Heavy Equipment Guide Logo

Paving train targets million-ton goal

Cat pavers and rollers aid crew with one-year, one-million-ton hot mix target


Phoenix, Arizona, is one of the fastest growing metropolitan areas in the United States; the 4.7 million metro population is expected to reach 6.3 million in 2030, according to the U.S. Census Bureau.

To keep pace, the Loop 202 (South Mountain Freeway) will add 22 miles of freeway to the existing Phoenix metropolitan transportation system. The freeway will connect the east and west valleys, while providing relief to existing freeway corridors and local streets. 

Connect 202 Partners, LLC, (C202P) has been awarded a design-build and maintain contract by the Arizona Department of Transportation (ADOT) to complete work on the $1.77 billion job, the largest highway project in state history.

Construction began in November of 2018, and is expected to be complete sometime late in the fourth quarter of 2019. Granite Construction will place approximately one million tons of asphalt as part of the job. To meet that need, the company added a second paving crew and had plenty of long days to work, according to Stan Jernigan, asphalt paving manager. "We own two Cat AP1055F pavers, and have the rollers and other equipment we need." 

The paving crew is placing a standard ADOT 416 mix. "In our main line production, we're running belly dumps with a windrow elevator and then running it in through a Cat AP1055F paver," Jernigan notes.  

Asphalt thickness varies, depending the soil and the amount of aggregate placed. "In this particular area, we're on about 16-1/2 inches of aggregate base, so we're putting down nine inches of asphalt," notes Jernigan in a December 2018 interview. 

The bottom six-inch lift is a standard ADOT 416 with 3/4-inch aggregate and PG 70-10 binder. The driving surface is a three-inch lift of ADOT 416 with 3/4-inch aggregate and PG 76-22 binder and an SBS modifier.  

There are no density specs on the job. "With ADOT 416, it's in-place voids. The mix goes down loose, and there's rock oil in the mix. As we squeeze it out, we're trying to leave a little bit of air void. The target for us is a seven percent air void," Jernigan says.

Versatility important for good compaction
With approximately 2,500 bridge tie-ins, ramps and shoulders, and mat widths ranging from 12 to 18 feet, versatility is key to successful compaction. "We vary what we do. We place lifts of five inches, and thinner stuff at two inches, three inches," Jernigan says. "We need versatility in our amplitude settings and our frequency settings. We need rollers that are capable of covering all of the widths, and keeping up with the rate of paving."  

With approximately one million tons of mix being placed within one year, the paving crew's goal is 3,000 tons per day, says Jesus Sanora, paving foreman.

To meet the challenge, the crew carries five Cat rollers – a pair of CB66B Tandem Drum Rollers, a CB44B Tandem Drum Roller, CW34 Pneumatic Roller and a CB24B Utility Roller. 

The CB66Bs are used primarily as breakdown rollers; the CB44B Tandem Drum Roller's jobs include finishing, the CW34 Pneumatic Roller provides versatility, and the CB24 Utility Roller is handy cross rolling joints at bridge decks. 

Rollers are on the mat before the temperature dips below 285 degrees F. "We typically have two breakdown rollers. They're running a pattern of three passes, then one with a static setting," Sanora says. "A rubber-tired roller is right behind him, and there's a finish steel drum roller after that. The rubber-tired roller hits it at 180 to 190 degrees, and then the finish roller at 140 to 160."

Work is being done with the understanding that C202P is responsible for the maintenance of the freeway after completion. "We're the joint venture who maintains the project for 30 years. Smooth pavements last longer, so pavement smoothness is one of our big things," Jernigan says. 

Pavement must achieve an IRI rating of 50. Belly dumps place hot mix in a windrow, and a windrow elevator moves material to the paver. This helps minimize paver stops. 

Paver automation simplifies operation
The AP1055F Paver utilized a Trimble 2D system. "We run on skis, and try to even the road on each lift. If we need to adjust, we can do it right away with the Trimble system," Sanora notes. "And it provides a lot of accuracy. We can make adjustments to one-sixteenth of an inch."

Sometimes the crew runs the 2D system off a string line, says Shane Leivdal, paving mechanic. "We run off of the distance between the sensor and the string, so we are more specific. We do that for some of our cross streets and bridge takeoffs." 

