Operaciones de Pavimentacion VOGOLE

Michigan 56th Annual Asphalt Paving Conference
Agenda: Paver Operations
What does it take to pave durable, long-lasting, smooth roads.
1. Principles of the Free Floating Screed

Forces Acting on the Screed
Issues Affecting the Forces that Impacts Smoothness & Density
2. Screed Adjustments Impacting Angle of Attack

Extension screed, Strikeoff, tow point position
Pulling off The Joint
3. Segregation
Typical Locations, Causes & Solutions
Principles of the Free Floating Screed
Conventional Screed Compaction:
1. Extrusion Compaction - Due to Bull nose on screed plate
2. Gradient Compaction - Due to screed angle of attack
3. Vibration Compaction - Due to screed vibration system
0 Compaction at Leading Edge
Main
Screed Vibration Compaction
Screed
Max Compaction at
trailing edge
Extrusion Compaction Gradient Compaction

- Due to Bull Nose - Due to Angle of attack Mat Thickness
Conventional Screed Compaction – For a given Mix design:
Extrusion Gradient Vibration

Compaction Compaction Compaction
Occurs at the Bull Nose Occurs along the flat of the plate Vibration Compaction
Influence by: Due to Angle of attack Influenced by the following:
1. Main Strikeoff Adjustment Influenced by the following: 1. Frequency
1. Screed weight – By design 2. Amplitude – By design
2. Head of material
3. Tow point position
4. Extension screed Angle of attack
5. Extension screed Match Height
C T M FS
Review of Key Components of the Paver / Paving:

Review of Key Components of the Paver:
Tow Point Tow Arm Screed Arm

Cylinder (Leveling Arm)
Tractor
Thickness
control Screw
Pivot Point
Screed
Tow Point Equilibrium Mat Depth

(Pull Point) Angle of Attack
(5 Forces in Balance)
Increase or Decrease Mat Depth At Balance / Equilibrium
Mat Depth is Increase or Decrease by Changing the Screed Angle - (Angle of Attack)
1. Manually By using the Thickness Control Screw
2. Manually By using the Tow Point Jog Switch
3. Or Automatically using Grade & Slope Control Systems
Increase Angle - Increase Mat Depth Decrease Angle - Decrease Mat Depth
5 tow arm length for 100% reaction to a change in angle of Attack

1 st. Tow arm length – Approx 65%
5 th 4 th 3 rd 2 nd 1st
100 % 85 % 65 %
Make a change and wait for the screed to respond

For quick response – Over correct and monitor
Allow the screed to react before checking Mat Depth

Free Floating Screed

Averaging Ski: Mechanical Drag Beam

Single Sensor referencing off a Drag Beam
30’ to 40’ Beam flexes to average the Grade Contour
Averaging Ski: Non Contact Beam

3 to 4 Sensor referencing off the Grade / Contour
30’-50’ Beam available
5 Forces acting on the screed to Hold Mat Depth

- For a Given Tow Point Position & Screed Adjustment
- NOT by any Mechanical or Hydraulic Devise
At Equilibrium:
All Forces are in Balance
Constant Mat Depth is Maintained

The screed is free floating with an
Equilibrium Angle (Angle of Attack)
Change in any of the 5 Force cause the

screed to Rise or Fall
Issues Affecting the Forces:

a) Pull Force (P) – Maintain a constant Speed as Possible
Speeding up & Slowing Down - Disrupt the Equilibrium of Forces
Changes Resistance of the screed against the head of Material
Resulting in Change in mat thickness / Rough Ride
Speed
Dial & Display

a) Pull Force (P)
Maintain a Constant Paving Speed as possible
Plan the Job
Paving Speed should be based on:
Material delivery
Rolling Capabilities
Tonnage delivered = Tonnage Laid
Tonnage Laid = Paving Speed X Mat Width X Mat Thickness
Several charts available to assist in Calculation

