer Western


Super compaction! The AB 600 TP2 Extending Screed

achieved CTB compaction of 98%.

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.

airport expansion with navitronic plus and the super 2100-2 // 25

Super capacity!

The material hopper on the SUPER 2100-2 can hold 30,865 lbs.

of mix. The large extra hopper ensured non-stop paving.


The extra material hopper is another time-saver

The SUPER 2100-2 can be fed with mix very cleanly, reliably

and rapidly. The material hopper has a capacity of 30,865 lbs.,

meaning that a sufficient amount of material is available in

just about every conceivable feed situation. If necessary, the

SUPER 2100-2 can also be equipped with an extra hopper, as was

the case in Fort Lauderdale. Justin D. Cooper, Project Manager

at Archer Western, explains:

“With the extra material hopper, we maintain continuous paving, as material is readily available for placing. This adds to a smooth end product with less stop and start when material is deficient in the hopper.”

Paving was completed in no time thanks to the combination

of Navitronic Plus, the AB 600 High Compaction Screed in the

TP2 version and the extra material hopper. Conclusion: VÖGELE

technology provides for highly efficient processes and perfect

surface quality. •


Super overall!

Saving a lot of time and money

thanks to VÖGELE technology.

SUPER 1300-2 Gives Canadian Contractor Best of B oth WorldsOne paver serves government, commercial and residential projects.

28 // site RepoRt

APPLICATION 3Mississauga, Canada

PRACTICAL SUPER 1300-2 Gives Canadian Contractor Best of B oth WorldsOne paver serves government, commercial and residential projects.

paRking lot Rehabilitation with the supeR 1300-2 // 29

David Tittley, Quality Paving Ltd.

“The SUPER 1300-2 gives you the stability of a large machine, and the maneuverability

of a small machine at the same time.”

A smaller-size asphalt paver with the right dimensions is

giving a Canadian asphalt contractor the ability to profitably

place pavements from residential streets to bike paths with

a single machine. Quality Paving does government road

construction, in addition to suburban residential work.

“We do 75 percent civic or government work, and the rest

commercial,” said Dave Tittley, president and owner, Quality

Paving 1994 Ltd., Kitchner, Ont. “We get the call because we

can do the small and the big pavements.”

That’s why Quality’s VÖGELE SUPER 1300-2 is the right paver for

its mission. “This smaller paver allows us to go into all kinds of

places that the bigger machines can’t get to, yet it’s a big machine,”

Tittley said. “It has the power to do road work. We can go into a

subdivision and do a 23- to 26-ft. roadway in two passes. The big

machines can do that, but we can take that 13-ft. screed down to

30 // site RepoRt

Canada

Ottawa

Greenland

Pacific OceanAtlantic OceanUSA

Mississauga

Canada // Mississauga

Job Site Details

Rehabilitation of a public parking lot in Mississauga,

Ont., Canada

Total length: 197 ft.

Width: 13 ft.

Paving Details

Paving width: 13 ft.

Layer thickness: binder course 2 in.

surface course 1.5 in.

Material

Binder course: HL8

Surface course: HL3

Equipment

SUPER 1300-2 with AB 340 V Extending Screed

HAMM HD 12 Tandem Roller

Paving widths range from 2 ft. 6 in. to 13 ft. 9 in.,

making the SUPER 1300-2

an incredibly versatile machine.

6.5 ft. and do a 6.5 ft. pathway, for instance for bikes or golf carts,

while none of the big pavers can do it.” To Tittley, the SUPER 1300-2

provides the best of both worlds. “The SUPER 1300-2 gives you

the stability of a large machine, and the maneuverability of a small

machine at the same time,” Tittley said.

Quality Paving acquired the SUPER 1300-2 in spring 2013, and

in late summer 2014 had some 800 hours on the machine. In late

summer on a water and sewer repair at light manufacturing plant

in Mississauga, Ontario, Quality Paving was placing a final wide

patch, 197 ft. long by 13 ft. wide. Approximately 66 t of hot mix

asphalt was placed in a morning.

“The plant put in new sewer lines, and we are putting in two

layers of hot mix asphalt, 2 in. of HL8 binder course, and 1.5 in.

of HL3 finish course,” Tittley said. The HL8 lift has a maximum

aggregate size of ¾ in., and the HL3 3/8 to ½ in. maximum

aggregate size. Is the size of machine “overkill” for the parking

lot utility patch paving done in southern Ontario? “At the end of

the day, when the equipment gives you a good quality job, it’s not

overkill,” Tittley said.

