ALEXANDRIA UNIVERSITY

FACULTY OF ENGINEERING

PAVER MACHINES

A Report
Submitted to the Management Department
Faculty of Engineering – Alexandria University
Course Title: Project 1
Prof.Dr. Sherif Hafez

By:

Kholoud El-Shennawy

Undergraduate

2023
 Contents

List of Figures ...................................................................................................................I

List of Tables .................................................................................................................. II

List of Abbreviation ......................................................................................................IV

1 | Abstract ................................................................................................................... 1

2 | Introduction ............................................................................................................ 1

3 |TYPES OF PAVER MACHINES ......................................................................... 2

3.1. Classification According to Material .............................................................................. 2
3.2. Classification According to Means of Power ................................................................. 3
3.3. Classification According to Functionality ...................................................................... 3

4 | TECHNICAL ASPECTS ...................................................................................... 5

4.1. Components .................................................................................................................... 6

a) Components of the material feeder system ............................................................ 6

b) Components of the material laying system ....................................................... 7

4.2. Operation System ........................................................................................................... 9
4.3. Operating Console .......................................................................................................... 9
4.4. Capacities ..................................................................................................................... 10
4.5. Functions and Methods ................................................................................................. 11

5 | Advantages and Disadvantages........................................................................... 12

6 | Case Study .......................................................................................................... 13

“Volvo P4370B paver’s productivity helps complete Maharashtra Road in record

time” ............................................................................................................................... 13

7 | Hazards and Precaution .................................................................................... 13

8 | Cost ...................................................................................................................... 15

9 | Conclusion........................................................................................................... 16

10 | List of References .......................................................................................... 17

List of Figures

Figure 1: Asphalt paver machine ...................................................................................... 6

Figure 2: PCC paver machine ........................................................................................... 7

Figure3: Tracked paver......................................................................................................7

Figure 4: Wheeled paver....................................................................................................8

Figure 5: Roller screed paver ………………………………………………………..…..8

Figure 6: Hybrid offset paver………………………………………………………..…..9

Figure 7: Inset paver.......................................................................................................... 9

Figure 8: Paver machine components ............................................................................. 10

Figure 9: Push roller and truck hitch...............................................................................10

Figure 10: Hopper............................................................................................................11

Figure 11: Screed …………………………………………………………………..…..12

Figure 12: Depth crank and sreed arm…………………………………….………..…..12

Figure 13: Operating system of paver ............................................................................. 13

Figure 14: Console .......................................................................................................... 14

Figure 15: Road from Aurangabad to Dhule, west of India............................................17

Figure 16: Paver machine of the incident........................................................................19

I
List of Abbreviation

HMA: Hot mix Asphalt

AC: Asphalt concrete

PCC: Portland cement concrete

GNSS: Global Navigation Satellite System

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1 | Abstract
Roads are the fundamental base of the cities, connecting routes, people, and structures
together. Whether it is for transportation of vehicles, foot traffic, or protecting the
underlying surface, paving is a crucial part of construction. To achieve high-quality
pavements, paver machines are necessary to ensure safe roads for vehicles, and people,
and less traffic; Moreover, provide protection of infrastructure systems, and the
surrounding structures. This smooth & reliable construction is completed with the help of
using various road construction equipment including; Equipment like the paver machine.
In order to achieve high efficiency and durability in a project, the right type of paver
machine and the right material is important.