Effect of Stopping and Starting
Settling Dents & Humps
Also be impacted by:
1. Automation Engaged When Stopped
2. Vibration Engaged when Stopped
3. Material cooling

Reducing Settling & Humps
- Use Screed Hold & Freeze when Available to Reduce Settling & Humps
- Operators - Disengage Neutral Lock and Start Moving Instantly

Effect of Stopping and Starting
Settling Dents & Humps Significantly impact Smoothness
IRI - International Ride Index (Inches / Mile)
MTV – Non Contact Continuous Paving


a) Pull Force (P)
Always ensure straight steering & smooth turns
Automatic
Ensures the screed is maintaining Consistent grade Turning /
Use steering guides or Auto Turning Radius if Available Radius

b) Head of Material (M)
Maintain a consistent even head of material, covering ½ auger shaft
Use Flow gates or Conveyor sensors

b) Head of Material (M)
Use Digital Display to monitor Material Delivery
Store Settings with Pave / Maneuver Mode
In case of Sensors failure use Back up Auto controls
ErgoPlus
Console
PPT
Video

c) Weight of the screed – (W)
A heavy screed is Less Reactive but more stable
Weight brings Rigidity & Ability to Maintain Adjustments

d) Reaction of Material Supporting the Screed – (R)
Mix Consistency / Design (Impact on the Mix Internal Frictional Resistance)
a) AC Content
b) Temperature Variation
c) Gradation Consistency
(All affected by Mix Design or Segregation – Will discuss later)


d) Friction or Shear Force (F)
1. Mix Consistence / Design

a) AC Content
b) Temperature Variation
c) Gradation Consistency
(All affected by Mix Design or Segregation – Will Discuss Later)
2. Screed Adjustments Impacting Angle of Attack:

a) Extension screed Angle of Attack (EIAA)
b) Vertical Position of extension screed
c) Strike-off adjustment
d) Screed Line of Pull
Screed Adjustments Impacting Angle of Attack
Extension Screed Angle of Attack C

- Always Relative to the Main Screed Angle of Attack
T
Main
Screed FS
Plane A
Plane B
Screed
Material Flowing Compaction
Under Screed (Angle of Attack) Mat Thickness
Extension Screed Angle of Attack vertical Adjust – Rear Mount

- Material Flowing Under all Screed Sections must Be Equal
Paving
Direction
A
A A
B
B B
Main LH & RH
Screed Extension
Amount of
material Flowing
Under Screeds Thickness
of Mat
Plane A
Plane B
Extension Screed Angle of Attack & Vertical Adjust – Front Mount Screed
9 EIAA - Ext. Independent Angle of Attack, Sets Leading Edges on the same plane
9 VA - Vertical Adjust, Sets the Trailing Edges on the same plane
9 Parallelism – Ensure VA is held at all paving width
Rotate
Amount of VA Main
material Flowing Screed
Under Screeds
Must be same
from End to End
Plane A
Plane B
EIAA
Extension Screed Angle of Attack & Vertical Adjust
Correct Angle of Attack & Vertical Adjust = Stabile Screed & Quality Mat
Screed Looking from Top
Surface of Mat….
Looking from Top
Cross Section of Mat

Extension Screed, EIAA Greater Than Main Screed Angle

9 The Result Is More compaction under the Extension & shadow at the Center
9 Inconstant Screed Compaction
Screed Looking from Top Main Ext.
Surface of
Mat…. Looking
from Top

Incorrect Vertical Adjust (VA)

Extension Screed Higher that the Main Screed
9 The Result Is Lines & Thicker Mat Under the Ext.
9 Inconsistent Screed Compaction
Screed Looking from Top
Surface of Main Ext.

