Asphalt Review - Volume 29 Number 2 (June / July 2010)

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ASPHALT REVIEW See Table 1. for a comparison of typical temperatures (degrees C) measured on a trial carried out on 10 March 2010 in Queen Street for the Parramatta Council. More benefits with LoCarb “LoCarb is a win-win for the environment and from a sustainability perspective, with a simultaneous reduction in energy consumed and emissions generated during the manufacturing process,” says Boral’s Asphalt Technology Manager, Trevor Distin. There is also a saving in the amount of non-renewable raw materials such as bitumen and aggregates required to produce asphalt. The benefits of using LoCarb asphalt extend further than those already mentioned. “The lowering of application temperatures means that we are now able to achieve the same, if not better, compaction and production rates in the field. This is because the mix compacts more uniformly and allows us to open it to traffic sooner,” Mr Distin says. “On a recent job the temperature was measured behind the paver for both a traditional hot mix and LoCarb asphalt using an infrared thermal imaging camera. The temperature readings recorded across the mat supported our belief that there was far less variation for LoCarb than hot mixed asphalt and this is a key factor to achieving a uniform density in the mat after final compaction.” The temperature profile measured by Thermovision Services across the mat behind the paver for HMA vs LoCarb. There is also a significant reduction in fumes and odours generated because LoCarb is produced and placed below the fuming temperature of bitumen. Bitumen typically fumes at a temperature around 135 degrees C and the rate of fuming doubles with every 10 degree increase in temperature. This helps improve the quality of air for people living within the vicinity of an asphalt plant and for the asphalt workers placing LoCarb. LoCarb Trials Since the first trial section in 2006, Boral has placed LoCarb on many streets across Australia. In 2009 an extensive trial was undertaken on the Deer Park bypass with the properties of the mix thoroughly evaluated. Further trial sections of LoCarb were placed on the Hume Highway in Melbourne in April this year as part of the national Warm Mix Asphalt validation project organised by AAPA in conjunction with all the State Road Authorities. Laboratory tests carried out to date have shown that the performance of LoCarb is on par with that of hot mixed asphalt. LoCarb technology is also very versatile and can be applied to most mixes from wearing course to base courses. On a recent job in Perth, 2000 tons of LoCarb was placed on the Great Eastern Highway as a patching material because Main Roads Western Australia wanted a mix that could be trafficked immediately after it was placed and compacted. Given the benefits to both the environment and the road provider there is a compelling argument that LoCarb should be considered as an asphalt material of first choice for your next road project. Plant LoCarb Hot mixed asphalt Asphalt temperature directly after mixing 138 172 34 Stack temperature 103 119 16 Paving Site Asphalt temperature in the truck at site 105 137 37 Asphalt temperature behind the paver 90 116 26 difference FULTON HOGAN PAVES THE ROAD TO SUCCESS Fulton Hogan, a Trans–Tasman leader in the construction and asphalt industries is using its Astec plant and equipment as an advantage to build a multi-million dollar road project in South Australia – possibly the state’s largest. To ensure that it was equipped to deliver on the project’s tight product specification and aggressive productivity targets, Fulton Hogan engaged Astec Australia to establish a modern asphalt production facility and paving equipment for the Northern Expressway Project (NEXY) The project is a 23 kilometre route that will connect key areas of metropolitan Adelaide and is considered a “benchmark for modern road construction in Australia”. From the start, Astec Australia worked in a partnering type relationship with Fulton Hogan, to understand and provide solutions for its exact project needs. A few years ago Fulton Hogan used Astec’s plant and equipment with great success on its high profile Eastlink Project in Victoria, so with those good experiences fresh in its mind, Fulton Hogan didn’t hesitate to engage Astec in the supply of a T200 M Pack Double Barrel Asphalt Plant, a SB1500 Material Transfer Vehicle and a RP 190 Roadtec Highway Paver. Astec Australia provided a ‘turnkey’ solution for Fulton Hogan. Fulton Hogan provided the hard stand area, gas and power and Astec Australia did the rest. Through its partnering arrangement with Fulton Hogan, Astec constructed the civil works for the plant site, and then used its in house expertise to manufacture, ship, install and commission the T200 Double Barrel Asphalt Plant equipped with Warm Mix and 50% RAP Technology. To handle the project’s productivity demands and the need for providing various mix types on any given day, Fulton Hogan opted for Astec’s Long Term Storage Silos. Three 150 tonne silos provide Fulton Hogan with the ability to store 450 tonnes of hot mix for 72 hours without loss of temperature or quality. Fulton Hogan has used the storage system to great advantage, increasing its productivity through those short winter Table 1 44 ROADS JUNE 2010/JULY 2010