Compacting screed

The highly versatile SUPER 1300-2 is the perfect machine for

commercial, utility and medium to light-duty paving. Its compact

and maneuverable design makes it right for precise and intricate

jobs, walking and biking paths, sidewalks, utility work and shoulder

paving. Paving widths range from 2 ft. 6 in. to 13 ft. 9 in., making

the SUPER 1300-2 an incredibly versatile machine.


VÖGELE AB 340 V screed

is used on utility patching applications.

The powerhouse is driven by a modern Deutz engine rated at

100 hp. By achieving a maximum laydown rate of some 390t/h,

the SUPER 1300-2 also is an excellent performer when it comes to

tackling major paving jobs.

The SUPER 1300-2 is paired with an AB 340 V screed from VÖGELE,

not commonly seen in North America. “Once we set the screed level,

we hardly ever touch it,” he added. “For the size of the machine,

it’s a very heavy-duty screed, it’s as heavy as a large highway

class machine.” On the plant parking lot, the vibrating screed

was getting about 90% compaction ahead of finish rolling by a

HAMM HD 12 CompactLine roller. “We don’t always use compaction

at the screed, but on road work, we will use it, depending on the

length of the road,” Tittley said. “It helps us get compaction a little

bit faster, so we don’t have to stay as long rolling.”

The HAMM compactor is a fine complement to the SUPER 1300-2,

he said. “It works fantastic,” Tittley added. “Its steering and vibration

are great, and the water control system is super. We’ve had great

results and productivity with it. By mounting the operator’s seat

high, with the seat movable back and forth, the operator can really

see what he is doing, he’s right there. And the front of the roller

is tapered in, so the operator can see the curb right beside him.”

Like all VÖGELE screeds, the AB 340 V is electric-heated. “One

of the biggest pluses of a smaller machine like the SUPER 1300-2

is that we have electric heat,” he said. “The screed is constantly

heated, and we always get a smooth finish, whereas a lot of small

machines don’t have that capability, instead using propane burners.

It’s one of the few smaller-size pavers that has the technology

normally seen in a larger paver.”

The paver incorporates the VÖGELE Niveltronic Plus system for

automatic grade and slope control, to achieve superior paving

results. “Because we’ve been doing mostly trenches this season,

we haven’t had the need to use it,” Tittley said. “But when we do

bridge work we’ll use the Niveltronic Plus. For this trench we’re just

matching to the existing pavement and don’t have it on.”

Powerful but economical

Quality Paving feeds asphalt to the SUPER 1300-2 using either a

dump truck, or front-end loader. “We can use both, depending on

what the project is,” Tittley said. “Most of the time we have our

triaxles dump directly in the hopper. The 100 h.p. engine provides

lots of power to push triaxles, tractor-trailer dumps and flow-boys,

we have no problem in pushing any of them. But if we’re in a

32 // site RepoRt

small area that a truck can’t back into, the paver is ready for a large

skid-steer or even a backhoe to feed with asphalt.”

Despite its ability to place wide street pavements, the SUPER 1300-2

is very easy to use for parking lot paving, Tittley said. “It’s very

maneuverable around small areas such as parking lot curbs,” he

said. “It’s still a larger machine in weight and size of engine, but the

outside of the track is 6 ft. 7 in., a little bit shorter, so we can turn

tighter than a larger machine. Smaller machines will turn even

more easily, but they don’t have the versatility of the SUPER 1300-2.

We have no problems going in and out of tight places.”

When you have a limited-size fleet of equipment, reliability is

paramount to a contractor. “This is a very reliable machine, so

long as everyone goes through the sequences of taking care of it,”

Tittley said. “If someone leaves the key on overnight, we will arrive

in the morning and the batteries are down. But normally the paver

is available when we want it, and the screed heats up fast. In five

minutes we’re ready to go.”

And when in action, VÖGELE’s ErgoPlus operating concept provides

intuitive and easy operation with great visibility.

“The paver is more economical to operate than other pavers we’ve

had, because we are able to select between three different operating

modes for the engine,” Tittley said. “Most of the time we keep it

in Eco mode, which is economical for general use. The only time

we change that is when we put the machine into production. For

that we have an Idle and also a Super mode, which really brings

the engine up when dealing with heavy asphalt loads, for example,

to push a truck whose brakes are on. Otherwise we can use Eco in

virtually every application.”

The material hopper also has an easy-to-use cleanout system, he

said. “One of the best things about the SUPER 1300-2 is that the

screed goes down to 6 ft. 7 in. wide, but the whole machine goes

down to 6 ft. 7 in. as well,” he said. “You can go through narrow

downtown alleyways – the whole machine goes right through them.