The AP1055F paver's automation simplifies operation. "There's not a whole lot of manual adjusting we need to do anymore. That definitely makes it convenient, quicker and you get a lot truer grade at the end," Leivdal says. 

 Day-by-day, the crew progresses toward placement of one million tons of asphalt, and the opening of Loop 202. 

Seeing is believing: cutting the time for machine maintenance

The Cat AP1055F Paver helps simplify and reduce the amount of time spent on machine maintenance.
For starters, access points are easily accessible. "Everything is visible so that you can see if from the outside, even the points where you drain fluids or take samples," says Shane Leivdal, paving mechanic.

"They actually have remote hoses that come out to the side of the equipment. There's no more trying to reach a plug that's buried inside the machine."

The machine features a convenient built-in hose reel, so the paver can be cleaned without the need for buckets or a second machine to pressure wash. "At the end of the day we might take 15 to 20 minutes to give it a good wash down, depending on what kind of mix we're using," Leivdal says.

Company info

9401 – 85th Avenue North
Minneapolis, MN
US, 55445


Read more

More from Roadbuilding

Roller revolution: an in-depth report on tandem rollers

The needs of roadbuilders vary from region to region. Evolving highway specifications, project owner demands, maneuverability and ease of operation are just a few things that contractors must factor in when choosing a tandem vibratory roller. 

Bomag's 600-hp-class cold planers boast reengineered milling chamber for increased performance

Bomag has reintroduced its 600-hp-class (440-kW) Bomag 2200/60 cold planer with a Tier 4 Final (Stage V) engine and multiple productivity enhancing design advancements. The reengineered milling chamber improves the robustness and design of the front material depressor, resulting in increased performance, lower wear and longer component life. A new inner scraper design and improved compartment seal help to prevent material loss. 

eRoutes 3.0 asphalt delivery solution from Caterpillar and Trimble set for release

Caterpillar Inc. and Trimble Inc. have released eRoutes 3.0, a subscription-based plug-and-play digital telemetry solution designed specifically to serve the asphalt paving industry. The addition of eRoutes technology gives customers a proven, scalable process control solution that helps coordinate and synchronize the timely delivery of asphalt to the job site, a key to paving efficiency and quality.

Contractors hit compaction quality targets with Cat COMMAND

Caterpillar has announced the release of Cat COMMAND for Compaction, an operator-assisted technology that automates the soil compaction process and helps contractors achieve compaction quality. The COMMAND for Compaction system is available for use on select Cat vibratory soil compactors as a dealer installed kit on both new and existing B-Series machines.

New generation of pneumatic tire rollers

The HP series of pneumatic tire rollers is packed with technical innovations and further developments. Hamm has developed a common platform as the basis for all model variants in every market throughout the world. In addition, there are important innovations affecting the operator's platform, the water and additive sprinkling system as well as the ballasting.

Neal Manufacturing's High-Volume Road Maintenance Vehicle boasts efficient, clog-free movement of material

Neal Manufacturing, a division of Blastcrete Equipment LLC and a manufacturer of asphalt pavement preservation equipment, offers its High-Volume Road Maintenance Vehicle for maximum efficiency and high-quality results on large road projects. With innovative features and in-cab controls for key variables, the High-Volume Road Maintenance Vehicle allows for fast, precise sealcoat application, even with larger aggregate mixes.

Subscribe to our free newsletter

Get our newsletter

Learn more

Bomag adds 10-foot highway-class paver with new features, improved operator experience

BOMAG 10-ft (3.0-m) pavers now include significant upgrades to the operator's platform, which improve visibility and the operator experience. New dual swing-out operator stations feature BOMAG's SIDEVIEW innovation in which the seat and console swivel outward at four differing angles to deliver unobstructed views to the sides of the paver and the screed end gates. An open-grate design on the platform floor affords the operator direct-line sight of the screed spreading augers.

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.

Subscribe to our free magazine

Get Our Magazine

Paper or Digital delivered monthly to you

Subscribe or Renew Learn more

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. 

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.

Subscribe to our free newsletter

Get our newsletter

Learn more

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.  

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. 

Subscribe to our free magazine

Get Our Magazine

Paper or Digital delivered monthly to you

Subscribe or Renew Learn more