The fully autonomous Robomag tandem roller can be used completely independently in a defined work area. For loading or manual operation, the Robomag tandem roller can be operated simply by remote control.
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
22 Whittier Street
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.
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."
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.
More from Roadbuilding
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.
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.
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.
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.
Volvo Construction Equipment is adding the P7110B and P7170B asphalt pavers to the company's Lifetime Frame and Structure Warranty program and also expanding the pavers' extended warranty. The warranties come standard on machines delivered on or after Jan. 1, 2019.
"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.
Carlson Paving Products, Inc., an Astec Industries Company, is set to unveil its new wheel paver platform at bauma 2019 in Munich, Germany. The global debut of the CP60 and CP65 wheeled asphalt pavers represent the company's entry into the international 1.8m city paver market.
New light tandem rollers from Ammann make it even easier for operators to work next to obstructions such as curbs.
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.
Carlson Paving Products, Inc. showcased the company's newest screed in Indianapolis: the EZR208. Completing the Tacoma-based manufacturer's lineup of rear-mount highway-class screeds available for all current North American paver models, the EZR208 is a technological leap forward for superior mat quality, performance, and wide width ability.
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.
Carlson Paving Products, Inc. recently unveiled the all-new 2019 CP75 II at World of Asphalt. Featuring all-new ergonomic controls and the choice of material conveyor systems, the new CP75 II joins Carlson's line up of high performance and heavy duty commercial platforms for North American contractors.
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.
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 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.
The Mecalac Group has built its innovative reputation on designing and producing construction machinery for urban jobsites. Since the acquisition of the British facility at Coventry in 2017, backhoe loaders, site dumpers and compaction rollers have been added to the existing ranges of excavators and loaders.
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.
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.
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, 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.
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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.
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.
JOSEPH VÖGELE AG are restructuring their extensive range of road pavers and screeds. The world market leader will be dividing its range into two lines: the Premium Line and the Classic Line. The company will also be subdividing its products into up to five classes within those lines.
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.
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 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.
Registration is now open for Volvo's 2018–2019 Road Institute, the paving industry's premier training program. Offering a mix of classroom and hands-on training on a variety of operations and maintenance topics, sessions start in late October 2018 and continue through May 2019.
ASTEC, INC., an Astec Industries company, announces the dates for the 2019 Customer Schools. Six weeks of schools are available. Attendees can choose to attend one of these sessions: January 7-10, January 14-17, January 21- 24, January 28- 31, February 4-7, or February 11-14, 2018.
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Neal Manufacturing, a Division of Blastcrete Equipment LLC, and a leader in asphalt pavement preservation equipment, offers its Asphalt Road Preservation Package for optimal efficiency and high-quality results on both detail and high-volume sealcoating applications. The package includes Neal Manufacturing's drivable DA 350 dual applicator for quick prep work and sealcoating around curbs and gutters, and its High-Volume Road Maintenance Vehicle that delivers high material output for efficiency on large projects.
New lightweight Bomag single-direction plate compactor designed to avoid asphalt material pushing, shoving and scuffing
An indispensable tool for repair, maintenance and paving applications, the new Bomag BVP 12/50 A single-direction vibratory plate compactor is specifically designed and equipped for asphalt compaction, expanding the machine's use beyond traditional soil compaction. This asphalt specialist features a base plate specifically designed to avoid asphalt material pushing, shoving and scuffing to deliver a superior finish. The highly wear-resistant cast iron base plate delivers exceptional service life.
The Wirtgen Group showed of a number of its latest innovations at Intermat this year, all 5 brands were strongly represented: Wirtgen, Vögele, Hamm, Kleemann and Benninghoven. Visitors had the chance to talk with experienced applications experts from the Group and got up to speed on the latest technologies for the entire road construction cycle while learning more about the Wirtgen Group's extensive range of service offerings. Here is an overview of some of the highlights:
W 150 CFi with 1800-mm milling drum assembly leads the Wirtgen line-up.
Hamm's leading-edge CompactLine of 15 smaller-sized rollers combines cutting-edge design with practical functionality.
The 9.9-ton (9-metric-tonne) DV+ 90i VV-S (vibration in both split drums), the DV+ 90i VO-S (vibration and oscillation in split drums), and DV+ 90i VT-S (vibration and pneumatic combi roller) are the latest tandem rollers in Hamm's DV+ series.