Other machines, you can get the screed down, but the paver stays

wide, even if it’s been folded, and it will still be 8 ft. wide.

“You can go through narrow downtown alleyways – the whole machine goes right through them. Other machines, you can get the screed down, but the paver stays wide, even if it’s been folded and it will still be 8 ft. wide.” •


The VÖGELE Niveltronic Plus

is set up and operated simply

via the screed operator’s console.

Premiere: Two InLine Pave Train s Working “Hot-to-Hot”Rehabilitation of airport runway in record time: 49 ft. 3 in.-wide compact asphalt pavement built in a single pass.

34 // site RepoRt

Premiere: Two InLine Pave Train s Working “Hot-to-Hot”Rehabilitation of airport runway in record time: 49 ft. 3 in.-wide compact asphalt pavement built in a single pass.

Rehabilitation of aiRpoRt Runway with vögele inline pave method // 35

Schedules for runway rehabilitations are always exceedingly

tight, and the project at Rostock-Laage Airport, Germany

was no exception. Here, though, a new approach was taken:

Two InLine Pave trains from VÖGELE were used to lay a new

binder course and surface course “hot-on-hot and hot-to-hot”

as a compact asphalt pavement. As a result, German contractor

Kemna Schwerin Tief- und Straßenbau GmbH not only finished

the job in record time, but also delivered maximum paving

quality.

FOD – For an airport operator, this abbreviation is akin to a red

flag to a bull. It stands for “Foreign Objects Damage” and describes

the danger caused by small objects on a runway, from as small

as 0.16 in. in size they can destroy entire aircraft engines. This

particular problem had arisen after bubbles – and subsequently

cracks – had formed on the runway at Rostock-Laage Airport.

The damage meant that large sections of the 1.55-mile-long runway

had to be rehabilitated, and as quickly as possible to minimize the

disruption to flight operations.

Rostock

Deutschland

Xxxxxxx

Xxxxxxx

Xxxxxxx

BerlinXxxxxxx

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

RostockNorth Sea

Germany

France

Switzerland

Belgium

Netherlands

Austria

Poland

Czech Republic

Berlin

For a video on this project, please visit our website at:

www.voegele.info> News & Media > Mediathek

Technology InLine Pave

36 // site RepoRt

Job Site Details

Rehabilitation of the take-off and landing runway

at Rostock-Laage Airport, Germany

Length of section: 6,036 ft. 9 in.

Width of section: 169 ft. 11 in.

Paving Details

Paving width: 2 x 49 ft. 3 in.

2 x 24 ft. 7 in.

2 x 11 ft. 2 in.

Layer thickness: level regulating course 1.6 - 3.1 in.

binder course 2.4 in.

surface course 1 in.

Material

Binder course: AC 16 B S

Surface course: AC 11 D S

Equipment

4 WIRTGEN W 210 Large Milling Machines

2 VÖGELE InLine Pave Trains, comprising:

MT 1000-1 and MT 3000-2 Offset Material Feeders

SUPER 2100-2 IP Paver with AB 600 TP2 Plus

Extending Screed for the binder course

SUPER 1600-2 with AB 500 TV Extending Screed or

SUPER 1800-2 with AB 500 TP1 Extending Screed

for the surface course

4 HAMM HD+ 120 VO Rollers

Germany // Rostock

For grade and slope control, the two

pavers of the InLine Pave trains

laying the binder course were equipped

with two Big MultiPlex Skis.


The ideal solution: The InLine Pave process

“The compact asphalt pavement obtained using the InLine Pave

process looked like the ideal solution in this case,” explained

Bernd Kanscheit, an engineer at the engineering consulting firm

Mecklenburgisches Ingenieurbüro für Verkehrsbau, Germany.

“First, InLine Pave gives you an excellent bond between layers,

which prevents bubbles from forming. Second, the InLine Pave

surface is very dense and low in voids, meaning neither water

nor de-icing agents can cause damage. Third, we benefit from

the very high compaction of the binder course in the InLine Pave

process, which is higher than in conventional paving. That’s

particularly important to us here. After all, the characteristic load

profile of the take-off and landing runway means we cannot expect

post-compaction by vehicles.” Read more about VÖGELE’s High

Compaction Technology on page 41.

In addition to the requirements on the asphalt, organizational

aspects also made InLine Pave an ideal choice. For one thing, the

binder and surface courses could be placed rapidly in one pass.