2 | Introduction
The modern system of road and building machines is a complex of high-performance
machines and mechanisms, of large and small capacity and productivity. Expansion of
paved roads network of use, increasing of pace and quality of work, ensuring reliability
and durability of highways have a major impact on the development of road construction
machinery. Thus, the scope of the report is to understand more about paver machines, its
function, components, and types to choose the right equipment for the project. Touching
on other important aspects; such as efficiency, cost, and safety hazards to ensure a well-
informed decision.
Paver Machine was first introduced by Barber-Greene in 1934, a self-propelled formless
laydown machine with a floating screed. Regardless of the evolving technologies, the
basic concept of the asphalt paver has remained relatively unchanged; The material,
which is often hot mixed asphalt (HMA), is loaded in the front, carried to the rear by a
set of flight feeders (conveyor belts), spread out by a set of augers, then leveled and
compacted by a screed. This set of functions can be divided into two main systems: The
tractor, and the screed.
The purpose of the paver machine is to lay asphalt flat on ground (e.g. roads, bridges, car
parks, etc.) and provide minor compaction before it is compacted with a roller. As well
as, the repairing of existing roads with the help of other equipment. Resulting in smooth
and safe roads, devoid of defects such as; potholes and road cracks.
Road construction industries, nowadays want an equipment that can deliver high quality
asphalt processing & laying systems. The paver equipment is a road equipment that has
various technical & non-technical aspects that can match the criteria of road construction
sectors. On the other hand, the paver machine has other benefits like automatic shutdown,
screen controlling system, etc., which can be used to develop infrastructure of roads,
footpaths and other pathways.
There are multiple factors why the need and demand for paver machines is increasing,
including; the urgent need for efficient and durable construction of roads due to the rapid
development of new routes and cities, the revival of old roads as a part of heritage
preservation, the increasing traffic, which accordingly increases the problems in existing
roads. This high demand highlights the importance of the equipment.
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3 |TYPES OF PAVER MACHINES
The two main types of asphalt paver machines are wheeled and tracked. Wheeled pavers
are more commonly used in urban areas and have better turning capabilities, while tracked
pavers are great for working on uneven surfaces and larger projects. However, there are
other classifications and variants of the paver machine. They can be classified according
to the material used, means of power, and functionality.

3.1. Classification According to Material

A paver often uses two types of materials in paving the roads which differ in their
properties however the application remains the same. Those two materials are asphalt
concrete (AC) and Portland cement concrete (PCC).
a) Asphalt Concrete: It is a composite of bitumen, cement, water, and aggregates.
Asphalt concrete has many different variants, examples are: (i) hot mix asphalt
(HMA), (ii) warm mix asphalt, (iii) cold mix asphalt, (iv) plant mix, (v)
bituminous mix, and (vi) bituminous concrete.

The most common type in paving is the HMA for the following reasons; its high
durability unlike the cold mix asphalt, hot mix asphalt allows the aggregate to
bind stronger, making the finished product more durable, it can withstand
environmental conditions such; as heavy rain, floods, and snow, it is cost efficient,
its rapid cool down, and its flexibility prevents premature cracking.

This works great for pavements with heavy traffic like roads and parking lots.

Figure 1: Asphalt Paver Machine

b) Portland Cement Concrete: It is a composite material that is composed of cement,

water, and aggregates (sand, gravel or crushed stone). When mixed together, they
form concrete, which is then used as a building material on construction sites.

It is often used in the construction of heavy loads roads; such as highways,

runways, and other transportation infrastructure.

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 Figure 2: PCC Paver Machine

3.2. Classification According to Means of Power

Modern asphalt pavers come in both diesel and electric variations. Diesel machines are
more powerful and commonly used for larger projects, while electric machines have
become more popular for smaller projects in residential areas as they produce no
emissions.

3.3. Classification According to Functionality

a) Tracked Paver: As of the name, this type uses tracks wheels which provides
dependable maneuvering, extra stability, and enhanced traction due to the high
static friction of the replaceable rubber tracks. It is ideal for steep hills or
mountainside applications, as well as uneven grounds. It is most commonly used
for large projects.

Figure 3: Tracked paver

b) Wheeled Paver: It is designed with six wheels and are ideal for mid-range paving
widths. The large back wheels deliver the majority of power. The rear set of front
wheels provide additional drive assistance and steering. Thus, they are more
commonly used in urban areas and have better turning capabilities.

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 Figure 4: Wheeled paver

c) Roller Screed Paver: It uses electrically-heated roller screed plates and variable-
width adjustments to minimize handwork. It provides a perfect finish due to its
smooth cylindrical screed.

