Heavy Equipment Guide Logo

This ad will close in 15 seconds

​A-1 Sandrock paves the way with recycled asphalt shingles and Terex equipment

North Carolina and surrounding states used more than 150,000 tons of recycled shingles for highways in 2017

A-1 Sandrock added two CBI 5800BT grinders in 2017 to help process asphalt shingles as well as wood waste.
A-1 Sandrock added two CBI 5800BT grinders in 2017 to help process asphalt shingles as well as wood waste.

With 12 million tons of tear-off roofing material being generated each year in the United States, and increased regulations, the industry demands efficient recyclers. Efficiency is second nature to A-1 Sandrock. The company has rose to the challenge over the last few years, growing their shingle disposal program into a massive operation that's convenient for roofers, communities, North Carolina, and the surrounding states.

A-1 opened their Greensboro, NC site back in 2007 after noticing a higher need for recycling with less waste going into landfills.

"I'd be confident saying we're grinding at least 80 percent of the shingles going in the road in North Carolina," said Jimmy Petty, General Manager of Mobile Operations at A-1 Sandrock. "The shingles are mainly tear offs from your regular home roofing jobs. Most of the sites you're taking them in, piling them up, and then they call us to come in and grind them. It's all about getting in, getting the job done, and getting out while giving customers a product that will pass state specs."

Meet the state specs while producing a high-volume—it's that easy to be successful... but it's also that hard.

In 2014, North Carolina made it a regulation that all recycled asphalt shingles had to be screened to 3/8" minus to go into a recycled mix for the highway road surfaces. The regulation didn't bother A-1 because they were trommel screening everything long before the state required it. 

A CBI 5800BT horizontal grinder and an Ecotec Phoenix 3300 trommel are among five Terex machines employed by A-1 Sandrock.

Being ahead of the quality curve gave them a sustained edge.

"When we first got started we were trommel screening everything with the Phoenix 2100 Trommel Screen," Petty said. "We wanted to make sure we were giving them the right product. We decided the safer route was to screen it all and know that it was good to keep it all consistent."

A-1's longstanding relationship with Powerscreen Mid-Atlantic (PSMA) has been critical to their growth. Two Terex Ecotec Phoenix 2100 trommel screens and a Phoenix 3300 trommel screen have significantly increased production while creating a premium end-product.

"Basically we're in the same town as PSMA, our shop is 20 minutes away from theirs, so it's great to work with PSMA locally," Petty said. "As far as getting parts and service, it's really convenient for us."

Powerscreen Mid-Atlantic, Inc. offers an array of crushing, screening, grinding, chipping, material handling, and specialty equipment. They serve customers in North Carolina, South Carolina, Virginia, and West Virginia and have been in business since 1996.

When Terex Corporation acquired Continental Biomass Industries (CBI) in 2015, Powerscreen could now offer world-class horizontal grinders at the local level, with local service. During this time, A-1's business had been expanding. They had to expand the crew and grinding production to meet the growing demand of multiple large highway customers. After seeing live demos of horizontal grinders, they decided in the end to add the CBI 5800BT back in June of 2017. 

They added another 5800BT four months later.

The 5800BT Horizontal Grinder was purpose-built for power, maneuverability, and easy transportation between jobs. With minimal transport restrictions, the grinder's compact dimensions have been great for A-1 as they move from job to job between a dense cluster of highway customers. Known for grinding biomass materials like whole trees, storm debris, slash, stumps, and regrind, the 5800BT's new shingle grinding configuration lets Petty switch between grinding gnarly wood and tough reject shingles. They've been impressed with how the 5800BT handles real-world grinding.

"I was really surprised how fast the 5800BT can pull a whole tree through it," Petty said. "When you put in a thirty foot whole pine tree, the 5800BT will pull the whole thing through in less than a minute. It amazes me how fast it pulls it through and spits it out. We had a pile of logs sitting in our yard for the last seven years on site that our other grinders couldn't handle. We put our 5800 in there and pretty much ground it all except the pieces that were so wide they wouldn't fit."

CBI's 5800BT grinder feeding a Terex Ecotec Pheonix trommel screen, processing used asphalt roofing.

While versatility for wood waste is nice, the majority of A-1's work is geared towards recycling asphalt shingles.

"For shingles, we do 80 percent tear offs which are old shingles right off the roof," Petty said. "They can be 30-40 years old--dried out and brittle--they are fairly easy to grind. There's not as much aggregate because it washes off with the rain over the years. Then you got reject shingles which come directly from the factory and they have a whole lot more aggregate in them. That can be really tough on the machine just because there's more material on the shingle—it's almost like trying to grind a bubble-gum type material. The 5800BT really handles it well."