On the other hand, the pavement was going to be rehabilitated in

potentially cool fall weather. In the InLine Pave process, however,

the asphalt stores a great deal of heat, ensuring both correct

compaction and slow cooling even at lower temperatures.

Material Feeder

MT 1000-1

SUPER 2100-2 IP

for the Binder Course

Extending Screed

AB 600 TP2 Plus

SUPER 1800-2

for the Surface Course

Extending Screed

AB 500 TP1

Kemna was already working “hot-to-hot” with the VÖGELE pavers.

A quasi-jointless strip with a width of approximately 49 ft. 3 in.

was laid on both sides, starting from the middle.

InLine Pave permits a thinner surface course

On top of the very even, level regulating layer, the InLine Pave

train then laid the binder course together with the surface course

in a constant thickness. Unlike the previous pavement structure,

the new surfacing is only 1 in. thick instead of 1.6 in. “We based

our calculations for the surface course on the requirements of

the German terms and guidelines for the construction of asphalt

roadways (ZTV Asphalt StB). The airport operators were absolutely

delighted with the savings this delivered in terms of surface course

material,” Kanscheit explained.

113,979 square yards in ten days

Once the go-ahead was given, the road construction contractor had

ten days in which to mill off the 1,025,800-sq. ft. center portion

of the take-off and landing runway, place the asphalt pavement

with a new profile, apply all the required markings and clean the

whole surface. Flights at the airport, which is for both military and

civilian use, were suspended during this period.

Before the pavers could get started, four WIRTGEN W 210 Large

Milling Machines removed the asphalt. The Kemna crew began

placing a level regulating layer of asphaltic concrete while the milling

work was still going on. Using two VÖGELE SUPER 2100-2 pavers,

they placed a layer 1.6 - 3.1 in. thick that guarantees water drainage

with a slope of 1.5% to each side. The grade and slope control was

carried out in the longitudinal direction by tracing tensioned wires.

38 // site RepoRt

Material Feeder

MT 3000-2 Offset

SUPER 2100-2 IP

for the Binder Course

Extending Screed

AB 600 TP2 Plus

SUPER 1600-2

for the Surface Course

Extending Screed

AB 500 TV


Thumbs up!

Bernd Hollerbaum (l.)

and Sven Albrecht (r.)

of the Kemna team were

delighted with the superb

paving quality.

Technology

InLine Pave

Minimizing the costs of future maintenance operations was also

the reason for another technical requirement set by the airport

operators: The landing runway was to have no longitudinal joint for

32 ft. 10 in. to the right and left of the middle, “because experience

has shown that the intervals between maintenance operations are

the longest then,” said Kanscheit. To meet this demand, he invited

bids to be made on the compact asphalt pavement in combination

with “hot-to-hot” paving.

An impressive premiere

Kemna completed the paving work with two InLine Pave trains in

just three days. On the first day the crews, each consisting of two

pavers and a material feeder, worked in parallel on the outside edges

of the landing runway, with each laying a 24 ft 7 in.-wide strip.

The second day saw the premiere, when the binder and surface

Ideal for airport projects:

High degrees of density are achieved

with InLine Pave.

courses were placed “hot-on-hot and hot-to-hot” with VÖGELE

InLine Pave. A 49 ft. 3 in.-wide compact asphalt pavement was

thus created in a single pass from the middle – an impressive sight

that was followed enthusiastically by everyone involved. On the

third day, the final asphalt strip, 49 ft. 3 in. wide, was laid on the

opposite side in the same procedure.

19,500 tons in three days

The changes in the paving widths of the screeds did not present

any problem, because VÖGELE equips its InLine Pave trains with

extending screeds. Anything between a paving width of

9 ft. 10 in. and 27 ft. 11 in. is possible. The screeds are extended

and retracted hydraulically, which enabled the Kemna team to lay

6,503 tons of asphalt on each of three successive working days

while meeting the high quality requirements of the customer.

40 // site RepoRt

The AB 600 High Compaction Screed in the TP2 Plus version

is ideal for the special requirements of “hot-on-hot” paving.

It features such a high compacting force that, depending on

the mix used, it can achieve extremely high degrees of density.

The density of the binder course is so high that the paver laying

the surface course (weighing some 44 tons including mix and

extra material hopper) can travel on the freshly paved and still

warm binder course without leaving any noteworthy traces.

Extras for a definite “plus” in compaction

The tamper, the first compacting system in the screed, has a

decisive impact on the compaction result. It packs the material

under the screed and ensures that it is effectively precompacted.