Figure 5: Roller screed paver

d) Hybrid Offset Paver: It is specialized construction equipment used to create

smooth and precise concrete surfaces. These machines automate the process of
pouring and shaping concrete, ensuring uniformity and accuracy in the final
surface. As the machine moves forward, it continuously pours concrete onto the
ground and uses adjustable forms to shape and mold the concrete into the desired
dimensions. It is based on GNSS (Global Navigation Satellite System), which
creates side curbs, bicycle lanes, and road islands.

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 Figure 6: Hybrid offset paver

e) Inset Paver: It is used for large widths up to 8 meters, it operates as follows; the
asphalt concrete truck unloads the material in front of the machine, then it spreads
the concrete over the full paving width with its auger or spreading plough and
forms the concrete profile for the roadway with the slipform mold. HF vibrators
inside the slipform vibrate at high frequency, expelling air from the concrete and
hence compacting it.

Figure 7: Inset paver

4 | TECHNICAL ASPECTS
In order to understand the machine more and be able to choose the right type of machine
for the project, it is important to know its components, operation system, operating
controller, and the various functions of the machine.

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4.1. Components
The components of the paver machine are divided according to their function into two
main functional systems: The material feeder system and the material laying system.

Figure 8: Paver Machine components

a) Components of the material feeder system

• Tractor: The tractor is one of the main parts of the machine that contains the
whole components of the system that carries out the feeding of the material
into the paver machine.
• Push Roller and Truck Hitch: Starting with two of the smallest parts but yet
important; the push roller is the part which contacts the loader truck, while the
truck hitch is a handle that connects the loader truck to the paver.

Figure 9: Push roller and truck hitch

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 • Hopper: It is the container of the HMA loaded by the loader truck which
carries it temporarily and passes it through the conveyor to the rear of the
machine. The hopper can be folded up to force the material to the middle and
into the conveyor. Additionally, the hoppers can be provided with inserts for
increasing the capacity of the machine, especially when it is to be supplied
with asphalt materials by a material transfer vehicle.

Figure 10: Hopper

• Conveyor: It is a belt made of rubber or metal that carries the HMA from the
hopper to the augers. It is either controlled manually (by variable speed or by
flow gates) or controlled automatically by feed control system.
• Auger: It is a spiral-shaped tool that receives the HMA from the conveyor
spreads it out evenly over the width of the paver. There is one auger for each
side of the paver and they can be operated independently. Some pavers allow
the augers to be operated in reverse direction so that one can be operated
forward and the other in reverse to send all the received HMA to one side of
the paver. The auger gearbox can either be located in the middle or on the
outside edge of each auger.

b) Components of the material laying system

• Screed: The self-leveling screed is the most crucial part of the machine. It
receives the HMA from the material feeder system, determines the profile and
thickness of the layer, lays it out, and provides initial mat compaction.

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 Figure 11: Screed

• Screed plate: The flat bottom portion of the screed assembly that flattens and
compresses the HMA.
• Strike-off plate: The vertical plate just above the leading edge of the screed
used to strike off excess HMA and protect the screed’s leading edge from
excessive wear.
• Screed arms: It is the long arm that connects the screed to the tractor.
• Depth crank: The manual control device used to set screed angle and
ultimately, mat thickness.

Figure 12: Depth crank and screed arm

• Screed heater: Heaters used to preheat the screed to HMA temperature. To

avoid the HMA to come in contact with a cold screed and cause mat tearing.
• Screed vibrator: Device located within the screed used to increase the screed’s
compacting effort.
• Screed extensions: Fixed or adjustable additions to the screed to increase its
width.

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 4.2. Operation System
To begin a road construction project, initially, the paver machine is positioned on the spot
that needs to be paved, then the operator turns a switch to start heating the screed to the
desired temperature. Then, the loader truck loaded with HMA is attached to the tractor
by the truck hitch and starts to unload the HMA into the hopper. The paver feed sensors
monitor the head of the material and the conveyor is turned on to transfer the HMA from
the hopper to the augers.
The role of the auger equipment is to pass the stockpile of the concrete to the screed. After
the material is transferred to the screed unit, the material is spread in the certain area of
road construction. In order to lay a smooth asphalt, the road paving equipment also has
an automated screening system & screed controlling unit. The role of the parts is to
automatically control the asphalt laying & processing system, and the screed controlling
unit allows the machine to lay the stockpile of material without any physical help
required.