days in South Australia to over 2500 tonnes per day. Fulton Hogan, whose Australian headquarters are based in Melbourne, is a major civil contracting company which offers services in civil contracting, construction, infrastructure maintenance, quarrying and asphalt production and surfacing. The company’s Asphalt Manager NEXY Project, Morrie Deller, says the Astec equipment has enabled Fulton Hogan to manufacture more than 400,000 tonnes since February 2009, and the project is on track for early completion in August – four months ahead of schedule. “Astec drives us to that high quality of performance maintenance. We have had very, very little down time on this project due to break down,” he says. “It gives us the most state-of-the-art plant in the world. These double barrel drum plants are top of the tree from a technology point of view. “There are very minimal issues with EPA – we can recycle material from the works back into the works so there is minimal waste.” Mr Deller, who brought the first Astec plant into Australia in 1996, is one of the most familiar in the country with the brand. “On this job we’ve got silos for asphalt storage where we can hold more than 400 tonnes of product for several days and we’ve got four bitumen kettles of about 50 tonnes each,” he says. “With Astec, it is the fact that they do the whole deal. They’ll put it all together for you. “We buy Astec equipment because it performs and because of the back up that we get from Astec in Brisbane.” Astec Australia General Manager, David Smale, says the challenge for Astec Australia since it acquired Q-Pave in 2008 is to not only demonstrate to industry that standards haven’t dropped but to exceed expectations. He says the contract with Fulton Hogan is one of Astec Australia’s biggest deals in relation to a relocatable plant and project equipment. “The NEXY Project is up there with some of the largest infrastructure projects in Australia, and in terms of being on time and being commissioned on spec, the delivery of the asphalt plant was certainly extremely important,” he says. “We worked with Fulton Hogan’s site people to have the whole site prepared. When building a plant there are 45 trailers of structures and equipment. We bring them in, in sequence, and as we take them off the trailers we stand them all on the concrete pads and everything is set out while people set it up. “Our business is fortunate to have a very capable service team, which had the whole plant standing in seven days and commissioned in 28 days – for a plant of this size that is pretty impressive” When work is finished on the NEXY project, the equipment is expected to be relocated. David Smale says his company focuses and delivers on the after sales service and support that Fulton Hogan requires to ensure their NEXY project is successful. Mr Smale says the relationship with Fulton Hogan began a number of years ago and included work on the 600,000 tonne EastLink project in Melbourne. “That proved to be a successful relationship in terms of Astec Australia providing solutions in asphalt plant installation and maintenance,” he says. “It gives the customer that complete confidence he won’t have any dreaded down time – I may not have this number exactly right, but I am told by Fulton Hogan that they only had 13 hours of down time on their Nexy Project during its two-years of construction.“ Australian Asphalt Pavement Association Queensland Executive, Rob Vos, says that the NEXY Project is one of South Australia’s largest infrastructure projects and is designed with deep lift asphalt pavement. South East Queensland has a number of these types of full depth asphalt projects which are a good design solution for long lasting pavement. Mr Smale says Astec’s “first and foremost” strategy is to maintain and improve on its core asphalt business, and to help the industry itself improve the market by providing solutions for sustainability. Astec Australia will also work on capitalising on its relationship with Astec’s Aggregate and Mining Group of companies and their products to develop the aggregate arm of its business in Australia. ROADS JUNE 2010/JULY 2010 45
Page 1 and 2: AsphaltReview Volume 29 Number 2 Ju
Page 3 and 4: Chairman’s report ASPHALT REVIEW
Page 6 and 7: ASPHALT REVIEW a range of different
Page 8 and 9: ASPHALT REVIEW AAPA/Austroads Warm
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Page 12 and 13: ASPHALT REVIEW research and quality
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Page 16: ASPHALT REVIEW Foamed bitumen The q
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Page 21 and 22: Fulton Hogan and PRS Join Together
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Page 33: VÖGELE VISION 5103-2 FEATURING HIG

Asphalt Review - Volume 29 Number 2 (June / July 2010)

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