Led by their five Terex machines, they ground 150,000 tons of shingles in 2017 with all of it going back into the roads of North Carolina and the surrounding states.

Recycling a large amount of asphalt shingles year after year has an obvious environmental advantage. The National Asphalt Pavement Association's (NAPA) 2016 industry survey estimates that the 2016 construction season saw more than 76.9 million tons of reclaimed asphalt pavement and nearly 1.4 million tons of recycled asphalt shingles go into new pavements in the United States, saving American taxpayers more than $2.1 billion.

Data for 2017 construction season is still being collected, but T. Carter Ross of NAPA contextualized savings per ton based on the most recently available data.

"For 2016, we calculate that every ton of RAS used is equivalent to about $74.026 in savings," Ross said. 

Based on that 2016 figure of $74 in savings a ton, A-1 Sandrock's 150,000 tons in 2017 represents $11.1 million in economic impact for customers, states, and local taxpayers.

It all comes down to efficiency.

"You can easily run 120 tons and hour through the 5800BT," Petty says, but mentions that a lot of the day requires setting up each mobile site, so it depends on the job."

The grinder is equipped with an over band magnet that pulls nails off the discharge belt and disposes them into a separate container. A clean end product is loaded into the trommel to be sorted into a refined pile that meets North Carolina's spec. 

Shingles are a whole different animal than pine trees. A-1 checks the tips every three hours and changes them as needed. Fast and thorough maintenance is another area where they optimize production time.

"The way the CBI 5800BT opens up and you're able to get to the teeth is very nice and easier on the guys—they can stand up while they're doing it, they don't have to crawl into something," Petty explains. "I think that's great. The screens are easy to take out and put back in. We're using the tall tips. With other machines they stop at two and a half hours, with a CBI we give it an extra thirty minutes that we feel comfortable running, which gives us more production time. The way we schedule our day, with the teeth changes and everything, if you take a CBI next to an older machine it's going to bury it."

Maintaining machines during reject shingle grinding is always a challenge because the dust flies everywhere. Taking covers off engine compartments and other parts of a grinder becomes redundant throughout the day and results in lost time. It's been an annoyance for A-1 in the past with other grinders but the open design of the 5800BT saves them maintenance time on the back-end. Manufacturers, too, relentlessly adapt to help end-users stay profitable.

"With the 5800, you've got everything open and you can get to the hoses and clean everything out a lot easier, without having to move three or four covers to get to what you're trying to clean," Petty said.

Beyond the high-production, good old fashioned customer service for both Terex brands gives them peace of mind. Quality local service through Powerscreen Mid-Atlantic can't be beat. A-1 called on a Friday towards the end of the day to replace a bearing on one of their machines, a service tech from PSMA stopped by on Saturday and had the job done in two hours, they were running on Monday no problem.

"That's the kind of service you get and you can't beat that," Petty said.

A-1 Sandrock's CBI 5800BT grinder is equipped with an over-band magnet that pulls nails off the discharge belt and disposes them into a separate container.

More from Roadbuilding

How technology is boosting cold milling productivity

Asphalt milling, asphalt grinding and asphalt planing describe the same process by which weathered, oxidized asphalt pavement is removed from a driving surface in varying depths, as specified, done in advance of a fresh asphalt overlay or pavement preservation treatment. 

Bergkamp Pivot Tack System for FP5 Flameless Pothole Patcher eliminates tripping hazards and keeps tack off of equipment

Tack that is sprayed into potholes to increase adhesion within a patch can also adhere to equipment hoses. In addition, the hoses can present jobsite tripping hazards. To address these common issues, Bergkamp Inc. has engineered a new Pivot Tack/Air Hose System for its FP5 Flameless All-In-One Pothole Patcher. Located at the back-right side of the FP5's hopper body, the system's pivoting arm holds the original tack hose off of the ground and parallel to the hopper, locked in place for transporting with a spring-loaded pin. 

Recycled aggregates for roads

Municipalities are responsible for the care and maintenance of vast amounts of roads, from lanes to highways. When those roads are repaired or replaced, there's the potential to generate a significant amount of aggregate material - concrete and asphalt removed from the surface that must be dealt with.
Today's roadbuilding contractors are taking this material and recycling it more than ever before. However, research is showing that some municipalities are far better than others when it comes to using this type of aggregate in their roads - and some are far behind.

Ground penetrating radar provides critical insight for maintaining Canada's aging roads and bridges

Municipalities across Canada are burdened with aging transportation infrastructure, much of which was constructed in the post-war era and is nearing the end of its useful life. The 2016 Canadian Infrastructure Report Card (CIRC) found that one third of municipal infrastructure across the country is in fair, poor or very poor condition, and this includes 39 percent of roads and 26 percent of bridges. Cold weather and the use of corrosive de-icing salts further threaten the reliability of the transportation infrastructure we rely on every day.