Figure 13: Operating system of the paver

4.3. Operating Console

There are different types of consoles, however, they mainly share the same controllers. It
is important to hire someone who is familiar with the operating console to minimize any
defects or errors in the process.

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 Figure 14: Console

A) Pavers are equipped with a lighting system for travelling on public roads. The
push-buttons for the direction indicators, warning lights, dipped beams and full
beams are clearly arranged side-by-side on the console.
B) Vital information is shown on menu level 1. Further paver functions such as
speeds of tamper and vibrators or feed rate of the augers can easily be set up via
the display, too. And the display gives access to machine-related information such
as fuel consumption or service hours.
C) This function group includes the controls for the material hopper, the steering and
the diesel engine. Various options are also operated from here.
D) All controls for the screed are grouped at the center of the paver operator's console.
E) All controls for the conveyor and auger are located here. The traction main switch,
the operating mode selector and the setpoint adjuster for the pave speed are also
included in this function group.

4.4. Capacities
Paver machines of different capacities for various infrastructure construction:
a) For large-scale projects

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 The machine models that offer paving widths between 2.5 meters and 7.5 meters, has
a laying capacity of 500-1000 tons/hr and a hopper capacity of 8.5 cubic meter. It has
a productivity of 2500-5000 tons a day.
b) For medium and large-scale projects
The machine models that offer paving widths between 2.5 meters and 5.5 meters, has
a laying capacity between 300 tons/hr and a hopper capacity of 4.25 cubic meter. It
has a productivity of 1,200-1,800 tons a day.
c) small-sized projects in confined conditions
The machine models that offer paving widths between 2.5 meters and 4.5meters, has
a laying capacity between 100-150 tons/hr and a hopper capacity of 4.25 cubic meter.
It has a productivity of 500-600 tons a day.

4.5. Functions and Methods

The modern road construction requires durability and productivity, The paver machine,
with its various types and capacities as listed above, provides smooth roads, bridges,
parking lots of asphalt concrete or cement concrete with very minimal human interaction.
Consequently, this road equipment can be a budget efficient & less labor workload
provider equipment.
The equipment is used in a wide range of projects including: constructing highways,
roads, and expressways due to their ability to produce durable and smooth pavements that
can withstand heavy traffic loads, constructing Airports runways that require robust and
reliable pavements to support aircraft landings and takeoffs, constructing industrial areas,
logistics hubs, and ports to facilitate the movement of heavy equipment and cargo,
constructing urban infrastructure, creating sidewalks, bike lanes, and pedestrian-friendly
areas.
As mentioned, paver machines are most commonly used for constructing new roads;
however, it can also be used for repairing existing roads. Potholes are one of the major
problems that can be solved with the help of using a road paver machine. Potholes are a
big issue on roads that can be evolved due to heavy rain or chances of any other mishaps
on the roads. The paver equipment has the ability to cover up the potholes by laying a
strong layer of asphalt on it. Once the material of concrete, cement, clay or any other
material is filled in the equipment, it can lay a smooth & flat layer of asphalt.
Another major problem that can be solved with the paver equipment is the road cracks.
The road paver equipment can be a beneficial equipment that can fill the cracks of roads.
While constructing with this equipment, some methods have to be followed to ensure a
flawless finish. HMA must be delivered to maintain a relatively constant head of material
in front of the screed. This involves maintaining a minimum amount of HMA in the
hopper, regulating HMA feed rate by controlling conveyor/auger speed and flow gate
openings, and maintaining a constant paving speed.
The hopper should never be allowed to empty during paving. This results in the leftover
cold, large aggregate in the hopper sliding onto the conveyor in a concentrated mass and