Mat…. Looking
from Top

EIAA, VA & Parallelism Could Be Out of Alignment in Several Areas

9 Rigidity & Ability to make Easy Adjustment is Critical
Ext too High

Incorrect Angle
Ext too Low /

Hunting Good
Strike-off Adjustment
- Impact on Extrusion Compaction
See Manufacturer
Specifications for correct
Strike-off Adjustment
Too Low: Too High:

False Angle of Attack / Instability False Angle of Attack / Instability
Premature Wear on the Bull nose Premature Wear on the Bull nose
Line of Pull:
Tow point
Approximately
inline with
Pivot point
Pulling off the Joint:

1. Determine Thickness of Starting Blocks (1/4” / 1” for Roll Down)
2. Lower the screed on Starting Blocks
3. Pull Forward at least 1 ½” to take up slack at Tow Point
4. Lower Augers approx 2” above screed plate
5. Position tow Point (In line with Pivot Point of Screed)
6. Energies Screed Float Switch In Pave Mode (On Vogele Pavers)
7. Null Thickness Control Screw
8. Take up screw slack & add 2 to 3 turns up depending on screed
9. Fill Auger Chambers
Segregation
What is Segregation?
Larger Stones rolling away from Smaller on Sloped Surface
Causing Inconsistent Gradation
Change in Internal Frictional Resistance
Resulting in Roughness followed by Premature Failure
Sloping Surface
Larger Stones
Segregation
Created at Two Typical Location on the Paver

A. In the Paver Hopper
B. Delivering Mix from the Paver Tunnels to Screed (Paver Induced)
A) In the Hopper B) From the Tunnels to the Screed

Segregation
A - In the Paver Hopper – Root Causes
1. Improper Truck Exchange

At the start & End of Truck Dump 2. Running Hopper or Insert too Low
Segregation
A - In the Paver Hopper – Segregation Profile
Constant Hopper Dumping Running the Hopper Too Low

X – Chevron At the center Y – At the Center of the Tunnel
Y Y
X
Segregation
Running the Hopper Too Low:

Difference in Gradation may not be significant enough for Grade Change
However Premature Failure will Occur
- Weak Point due to Segregation
Segregation
At End of Load / Running the Hopper Too Low

Different Gradation leading to Change in Mat Thickness
Typical failure Point:
- Increase dynamic loading due to roughness
- Weak Point due to Segregation
Segregation
A. Segregation Created in the Paver Hopper

Joint Construction
How to Minimize Segregation in the Hopper:
1 Proper Truck Exchange – Refer to TAS 32 (Proper Truck Exchange)
NAPA - TAS 32
2 Material Indicators to prevent Hopper from getting too Low (Proper Truck Exchange)
3 Material Transfer Vehicle (MTV) – Will Discuss Later
1. 3.
2. 4.
Segregation

Segregation in Insert
Larger stones rolled to the insert wall
Sloping walls leads the segregated stones to the edge of the conveyor tunnel
The larger stones flow to the rear of the tunnels and out towards the bearing hanger
The segregated stones are placed as it reaches the bearing hanger
Segregation
in Insert
Segregation
B. Created when Feeding mix from Paver Tunnel to screed

Does not Typically cause Roughness
However it would lead to Premature Failure
Segregation
Root Causes
Streaks
A – Center Line, Under Auger Box
Difficulty in feeding under the auger box
Large stones gather to the center
B – At the edge of the Tunnel

Large stones roll farther as material leaves tunnel
C – At the Edge of Fenders / Main Screed

Under Auger bearing hanger
Edge of Tractor Fender
Edge of Main screed
D – At the End of the Material Roll

Material Natural flow to the End Gate
Segregation
Features that Reduces Segregation during this process
1 Automatic Conveyor Control Sensors

2 Automatic Auger Control Sensors
3 Auger Extensions beyond Bearing Hanger
4 Adjustable Pitch auger flights at Drive Box
5 Material Chutes under conveyor tunnels
Segregation
B. Created when Feeding mix from Paver Tunnel to screed:

Features That reduce Segregation during this Process
1. Automatic Conveyor Flow Control Sensors

Provides an even and consistent head of Material
reduces material drop height
Segregation