Case adds two new vibratory rollers to DV Series

Case Construction Equipment has introduced the latest additions to the DV Series of vibratory rollers. With models available in both double drum and combination (front drum with rear pneumatic tires) configurations, these rollers are powerful, easy to transport and nimble enough to work in a variety of residential and commercial construction applications where the operator may encounter tight quarters, curbs, structures and other obstacles.

State-of-the-art high-performance W380 CRi cold recycler from Wirtgen

Due to the rapid increase in heavy-duty transport, the global road network is showing visible signs of aging in many places. In order to ensure that the road infrastructure remains functional over the long term, roads are increasingly requiring structural rehabilitation. Wirtgen developed the high-performance W 380 CRi cold recycler specifically to meet these requirements. This innovative machine will be unveiled to the world at the Bauma trade show. 

free-paper-airplane

Get our newsletter

Learn more

Wacker Neuson restyles ride-on roller for improved visibility and curb clearance

Wacker Neuson has updated its 1.2-ton tandem vibratory roller line to include improved visibility, curb clearance and easier service access. The RD12 series has dominated the industry since it was originally developed and introduced to the North American market 30 years ago. These popular ride-on rollers are the perfect fit for residential and commercial construction for asphalt and subbase soil compaction of parking lots, driveways, secondary roads and nature trails. Additionally, they are an excellent choice for landscape and golf course contractors to statically roll sod, fairways and greens.

Efficient fleet management with WITOS FleetView from Wirtgen Group

"A penny saved is a penny earned." WITOS FleetView is a must-have for anyone who takes this old proverb to heart, because with the fleet and service management solution from the WIRTGEN GROUP, users and machine operators have diverse advantages that are worth their weight in gold. An example from the field confirms it: GSI-Asphalt, a medium-sized enterprise in Eging am See, near Passau, Germany, has been using WITOS FleetView for years in conjunction with the SmartService service agreement. While SmartService provides for regular inspections in accordance with the instruction manual, the telematics solution WITOS FleetView additionally supports proactive maintenance planning and a rapid response in the event of faults. Both services guarantee maximum machine availability - enhancing the cost-efficiency and value retention of the machinery.

World premiere of Bell Equipment's B45E 4x4

With the launch of the new Bell B45E 4x4 at bauma, Bell Equipment will add a new model to its range of articulated 4x4 two-axle ADTs. Similar to the sixty-tonner B60E and the smaller Bell B30E 4x4, the new truck is configured to provide a highly efficient and cost-effective transport solution for niche applications in the mining and construction industry.

New Dynapac pavers take commercial class to the next level

Dynapac North America upgrades its commercial class paver range with the new FC1700C, FC1400 II, and FC1300 II.  The new pavers are equipped with EPA Tier 4 Final certified emissions regulations-compliant engines and offer new features that takes the Dynapac commercial class paver range to the next level.  The launch of the new FC1700 will take place at the National Pavement Expo in Nashville, TN.  

free-magazine-subscription

Get Our Magazine

Paper or Digital delivered monthly to you

Subscribe or Renew Learn more

Bomag BF300 commercial pavers bring unique features to improve quality and efficiency

BOMAG introduces the new BF 300 series of commercial pavers that offers big paver features and efficiency in a 6-ft (1.8-m) paver. The rubber tire BF 300 P-2and BF 300 C-2 track pavers are designed to elevate paving quality and productivity, while reducing costs on a range of municipal, department of transportation, city development, and bike and cart path applications. 

Volvo CE expands ActiveCare Direct to pavers

Originally launched in 2017 for excavators, articulated haulers and wheel loaders, ActiveCare Direct is now available on select Volvo asphalt pavers. Starting February 2019, the P7110B and P7170B will be eligible for a one-year free subscription to ActiveCare Direct with a new machine purchase.

Bridgestone brings portfolio of OTR tire solutions to AGG1

Bridgestone Americas, Inc. will exhibit its integrated portfolio of off-the-road (OTR) products, technologies and services at the National Stone, Sand and Gravel Association Aggregates Academy and Expo (AGG1) and World of Asphalt 2019 Show and Conference, Feb. 12-14 in Indianapolis, Indiana. Located at booth 31089, Bridgestone will showcase the benefits of using products backed by integrated technologies to drive increased productivity for customers.

CASE launches new series of small-frame vibratory rollers

Case Construction Equipment has announced a new series of small-frame vibratory rollers. Available in both double drum and combination (front drum with rear pneumatic tires) configurations, these compact rollers are easy to transport and are ideal for working in residential and commercial construction applications where the operator may encounter tight quarters, curbs, structures and other obstacles.