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then being placed on the mat without mixing with any hot or fine aggregate. This can
produce aggregate segregation or temperature differentials, which will cause isolated low
mat densities.
Also, an inadequate amount of HMA must be distributed under a middle-located gearbox
so it won’t result in a thin longitudinal strip of mat aligned with the gearbox that exhibits
lower densities from aggregate segregation and/or temperature differentials

5 | Advantages and Disadvantages

Advantages of the paver machine:

• Saves time and labor: This equipment speeds up the construction process,
allowing for the rapid completion of large-scale projects. It requires minimal
labor saving more time and human resources.
• Uniform pavement quality: The machine produces and maintains an excellent
pavement thickness, smoothness, and surface finish due to its precise control.
• Enhanced Precision: Concrete paving machines use advanced technology and
automation to ensure precise alignment and leveling, minimizing the need for
corrective work.
• Cost-Effectiveness: Despite their initial investment, concrete paving machine
proves cost-effective in the long run due to increased productivity and reduced
maintenance needs.
• Versatility: Concrete paver machines can handle various pavement widths,
forms (slip form pavers), and thickness, making them suitable for various
projects.

Disadvantages of the paver machine:

• High initial cost: The biggest disadvantage of these machines is their high
cost. Since high technology is needed during production, its price can be
expensive compared to many other construction equipment.
• Limited maneuvering: It is hard to use for large-capacity jobs. Because the
maneuverability of the machine is hard due to its size.
• High maintenance and repair cost: Pavers can be difficult to maintain and
repair. Since the machine has many parts, it should be maintained by a
specialist technician.
• Need of expertise: These machines are bulky and difficult to use, demanding
for a labor with expertise.
• Storage: It needs a spacious storage to be stored in.

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6 | Case Study
“Volvo P4370B paver’s productivity helps complete
Maharashtra Road in record time”
In four months, the Volvo paver helped Indian construction contractor Deshmukh & Co.
finish a 130 km road from Aurangabad to Dhule in western India. Manufactured at
Volvo’s plant in Bangalore, the P4370B wheeled sensor paver has a basic width of 2.5 m,
a rated power of 88 kW and a paving output of 600 t/h. The wheeled sensor paver features
intelligent operating technology that helps the machine meet three requirements in line
with highway design: mat thickness, mat level and grade requirement. The company says
the P4370B’s productivity makes it a standout performer.
“We average 5 km a day with the Volvo P4370B paver,” Deshmukh said. “While the
P4370B delivers quick work, it doesn’t compromise on quality either. Every road is
finished smoothly, consistently and flawlessly.”

Figure 15: Road from Aurangabad to Dhule in western India.

7 | Hazards and Precaution

“Paver machine operator is the 5th most dangerous job in the US. according to a recent
study by the small business experts at AdvisorSmith.”
Considering this study, knowledge about the dangers that face workers on the
construction site can help in preventing accidents, injuries, and encourage implementing
precautions to protect the human life.
a) A list of different hazards related to the paver machine, accompanied with
the needed precautions to avoid danger

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 • Traffic hazards: Paver machine construct roads which makes traffic crashes
the primary cause of death for paving professionals, implementing an effective
traffic safety program is key for reducing occupational injury. Make sure that
your work zone has highly visible signs and barricades to clearly signal to the
traveling public to drive cautiously.
• Dangerous zones: The paving machine itself poses as the most dangerous
hazard due to its bulkiness and heavy weight. The zones around and between
paving equipment can be very dangerous for paving operators and their teams,
especially the zone between the tractor and the loading truck.
• Fire hazards: Cutting and grinding asphalt produces a lot of heat,
consequently, quipping units with fire-suppression systems is crucial due to
the nature of hot asphalt materials alongside hydraulic hoses, rubber drive
belts, and tires.
• Equipment surfaces hazards: When getting on and off paving equipment,
make sure that the machine floor and stairs are clear of slip hazards, to prevent
workers from slipping under the machine.
• HMA hazards: Hot mix asphalt can burn the skin if it directly contacted the
skin, as well as the fumes that is produced while heating. For those reasons,
safety clothes are required to keep the skin safe, and reduce any health risks.
• Heatstroke: The hot mix asphalt and the machine produces so much heat,
along side with the sun exposure, workers are at risk of heatstroke if they’re
not well protected from the sun, hydrated, and cooled down.
• Down equipment hazards: A down piece of equipment on a paving operation
is a safety hazard itself. Sound maintenance can keep equipment and
associated operators and workers from injuries.
• Machine hazards: Make sure no one is near an operating auger or conveyor or
climb into the hopper when the engine is running.

b) Case study: Asphalt machine runs over and kills worker, Iowa.

