Advancing asphalt paving technology (World Highways)

 · 9 min read

Advancing asphalt paving technology

First publishedin World Highways
March 2016
Ammann paver
The new Ammann pavers meet the latest emissions requirements
Asphalt paver manufacturers are meeting demands for high performance machines that can deliver a quality mat - Mike Woof reports

Major manufacturers are rolling out ranges of new asphalt pavers designed to meet the latest emissions regulations for Europe, as well as developing models to suit customers in developing nations. The firms have designed many of the latest machines to meet tough new emissions legislation, although versions will also be available for less regulated markets also.

Ammann has updated both its wheeled and tracked paver models to be able to meet all emission regulations worldwide. A key launch is the compact AFW 150-2 mini paver, which suits duties in restricted spaces or for road repair work. This now features a 120mm diameter auger instead of the 100mm unit used on the earlier model, which is said to ensure proper material distribution along the screed. A new material flow sensor helps ensure consistency, while the hydraulically extendible screed operates in a similar fashion to those on larger pavers. The material flow divider is operated with hand levers and allows the operator to select whether material should be distributed on both sides, only one side or stopped completely. 

The firm’s wheeled AFW 350-2 and tracked T 350-2 also now meet the Tier 4 Interim requirements and the machines offer paving widths from 1.83-3.5m. 

Meanwhile the wheeled AFW 500-2 and tracked T 500-2 meet Tier 4 Final requirements and offer paving widths of 2.5-4.5m and 2.55-4.9m respectively.

Atlas Copco has made major upgrades right across its Dynapac paver range and these improvements help boost both paving quality and productivity, as well as operator comfort. A key advance is with paving technology and the Dynapac SD2500 and SD2550 paver models now offer better paving process control as well as increased output and better ergonomics. The new control features include the TruckAssist and SetAssist systems, as well as an upgraded operator panel with a new display. A major gain is for job site planning, follow-up and paving process optimisation, which is said to be simplified by coupling Atlas Copco’s Dyn@Link fleet management system with the BPO ASPHALT package.
Atlas Copco Dynapac SD1800 paver
The Atlas Copco Dynapac SD1800 pavers share sophisticated features with the firm's larger models
The TruckAssist system is intended to help material delivery by simplifying communications between the paver operator and truck driver. The SetAssist package reduces setting and transport times on the job site. The paver driver can save the position of the auger and screed before moving from one section to the next. Both of these systems are being offered on the SD2500/2550 pavers as well as on the SD1800.

Atlas Copco has made improvements to the screed design and also now includes data from optional screed width and layer thickness measurement systems in its paver operating system, PaveManager 2.0. Both systems integrate with the screed controllers and the main operator display.  And the firm now links the Dyn@Link fleet management system with BPO ASPHALT developed by German firm Volz Consulting. The BPO ASPHALT package is designed to help optimise construction processes and planning according to the firm. Paving parameters, including the screed width and layer thickness, can be transferred to Dyn@Link and exported for job site documentation or used by the BPO ASPHALT package. The system can also import data from Atlas Copco’s Dyn@Lyzer compaction control system and be linked to a truck fleet management and mixing plant systems.

Meanwhile high paving quality and productivity are claimed by Atlas Copco Dynapac for the new SD1800 Citypaver. The machine offers a capacity of 350tonnes/hour and can be used for paving widths from 0.7-4.7m, suiting it to use in urban road construction and repair work. The new machine benefits from the firm’s proven PaveManager 2.0 system, which optimises performance and can work with levelling equipment from MOBA.

Equipped with electro-hydraulic controls, the SD1800 is powered by an emissions compliant Deutz diesel delivering 54kW but with reduced fuel consumption compared to earlier models. 

The screeds feature proven designs first seen on the firm’s large pavers. The V3500 is said to be stable due to its robust dual-tube extension system. The new screed range is available with vibration only, or tamping and vibration pre-compaction systems, while heating can be electric or by gas.
BOMAG paving machine
BOMAG's new material feeder suits use in high capacity paving applications
At the smaller end if its range, BOMAG has upgraded its compact city paver, increasing output while reducing exhaust emissions and fuel consumption. A new engine meets the Tier 4 Interim/Stage IIIB emissions standard, while a Tier 3/Stage IIIA diesel can also be fitted for markets where low sulphur fuel is not available. Customers can also choose from wheeled or tracked variants. The Ecomode regulates the hydraulics, engine speed and ventilation as required, saving fuel and reducing noise. 

The BF 300-2 offers a throughput of 300tonnes/hour and the tracked version can pave widths of up to 5m, while the wheeled version can pave widths up to 4.4m. The paver is said to be suited to urban road projects, housing developments or parking areas, although it can also be used for rural road construction or highway shoulders.

The BF 300-2’s efficient screed heating is said to take just 20 minutes to achieve working temperatures. 

"The paver is said to be suited to urban road projects, housing developments or parking areas"

The pavers are offered with an optional hydraulic front flap, which makes emptying the hopper faster and easier. Options include a fumes removal system, as well as LED headlamps or balloon lighting.

BOMAG is also adding material feeders to its range. The new BMF 2500 feeders can help boost paving efficiency, productivity and quality by allowing a more homogenous flow of asphalt into the paver. These machines reduce the problems of asphalt segregation as well as cold spots forming in the mat. Using a BMF 2500, contractors can also boost output on large highway paving jobs.

The firm is introducing three different models, including a version with a medium-length fixed belt. A key feature of the new BMF 2500 is the high throughput of 4,000tonnes/hour. Its compact design and width of only 2.55m is narrow enough for transport without a special permit. And distance sensors allow the units to be operated automatically, including following a stringline. 
Volvo CE paving machine
Volvo CE is now offering pavers that meet Tier requirements and which are designed for the needs of emergent markets
The conveyor belt on the BMF 2500 has a width of 1.2m and gives optimum material flow with minimal segregation. The BMF 2500 has a large hopper with individually controllable wings for quick discharge as well as slewing bumper rollers for docking trucks. 