Komatsu America and Bomag distribution partnership paves way to new market opportunities

Bomag Americas, Inc. and Komatsu America Corp. are pleased to announce that Komatsu's six company owned dealerships (Edward Ehrbar, Komatsu Equipment Company, Komatsu Northeast, Komatsu Southwest, Midlantic Machinery and Pine Bush Equipment) have entered into an arrangement for the sale and support of Bomag compaction, milling, paving and reclaiming/stabilizing equipment for roadbuilding and other construction markets. 

Bomag's new paving training programs help operators and companies get the most from their equipment

For asphalt contractors to be successful in today's competitive paving market, paver and roller operators must acquire a deep knowledge of the equipment's features and put this knowledge into practice at the jobsite. With long-time equipment operators retiring at a high rate, the next generation of operators must receive extensive in-depth training on the equipment in order to meet project specifications without costly rework so companies can maximize equipment return on investment.

Asphalt Drum Mixers offers crane-set and self-erect asphalt storage silos

Asphalt Drum Mixers, Inc. offers crane-set and self-erect asphalt storage silos, which are compatible with both the company's own and similar competitive models of asphalt plants. ADM silos are available in many configurations from single self-erecting silo to multiple crane-set silos and several drive-through configurations. Capacities are available between 30 and 300 tons. Custom designs and capacities are also available to accommodate any producer.

free-paper-airplane

Get our newsletter

Learn more

Road Dryer RD-1200 safely dries pavement in one pass for paving, surface treatments

The RD-1200XT pavement-drying unit from Greenville, South Carolina-based Road Dryer, LLC, quickly dries asphalt and concrete pavement, allowing crews to pave or apply surface treatments or striping after just one pass. The unit, which blows heated air up to 300° F directly downward through multiple nozzles, eliminates the risk of "flying objects," and allows traffic to flow in nearby lanes — reducing congestion caused by traffic restrictions. Available as a simple-to-operate trailer- or truck-mounted unit, the RD-1200XT can be adjusted for 8-ft to 12-ft (2.4m to 3.7m) drying widths. Because it dries pavement on demand, it provides flexibility for contractors and government agencies to meet timetables by minimizing delays from weather- and project-related wet conditions.

Move big snow with Torwel's heavy-duty snow pushers

Torwel Limited has announced its new and improved Heavy-Duty Snow Pushers in widths from 8' through 18'. All models boast robust design and upgrades that include adjustable skid/wear shoes and easy to use attachment systems that include the universal skid steer mounting system and the new versatile utility tractor/loader global mounting system.

In-depth report: asphalt pavers

Trends in asphalt paving centre around making it easier and faster to lay down the highest quality pavement. In our latest in-depth report, our panel of experts from five manufacturers take a look at advances and technologies that are available in asphalt pavers, their current level of adoption, the advantages they offer, plus considerations when looking at the purchase of a new machine. 

Vögele offers new app for paver operators

JOSEPH VÖGELE AG are further extending their range of service and training options for users: using a specially developed app and the associated web special, job-site professionals can now get to grips with the ErgoPlus 3 operating concept quickly and easily with the aid of numerous animations. 

NC Equipment purchases DYNAPAC’S NEWEST MOBILE Feeder in North America

Segregation - the separation of asphalt mats that can cause headaches for road maintenance crews - is a hot topic in the paving industry as more contracts include clauses regarding this challenging condition. 
As a long-time dealer and rental house serving northern Alberta's asphalt contractors, NC Equipment keeps track of the trends in the industry. As a full-time Dynapac dealer since 2017, it has taken the lead for its customers by bringing in a North American first to help reduce segregation problems on roadbuilding jobs.

Topcon acquires ThunderBuild, expanding paving solutions portfolio

Topcon Positioning Group announces the complete acquisition of ThunderBuild BV Group, expanding the portfolio of Topcon paving solutions. Based in Eindhoven, the Netherlands, ThunderBuild develops software related to logistics management with a primary focus in the asphalt market, as well as additional applications that pertain to the transport of bulk materials.

Cat pneumatic compactor in nine- and eleven-wheel models is ideal for all types of asphalt mix

Designed for use on granular materials and all types of asphalt-mix designs, the new Cat CW16 pneumatic (rubber-tire) roller is available as a standard nine-wheel model with a 69-inch (1,754-mm) compaction width or as an optional 11-wheel model with an 84-inch (2,132-mm) compaction width. The CW16 is designed for efficient performance on highways, city streets, county roads, lane additions, industrial sites, overlays, or other mid-size jobs.

free-magazine-subscription

Get Our Magazine

Paper or Digital delivered monthly to you

Subscribe or Renew Learn more