2. Automatic Auger Control
Always ensure continuous Auger rotation
Flush any segregated mix Under the auger box
Ensure that the Augers are ½ Covered
Segregation

3. Auger Extensions beyond bearing Hangers
Helps material movement & re-blending
Outer Tunnel
segregation
Segregation

4. Reverse flights next to the auger box
RH Reverse Flight Pushes center segregation to the LH
LH augers re-blend
(LH & RH Reverse flights / Kickers tucks segregated material to center)
¼ flights
Augers must Rotate Continuously to be Effective pushing
to center
Segregation

5. Material Chutes & Inclined Floor Plate

Allows the material to flow into the Augers for re-blending
Non-contact Continuous Paving
Proper Truck Exchange
NAPA - TAS 32 (Proper Truck Exchange)

Non-contact Continuous Paving
Material Transfer Vehicles
NAPA - TAS 36 (Use of MTV)

Questions
Thank You
Longitudinal Joint Construction
To Building a Sound Longitudinal Joint:
- Proper construction is critical to the performance of pavements.
- Joints should not open up and fail before the rest of the pavement.
Steps in Making Good a god Longitudinal Joints
1. Control Segregation at the Outside Edges of the Mat

2. Steer a Straight Line
3. Compact Unconfined Edge
4. Maintain Correct Overlap
5. Place the Proper Depth for Roll Down
6. Do Not Lute the Joint
7. Compact the Joint for Density
1. Move to the Endgates consistently

- Ensure that the augers are turning Continuously
Some State specify 18” to 24” From endgates
- Use Augers Extensions to Help move the material to the Endgates
- Use Tunnel Extensions to Confine material
2. Always Steer Straight
Would be difficult to have a proper overlap on a crooked Joint

3. Compact Unconfined Edge

- Keep Pneumatic tire 6” from Un-supported edge
Not
3 Recommended
Recommended
6”
4 & 5. Minimum Required Overlap for Compaction is 1/2 Inch (13mm)
If the Overlap is Correct

Little or No
Hand work in required
6. Do Not Lute Joint
Luting Moves Material

Away from the Joint
Resulting in Low Density

At the Joint
7. Compacting Longitudinal Joints
First Second
Pass Pass
Hot
6” to 8”
Automatic Grade & Slope
Popular Brands of Automatic Grade & Slope Systems:
Vogele Niveltronic MOBA Topcon / TSD

Automatic Grade Control:

A single grade control used to precisely follow Known References:
Reference a Joint – Joint Matcher
Reference a Curb
Reference a String Line
Reference off a Drag Reference Ski
(Non-Contact Ski uses multiple sensors)

Grade control Sensor Position:
- Position Approximately At the centerline of the Drive Wheel
- Usually better Mounted on The Endgates
- Same for Track & Wheel Pavers

- Non-contact – Sonic Grade Controls
Vogele & Vogele Niveltronic & MOBA Non Contact

Topcon
MOBA
18 – 22”

- Contact – Mechanical Grade Controls

Referencing off a Mechanical Drag Beam
- A Single Grade Sensor referencing off a Drag Beam
- A 30’ to 40’ Beam flexes to average the Contour / Grade
Non-Contact Ski with Multiple sensors

- Multiple Noncontact Sensors mounted on a Beam fully supported on the tow arm
- The Individual reading of each sensor is combined to provide an Average
- Beam could be up to 15 to 50’ Long
Mat Reference Ski - Last Sensor Swivels over Mat


Vogele, MOBA & Topcon Non Contact Ski
- Folds for easy Storing or Transport
Topcon / TSD MOBA & Vogele

4 sensors 3 Sensors
Automatic Slope Control:

- Slope is used to hold a desired angle Traverse to the direction being paved
- Slope is always a Slave to Grade
If Possible, avoid using slope when paving over 18’ wide
- Use two grade controls instead.
Though to control Yield When using Grade & Slope
Maintenance
Screed Inspection and Adjustments:

Extension Screed Independent Angle of Attack Adjustment – Front Mount Screed
Parallelism
Vertical Adjust ( Match Height), On the fly Operation
Use Vertical Adjust Switch to bring Trailing edge of Extension Screed to Touch Straight Edge
Use Angle of attack (EIAA) Screw to flat Extension Screed on the Straight Edge
Move Straight to Inside, Ext Screed should be flat with Straight Edge, If Not ??????????
Maintenance

Run Extension out and Observe the trailing of extension touching the straight Edge, If Not ??????
Parallelism Could be out
Slope could be out
Extension screed Base not Flat
See Manufacturers Adjustment Procedure
Maintenance

Extension Screed Angle of Attack Adjustment – Rear mount Screeds:
Same Straight Edge Procedure Except:
The Extension Screed Angle of Attack should already be Close to Flat
Maintenance
Feeder System Inspection and Service:

Auger Flight – Replace Broken, Missing or Worn Flights
Replace Missing Chutes under Conveyor
Ensure Flight Chains are properly adjusted or Use Auto Chain Tensioning
Ensure Feeder Bearings are properly greased or use Auto Lube
Ensure Engine Vitals Checked or use Auto Vital Checks
Questions
Thank You

Operaciones de Pavimentacion VOGOLE

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Operaciones de Pavimentacion VOGOLE

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Michigan 56th Annual Asphalt Paving Conference

Agenda: Paver Operations

What does it take to pave durable, long-lasting, smooth roads.

1. Principles of the Free Floating Screed

2. Screed Adjustments Impacting Angle of Attack

0 Compaction at Leading Edge

Extrusion Compaction Gradient Compaction

Conventional Screed Compaction – For a given Mix design:

Extrusion Gradient Vibration

Review of Key Components of the Paver / Paving:

Review of Key Components of the Paver:

Tow Point Tow Arm Screed Arm

Tow Point Equilibrium Mat Depth

Increase or Decrease Mat Depth At Balance / Equilibrium

5 tow arm length for 100% reaction to a change in angle of Attack

Make a change and wait for the screed to respond

Allow the screed to react before checking Mat Depth

Free Floating Screed

Averaging Ski: Mechanical Drag Beam

Averaging Ski: Non Contact Beam

5 Forces acting on the screed to Hold Mat Depth

Constant Mat Depth is Maintained

Change in any of the 5 Force cause the

Issues Affecting the Forces:

Issues Affecting the Forces:

Issues Affecting the Forces:

Issues Affecting the Forces:

Issues Affecting the Forces:

MTV – Non Contact Continuous Paving

Issues Affecting the Forces:

Issues Affecting the Forces:

Issues Affecting the Forces:

Issues Affecting the Forces:

Issues Affecting the Forces:

(All affected by Mix Design or Segregation – Will discuss later)

Issues Affecting the Forces:

1. Mix Consistence / Design

2. Screed Adjustments Impacting Angle of Attack:

Extension Screed Angle of Attack C

Extension Screed Angle of Attack vertical Adjust – Rear Mount

Extension Screed Angle of Attack & Vertical Adjust

Screed Looking from Top

Cross Section of Mat

Extension Screed, EIAA Greater Than Main Screed Angle

Screed Looking from Top Main Ext.

Cross Section of Mat

Incorrect Vertical Adjust (VA)

Screed Looking from Top

Surface of Main Ext.

Cross Section of Mat

EIAA, VA & Parallelism Could Be Out of Alignment in Several Areas

Ext too High

Ext too Low /

Too Low: Too High:

Pulling off the Joint:

Resulting in Roughness followed by Premature Failure

Created at Two Typical Location on the Paver

A) In the Hopper B) From the Tunnels to the Screed

A - In the Paver Hopper – Root Causes

1. Improper Truck Exchange

A - In the Paver Hopper – Segregation Profile

Constant Hopper Dumping Running the Hopper Too Low

A - In the Paver Hopper – Segregation Profile

Running the Hopper Too Low: