Paving a Caterpillar Publication Serving the Global Paving Industry
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Issue 2 2013 NEWS PAVING A Caterpillar publication serving the global paving industry Seismic Change Bay Bridge Project a Paving Marvel Revamped Runway Intelligent Compaction, 3D Paving Key to Project VIEWPOINT Computer Savvy and Street-Smart eing computer savvy and crews do the work, but especially street-smart sounds like in this case, the paving estimator Bthe description of a person had to figure out how to efficiently who grew up in the Bronx and now schedule the resources for dozens works in Silicon Valley. In reality, it of street projects. describes a lot of the people working Each project had its own unique in the asphalt paving industry. requirements and there was tremen- That fact was brought home to me dous pressure to track production when I read the job stories in this issue details and meet local restrictions of Paving News. Talk about a range of on traffic control, truck routes, skill sets. noise permits and starting times. The story, “Revamped Runway,” Managing the constantly changing (pages 4-7), illustrates just how far conditions and communicating with paving technology has advanced numerous governmental agencies in recent years. Granite Construc- takes a special set of skills—what I Jim McReynolds tion completed resurfacing of the call street smarts. President, middle runway at Salt Lake City Finally, read about the com- Caterpillar Paving Products International Airport using three- plexities faced by O.C. Jones & dimension milling and paving, plus Sons while paving the Oakland intelligent compaction. Bay Bridge. That story, “A Seismic As the project manager points Change,” (pages 12-17), shows that out, all the information regard- paving contractors sometimes face ing profiles and elevations is the combined challenges of new programmed into a digital model. technology and stressful logistics. No stringlines or elevation grid Any bridge project takes extra references marked on the runway. planning and management. Throw The equipment is controlled by in the requirement to use a new information sent from robotic total material, Epoxy Asphalt Concrete, stations. that is extremely sensitive to time It took some training, but the and temperature and you’ve got to crews responded to the challenge be both a chemical engineer and a of learning new technology and traffic cop. met the tough FAA specifications. I am constantly impressed by Follow that by reading “One the people in the paving industry. Piece at a Time” (pages 8-10), They invest heavily in technology. the story of how TC Construction They invest in training and educa- handled the logistical complexi- tion. The asphalt paving industry ties of a massive street overlay truly has integrated brainpower program in San Diego. The paving with manpower. ■ Paving News is published in a cooperative effort between the Global Paving Marketing Communications Group at Caterpillar Inc. and High Velocity Communications Inc. It is distributed free of charge to those in the paving and road building industries. If you are not currently receiving Paving News and would like to, or have a change of address, please send your name, company name and address to: Paving News Subscription Dept., 1720 Dolphin Drive, Waukesha, WI 53186-1489. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. All contents of this publication are protected under U.S. and international copyright laws, and may not be reproduced without permission. Featured machines may include additional equipment for special applications or customer modifications not offered by Caterpillar. Because specifications are subject to change without notice, check with your Cat Dealer for the latest equipment information. Printed in the U.S.A. Volume 4, Number 2. © 2013 Caterpillar All Rights Reserved 2 PAVING NEWS | ISSUE 2 2013 CONTENTS Feature Articles Paving News: 2013 - Issue 2 Revamped Runway 4 3D Paving, Intelligent Compaction Key to Project One Piece at a Time 8 Many Small Overl ay Projects Create Challenges Tune Up Your Team 11 Off-Season Training Pays Benefits During Season A Seismic Change 12 Bay Bridge Project a Paving Marvel, Too News and Notes 18 Paving an Island Paradise; Books on Soil Compaction, Asphalt Compaction Now Available TION ® PAVING PRODUCTS C CAT CAT GUIDE TO SOIL COMPA CTION ® PAVING PRODUCTS GUIDE TO SOIL COMPA COMPACTION ASPHALT TO GUIDE GUIDE TO SOIL COMPA CAT CAT ® ® PAVING PRODUCTS PAVING PRODUC PAVING GUIDE TO ASPHALT COMPACTION TS C TION PAVING NEWS | ISSUE 2 2013 3 Revamped Runway 3D Paving, Intelligent Compaction Key to Project t was 10 years ago that Granite Construction milled Preparation and resurfaced the middle runway at Salt Lake City The 3D paving process required surveying technology IInternational Airport. The work is mandated to occur that Granite had utilized on previous projects. The elevation about every decade, so earlier this spring Granite crews was created digitally and referenced during both milling and were back at the airport. It was the same city, same airport, paving. “We had been using it on motor graders for finish same runway—and a very, very different plan. grading for years,” Smith said. “The technology itself is not “A lot has changed in 10 years,” said Kyle Smith, project new to our surveyors.” manager at Granite. “Ten years ago, we completed this job It was new to paving crews, and changed their roles. The with one crew and wireline. This time we used two crews, pavers—a Cat® AP1055D and AP1055B—received informa- a wireless system and 3D paving in echelon—and we are tion from up to 12 robotic total stations as they moved down using intelligent compaction.” the runway. That information directed the screed to be raised or lowered to meet the elevation requirements. All screed The Project adjustments were automatic. The project called for profile milling and resurfacing Smith acknowledged starting the process was stressful, of a runway and all the taxiways. Crews removed 102 mm particularly given the strict FAA standards. Granite arranged (4 in.) of asphalt during milling and replaced it in two 51 training through the local Cat dealer, which spent more than mm (2 in.) lifts. During the job, 72,600 metric tons (80,000 a week on the jobsite ensuring all crew members were up to tons) were placed. Time, of course, was a factor as well. The speed. The training included paving with sand to provide the entire project had to be completed within 60 days. crew with hands-on experience. Specifications required paving to an elevation, and echelon paving was used to minimize the number of cold Paving joints. The echelon requirement meant wireline could not be The preparation for 3D paving takes a great deal of work, utilized for elevation control. Smith said, but when work starts it moves along quickly. This led Granite to launch the use of a Trimble 3D pav- “The prep work is all basically done by building the model,” ing system. “We use 3D grading all the time,” Smith said. “As we looked at the need for echelon paving, and the tight tolerances of the FAA, we concluded that 3D paving was our best option.” The pavers worked at a pace of 6.1-7.6 m (20-25 ft.) per minute. 4 PAVING NEWS | ISSUE 2 2013 CUSTOMER STORY Smith said. “We don’t need surveyors setting elevations and “Ten years ago, we completed this job installing wireline. That prep work is done prior to the start of the project, so we can just get out there and pave.” with one crew and wireline. This time we FAA specs required the utilization of material transfer vehicles. Belly dump trucks, with capacities of 34 metric used two crews, a wireless system and tons (38 U.S. tons), delivered mix to the jobsite. The trucks were 30 minutes from the plant. The paving 3D paving in echelon—and we are using began in April—“There was still snow in the mountains,” Smith said—so quickly cooling mix was a concern. intelligent compaction.” The paver worked at a pace of 6.1-7.6 m (20-25 ft.) per – Kyle Smith minute during the early, cooler days. “That pace is driven Granite Construction by surface temperatures,” Smith said. “With the 2-inch mat, we can’t let the paver outrun the rollers. The pace is strictly a function of compaction and has nothing to do with the technology.” The paver operator steers the machine and sets the pace. Screed personnel are responsible for switching the signal reception from one station to the next as the paver moves down the runway. They also monitor an on-board display to ensure the screed is responding properly. PAVING NEWS | ISSUE 2 2013 5 CUSTOMER STORY Fundamentals, such as proper head of material, are crucial Data was available to operators, and stored for no matter what technologies are utilized. later analysis. The pace was slowest at the start lift and 5.8 m (19 ft.) on the second lift. “The intelligent compactors have of the project while crews adjusted to “We started with a narrow approach GPS,” Smith said. “We utilized pass the echelon paving process, and the so the crew could become comfortable counts and mapped temperatures. volume of machines and personnel. with the 3D system while working with Operators had screens on their rollers. “Trying to get two pavers to work side- a more traditional width,” Smith said. They could easily see where they had by-side, it’s a challenge,” Smith said. been and they knew the mat tem- The pavers worked within 30 m Compaction peratures and whether they should be (100 ft.) of each other.