The tamper on the AB 600 TP2 Plus has also been specifically

modified to boost the compacting performance. For instance,

the geometry of the tamper bar was optimized and the

maximum stroke length increased from 0.28 in. to 0.35 in.

Pulsed-flow hydraulics for the highest degrees of density

The pressure bars, operated by pulsed-flow hydraulics, represent

the heart of the VÖGELE High Compaction Technology

installed in the AB 600 TP2 Plus. A so-called “pulse generator”

produces high-frequency pressure pulses.

As a result, the pressure bars are in constant contact with the

pavement. The thicker the layer and the more difficult the

mix is to compress, the higher the pressure that needs to be

exerted by the pressure bars. The pressure is infinitely variable

between 581 psi and 1,744 psi.

To be able to transfer the high compacting energy of both the

tamper and the pressure bars into the paving material, the

mass of the AB 600 TP2 Plus has been increased with additional

weights.

Conclusion:

The AB 600 TP2 Plus is ideal for all applications where the

highest degrees of density need to be achieved right behind

the paver.

High Compaction Screed AB 600 TP2 Plus

AB 600 TP2 Plus

Depending on the material placed, the AB 600 Extending

Screed in the TP2 Plus version yields density values of

over 98% with its special tamper and two pressure bars.

T = tamper, P1 = pressure bar 1, P2 = pressure bar 2

T P1 P2

Rehabilitation of aiRpoRt Runway with Vögele inline paVe Method // 41

The material feeder alternately transfers

materials for binder course and surface course

to the two pavers.

42 // site RepoRt

“The ‘hot-to-hot’ joint is as good as invisible,” said a delighted

Torben Eymer, engineer and Site Manager. Planner Kanscheit

added: “Samples show that there are no structural irregularities in

the binder at the joint. And that’s exactly what’s required.”

PowerFeeder MT 3000-2 Offset

Apart from “hot-to-hot” paving with the InLine Pave trains,

there was another highlight to marvel at on the job site:

The PowerFeeder MT 3000-2 Offset from VÖGELE ensured that

both pavers were kept permanently fed with material. At a paving

speed of around 13 ft./min. and a paving width of 24 ft. 7 in.,

the material feeder delivered some 441t/h of asphalt to the pavers,

including 309 tons for the binder course and 132 tons for the

surface course. This performance made a lasting impression.

The ErgoPlus operator’s stand,

which can be swung out

beyond the width of the paver,

provided the best view of the whole site.

The material feeder also demonstrated its superiority when it came

to laying the 11 ft. 2 in.-wide – or should that be narrow – shoulder.

“If the mix had been delivered directly by a feed vehicle, the existing

pavement edge up to the shoulder would certainly have sustained

damage. Thanks to the pivoting conveyor though, the feed vehicles

were able to drive alongside. Not only did that enhance our quality,

it also made us considerably quicker,” said Site Manager Eymer in

praise of the benefits of the offset material feeder from VÖGELE.

On schedule

Kemna was able to wrap up the job on schedule just ten days after

getting started. “We thought of everything. The whole job went

according to plan,” a satisfied Torben Eymer concluded. After this

premiere with a 49 ft. 3 in.-wide strip paved by the InLine Pave train,

he was confident of one thing:

“This technology has a great future, especially for large projects.” •


2370

244

US/

03.1

5/U

S

® ERGOPLUS, InLine Pave, NAVITRONIC, NAVITRONIC Basic, NAVITRONIC Plus, NIVELTRONIC, NIVELTRONIC Plus, RoadScan, SprayJet, VÖGELE and VÖGELE PowerFeeder are

registered Community Trademarks of JOSEPH VÖGELE AG, Ludwigshafen/Rhein, Germany. PCC is a registered German Trademark of JOSEPH VÖGELE AG, Ludwigshafen/Rhein,

Germany. ERGOPLUS, NAVITRONIC Plus, NAVITRONIC BASIC, NIVELTRONIC Plus, SprayJet, VISION, VÖGELE and VÖGELE PowerFeeder are trademarks registered in the

US Patent and Trademark Office to JOSEPH VÖGELE AG, Ludwigshafen/Rhein, Germany. Legally binding claims cannot be derived from written information or pictures

contained in this brochure. Pictures may include optional extras. We reserve the right of technical or design alterations.

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

VÖGELE on the Web The latest information on VÖGELE products and technologies is available online.Visit us at www.voegele.info, www.wirtgenamerica.com, www.wirtgen-aust.com.au or www.wirtgen.co.nz.

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