The BMF 2500 S is the base model but can be fitted with a slewable offset belt to load two pavers, while the BMF 2500 S Offset has the offset conveyor as standard. The BMF 2500 M has a longer, height-adjustable conveyor belt, allowing it to supply pavers with high capacity hoppers. 

German firm Vögele is also upgrading its paver lineup, and designed for compact paving applications, the SUPER 800-3i offers a range of pave widths from 0.5-3.5m. The machine can operate in confined spaces such as in towns and cities and suits duties with local authority contractors.

Of note is that it has an AB 220 TV screed, a tamper vibrating model that is unusual in this compact asphalt paving class (competing models tend to feature vibration only). This offers paving widths of 1.2-2.2m but can be built up using bolt-on extensions. The pave width can also be reduced to 0.5m without the need for modifications. 

Power comes from a four-cylinder Deutz diesel engine delivering 55.4kW, 20% more than its predecessor, while featuring low noise and exhaust emissions. The machine has an innovative material conveying system and benefits from the novel ErgoBasic operating system. The machine also has an electronically-controlled traction drive, for precise tracking and cornering while it has the ErgoBasic operating system, which was developed from the proven ErgoPlus installed in the large pavers. 

This machine can pave to within 50mm of boundaries and has a low overall height of less than 2m. It has a small clearance width of 1.4m and a low outer track gauge of just 1.14m. Its material hopper has separately folding sides and can be fed from the front by a truck or from the side using an offset feeder. The push-rollers can be moved to the left when paving along walls and combined with an asymmetrical material hopper, can be supplied with material by a truck if required.

Vögele continues to develop its sprayer technology with the introduction of the new SUPER 1800-3i SprayJet. A key feature is that operation of the spray module has been integrated into the sophisticated ErgoPlus 3 operating system. The spray module has also been designed as a self-contained functional unit and the machine has a modular design that eases servicing and allows it to be used as a spray paver and as a conventional asphalt paver. The machine has a maximum spray width of 6m, while as a conventional paver without spray function it can pave widths of up to 9m.

The company claims that the system is suited for paving thin layers hot on spray seal or tack coat. The newly developed module is said to be an economical and clean alternative wherever emulsion is sprayed before paving with asphalt.

The system comes with an insulated emulsion tank with a capacity of 2,100litres and that can be increased to 7,100litres using an optional additional tank. Integrated electric heating ensures that emulsion is maintained at the ideal temperature for spraying, while a heated pump circulates the material in the tank, ensuring that it is homogenous. 

The SUPER 1800-3i SprayJet has five spray bars, which allows full coverage. The nozzles operate in pulsed mode and the frequency is adjusted automatically in relation to the rate of spread, pave speed and pave width. The system is said to deliver a uniform film of emulsion, without overlaps. 
SprayJet machine from Vögele
The upgraded SprayJet machine from Vögele is built on modular lines, allowing it to be used as a spray paver or conventional paver
The new model also includes all the features of the Dash 3 paver generation, such as the advanced EcoPlus package that lowers fuel consumption and noise levels as well as the AutoSet Plus functions. This last also makes it possible to store individual and frequently recurring paving settings. 

The machine has the ErgoPlus 3 operating system and spraying functions are integrated into the large colour display on the console. Essential screed data is displayed on the two ErgoPlus 3 screed consoles. Hydraulic adjustment of the crown can be carried out using the ErgoPlus 3 screed consoles. 

The machine has two screed options, the AB 500 and AB 600, either of which can handle pave widths up to 6m. The AB 600 comes with a basic width of 3m and extends hydraulically up to 6m. The AB 500 builds up to its maximum width of 6m with additional bolt-on extensions. However, used as a conventional paver without the spray function the machine can pave widths of up to 9m with the AB 600.

Either screed is available in TV version (with tamper and vibrators) or in TP1 version (with tamper and one pressure bar), while heating is electric.

From Volvo CE comes the new P7820C ABG and P8820C ABG pavers, aimed at customers in less regulated markets where low sulphur fuel is not available. The machines meet the Stage IIIA/Tier 3 emissions requirements and both are designed to be able to cope with tight turns and steep hills and can deliver a smooth mat, even in demanding conditions. 

The P7820C ABG is powered by a Volvo D7 diesel delivering 170kW while the P8820C ABG is powered by an engine rated at 182kW. These engines are said to deliver high power outputs, while featuring low noise and low fuel consumption. As most paving jobs do not require full output from the engine, a smart power mode is fitted, reducing the RPM to better match demand, resulting in fuel savings of up to 30%. 

The P8820C ABG can pave widths of up to 13m and provide a maximum throughput of 1,100tonnes/hour, while the P7820C ABG can pave widths up to 11m and place up to 900tonnes/hour. The machines suit a wide range of applications including municipal roads and highways and can also pave wearing courses and binder courses as well as base courses.  

The operator platform is said to offer a good view into the hopper, auger channel and work area, while the central control panel can be swivelled, tilted and extended and also features the latest electronic paver management II system (EPM II). The EPM II controls paving processes and operators can select menus for the engine data while the system also monitors fuel consumption, service needs and paver settings. 

Volvo’s ABG models offer fixed and variable extending screeds, while extensions can be added or removed quickly, using a quick coupling system. Variomatic (variable extending screeds) have dual-electric heating, while the fixed width screeds feature gas heating and can be fitted with fixed and variable extensions.

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