In the summer of 1996, a 35-year-old construction worker, who had been on the job only
four days, died after being run over by an asphalt road-widening machine when it ran
backwards over him. The man was part of a 9-man crew who were widening a state
highway. The victim’s job was to walk to the side and rear of the road widener, visually
adjusting the machine’s side-mounted spreader arm. The road-widening crew normally
lays down two layers of asphalt: the machine moves slowly forward applying the first
layer, then must back up to lay the second layer. After the first layer was applied, the
victim apparently jumped on the machine as it was backing up, slipped off and was run
over by the right front tire. Fresh asphalt on the bottom of his boots may have contributed
to his fall. The machine weighed 40 tons and amputated his left leg and injured his
hemipelvis. The man was flown to a regional hospital and had major complications of
significant internal bleeding and cardiac arrest, and died nine days later.

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 Figure 16: Paver machine of the incident

8 | Cost
Analyzing the cost and the profit of any project is a crucial step. And because the
equipment used for construction make a huge impact on the total cost of the project, it is
important to breakdown the prices of the paver machine for road construction projects.
a) A cost breakdown for the paver machine as follows:

Equipment cost (Average sized paver machine):

48,000-86,000 US$ / Piece for the following equipment specification; 600t/hr.
Productivity Capacity, for widths 2.5m-7.5m.
Operating cost:

• Repair and maintenance: 4200 usd/month

• Labor wages: 2400 usd/month
• Fuel consumption: 3200 usd/month (20 usd for 22 lit/hr.)

Owning cost:

• Equipment cost: 60000 usd

• Storage rental: 600 usd/month
• Taxes: 20% of the equipment cost

b) Case study: Project U.S. Highway 14 Concrete Paving, Near Waseca,

Minnesota.

• The paver machine was used for paving a 30 km road in 22 days with 13
workers.
• Machine productivity: 1450 meters/day

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 • Unit cost to pave: 2.4 usd/sq meter
• Total cost: $923,800

9 | Conclusion
Furthermore, paver machines are designed to provide precision and accuracy in the
laying of asphalt or concrete. They are equipped with advanced technology that allows
for the adjustment of the thickness and width of the pavement, ensuring that the final
product meets the required specifications. This level of precision is crucial in ensuring
that the pavement is durable and can withstand heavy traffic and adverse weather
conditions.

Moreover, paver machines are highly efficient and can cover large areas in a short
amount of time. This reduces the time and labor required for construction, making it a
cost-effective option for contractors and project managers. Additionally, paver
machines are designed to minimize the environmental impact of construction by
reducing emissions and noise pollution.

In conclusion, paver machines are an essential tool for the construction industry. They
provide precision, efficiency, and cost-effectiveness in the construction of high-quality
pavements and roads. Understanding the different types and functionalities of paver
machines is crucial in choosing the right equipment for a project, ensuring that the final
product meets the required specifications and standards.

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10 | List of References
The University of Iowa report to Director, National Institute for Occupational Safety
and Health.

Pavement Interactive: https://pavementinteractive.org/

Whole Building Design Guide: https://www.wbdg.org/

ConstroFacilitator: https://constrofacilitator.com/

Volvo Construction Equipment: https://www.volvoce.com/

Construction Equipment for paver operators: https://www.constructionequipment.com/

Made in China: https://hl-industry.en.made-in-china.com/

C.S. McCrossan Paving Division

Wirtgen Group: https://www.wirtgen-group.com/

Unipave: https://www.unipaveindia.com/

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