Combination of top VÖGELE technologies lends maximum flexibility to rehabilitation projects.

In many countries, construction companies are hired to rehabilitate existing roads much more frequently than to build new ones.

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.

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.

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.

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.