Combination of top VÖGELE technologies lends maximum flexibility to rehabilitation projects.
In addition to the conventional process of milling off the surface and
replacing the asphalt pavement, two others exist that are gaining ground
worldwide: paving thin overlay on spray seal and the “hot on hot”
paving of compact asphalt pavements. These two methods were made
possible by Joseph Vögele AG and their specially developed machine
technologies. The world market leader has now combined these two
innovations into one. The solution emerged with and for Rask Brandenburg
GmbH, a customer that has specialized extensively in modern methods of
rehabilitation.
Innovative, leading technology at work:
rehabilitating the carriageway on the A 113 motorway in Berlin with the
VÖGELE InLine Pave train; in the middle is the new SUPER 2100-3i IP for
placing binder course.
The machines behind these modern methods
of road rehabilitation are the SUPER 1800-3i SprayJet paver (for thin
overlay) and the VÖGELE InLine Pave train (for compact asphalt
pavements). The latter comprises a VÖGELE MT 3000-2i Offset PowerFeeder,
a SUPER 2100-3i IP for placing binder course and another VÖGELE paver
for the surface course. "With our InLine Pave train and the SUPER
1800-3i SprayJet as the surface course paver, we really have a jack of
all trades in our machine fleet," says Bernd Malcharek, President of
Rask Brandenburg GmbH. The combination of leading technologies from
VÖGELE gives us maximum flexibility." The underlying idea is that Rask
Brandenburg can take on conventional paving jobs in future, and still be
prepared for thin overlay and compact asphalt paving.
Paving thin overlay and compact asphalt are the future
Just a few weeks after shipment, the SUPER 1800-3i SprayJet had already
clocked 600 operating hours, all of them spent on spray paver jobs, i.e.
"hot on hot" jobs using InLine Pave technology. "The future belongs to
this process. Construction projects can be completed quickly, and that
benefits traffic flows. They are cost-efficient, in part because the
step of pre-spraying emulsion is entirely eliminated. And the results
are high-quality, because the bond between layers is outstanding,"
summarizes Roland Schug, Head of Marketing at VÖGELE.
Rehabilitation with the compact asphalt method alongside flowing traffic
In the InLine Pave process, the binder and surface courses are paved
"hot on hot" in a single pass. In other words, the two VÖGELE pavers
work "in line", with just a few metres between them, so that one lane
can remain open to traffic. A VÖGELE MT 3000-2i Offset PowerFeeder with
pivoting conveyor and automatic distance control ensures a continuous
supply of material. The paver operators can therefore concentrate
entirely on paving.
The mix is transferred by a VÖGELE MT 3000-2i Offset PowerFeeder,
which alternates between mix for the binder and surface courses. The
latter is conveyed by the transfer module to the downstream paver for
the surface course.
New "Dash 3"-generation paver for placing binder course
The central technological component of the InLine Pave process is the
SUPER 2100-3i IP for placing binder course. Apart from the innovations
of the latest "Dash 3" paver generation, this advanced machine has an
entirely redesigned transfer module whose heated conveyor system has
been extended by 1m. It transfers the mix for the surface course to the
downstream paver. At a defined point, the new transfer module can easily
be removed, a feature that boosts the machine's capacity utilization.
What is more, the height of the seats on the two operator's platforms
can now be adjusted hydraulically. "Advancements like this are one of
the main reasons why more and more companies are choosing InLine Pave,"
explains Ray Löffler, General Manager of WIRTGEN ZWICKAU, who is
responsible for Rask Brandenburg GmbH. "The InLine Pave process is fully
developed and increasingly winning over the market."
Durable binder course thanks to VÖGELE high compaction technology
Equipped with an AB 600 TP2 Plus Extending Screed, the SUPER 2100-3i IP
places such a highly compacted binder course that the surface course
paver can travel over it without prior rolling. This is made possible by
another core innovation: high compaction technology with VÖGELE’s
unique pulsed-flow hydraulics. In this step, the asphalt is precompacted
during paving by a tamper and two pressure bars.
Paving the surface course with the SUPER 1800-3i SprayJet as part of
the InLine Pave train. In this case, the spray and standard paver does
not spray any bitumen emulsion. The machine's ability to operate in both
conventional and spray paving mode increases its utilization.
Compelling advantages of SprayJet technology
For Rask Brandenburg, VÖGELE adapted the technology on the SUPER 1800-3i
SprayJet in such a way that the machine can take over the job of paving
the surface course in the InLine Pave train. The machine operates here
in the conventional manner, i.e. not in spray mode. This is because the
"hot on hot" method achieves a perfect bond between layers and strong
interlocking, even without spraying bitumen emulsion. The modifications
made to the SUPER 1800-3i SprayJet include the incorporation of a water
spray system and wider crawler tracks. For spray applications, the paver
is equipped with a removable SprayJet module, which enables it to
simultaneously pave and accurately spray the emulsion.
Machine technology passes acid test in Berlin
After the surface course is paved (by the SUPER 1800-3i SprayJet in the
case of Rask), rollers are used as usual to achieve final compaction. A
demonstration on the A 113 motorway in Berlin proved just how well the
high-tech machine systems from VÖGELE work together: the paving train
rehabilitated several sections totalling 2km in length, which were
opened to traffic on schedule at the end of the summer school holidays.
Background information: InLine Pave
VÖGELE have pulled off a hat trick with this development: they have
speeded up paving considerably, cut costs and improved road durability.
In the InLine Pave process, binder and surface courses are paved "hot on
hot" in a single pass, greatly accelerating activities on a job site.
In addition, it is unnecessary to completely close down the road: the
three machines – a paver for the binder course, a paver for the surface
course and a material feeder – work "in line", one behind the other,
leaving one lane open to traffic. An ideal solution for rehabilitation
of heavily travelled roads. The process is both economical and highly
eco-friendly: the layer thickness can be reduced in "hot on hot" paving,
thus lowering consumption of the costly surface course mix. Quality is
another aspect: VÖGELE InLine Pave produces a perfect bond between the
binder and surface courses, making the new pavement very durable. The
InLine Pave train also has a modular design to maximize economic
efficiency: it includes only slightly modified, standard machines, all
of which can additionally be used individually for other paving jobs.
Background information: SprayJet technology
This innovation by VÖGELE is the method of choice for the economical
paving of high-quality asphalt surface courses. With VÖGELE SprayJet
technology, bitumen emulsion can be sprayed and overlaid with an asphalt
surface course, all in one pass. Spray pavers suitable for this process
existed in the past, but never became established, mainly because they
were suitable only for spray paving jobs, but not for conventional
paving. With its SprayJet technology, VÖGELE have remedied this
shortcoming. The SUPER 1800-3i paver in standard design is converted
into a spray paver quickly and easily by adding a module. The spray
function is easily activated and deactivated at the push of a button.
Because the machine can also be used for conventional paving jobs at any
time, the investment quickly pays off. The special advantages of the
innovative VÖGELE SprayJet technology lie in its cost-efficiency and
excellent environmental credentials. The process optimizes the placement
of thin, resource-saving, low-noise asphalt layers. The rate of spread
can be set exactly, ensuring that only as much bitumen emulsion as
actually needed is applied – no more, no less.
Công nghệ khác
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SprayJet versus Conventional Paving with Pre-Spraying of Emulsion