Building roads that last, boosting cost-effectiveness: VÖGELE InLine Pave®   Two Layers, Well Interlocked, for Longevity of Road Pavements     Those letting contracts for construction or rehabilitation of roads call for long-lasting pavements, contractors dream of flexible machine technology and road users want as little inconvenience from roadworks as possible. VÖGELE’s reply to these demands is InLine Pave®. This innovative and cost-effective concept is ideally suited for building compact asphalt pavements “hot on hot”. When applying the InLine Pave® method, binder course and surface course are placed in a single pass, thus yielding not only a perfect bond of layers but also strong interlocking. Both properties are fundamental requirements for the longevity of roads. Beyond that, InLine Pave® offers a significant economical advantage: the same machine technology can also be used for conventional paving jobs at any time.             Rehabilitation of road pavements in single-lane width is a measure carried out in large numbers in many countries all over the world. These roadworks, however, often involve long-term job sites with traffic piling up for kilometres, a burden for the countries’ national economies. Now, thanks to InLine Pave®, the duration of roadworks can be reduced considerably. What’s more, the compact machine technology allows roadworks to be carried out while traffic keeps flowing, a circumstance reducing the potential of pile-ups considerably. The InLine Pave® machine concept handles pave widths from 3m to 8m. This allows a wide range of applications ranging from cross-town links, rural roads and highways through to motorways.     Slightly modified machinery of series production       The InLine Pave® process is based on the use of machine technology very similar in design to VÖGELE pavers of series production, but slightly modified for “hot on hot” paving. For contractors, this means that every single machine of the InLine Pave® train – the MT 1000-1 IP Mobile Feeder, the SUPER 2100-2 IP paver for binder course and the SUPER 1600-2 or SUPER 1800-2 paver for surface course – can also be used for conventional paving jobs at any time. This substantially increases the productive utilization of the contractor’s equipment pool and enhances the return on investment. Thus, the InLine Pave® technology is tailored not only to large road construction companies, but also made for small and medium-sized contractors.     1.5 million m² of road pavement built with InLine Pave®       Thanks to the impressive concept, some 1.5 million m² of road were paved throughout Europe using the VÖGELE InLine Pave® method in just three years since its launch. This innovative technique has been applied in single-lane and dual-lane rehabilitation projects, as well as for the construction of numerous new motorways, highways and rural roads.     Quickly ready for operation on the job site       The InLine Pave® machines stand out through compact design. The maximum transport width is 3m, which allows easy transfer to the job site. Once arrived, the entire InLine Pave® train can be put into operation within a very short period of time. For the paving team, set-up of all machines involved, in their basic configurations, takes no more than two hours. Thanks to the fast set-up and compact dimensions, also short job sites, such as cross-town links, can be handled quickly and very economically.     “Hot on hot” paving offers many advantages       The two-layer construction of asphalt pavements by “hot on hot“ paving is a particularly efficient method of building long-lasting roads. When using this method, binder and surface courses are laid one immediately after the other. This offers a number of advantages. When paving two layers “hot on hot”, the usual ratio of 8cm binder course and 4cm surface course can be abandoned and another ratio be selected. For “hot on hot” paving, a ratio of 10cm binder course and 2cm surface course is common practice. As the two layers are placed one immediately after the other, the ideal mix temperature inside the asphalt package can be maintained for a prolonged period of time. The heat is stored, so to speak. This circumstance is to the benefit of final compaction by rolling, as the higher temperatures in both binder and surface courses allow a substantially higher degree of density to be achieved by the rollers along with a lower voids content. As a result, the road pavement’s longevity is enhanced. Furthermore, paving “hot on hot” with InLine Pave® is an effective means to prevent rutting. The 10cm binder course – thicker compared to conventional paving –, the thin surface course of no more than 2 to 2.5cm as well as the high density of the overall asphalt package improve the pavement’s resistance to deformation and counteract the formation of ruts.     Maximum compaction when paving binder course       The core element of the InLine Pave® concept is the VÖGELE High Compaction Technology based on pulsed-flow hydraulics. Only thanks to the high pressure of its 2 pressure bars is the AB 600-2 IP Extending Screed, mounted to the paver for binder course, capable of placing a layer that strong, that the paver for surface course, following behind, can travel on it. This paver, including material and extra storage hopper, weighs some 40 tonnes. In recent years, the AB 600-2 IP Extending Screed has been developed further and perfected in order to meet the special requirements of “hot on hot” paving. The screed applied for InLine Pave® generates such a high pre-compaction that, as a function of the mix used, a density of 98% or greater can be achieved. Please note that this is the density prior to rolling. The mix composition for the binder course should be selected so that the forces from traffic are distributed downwards onto the sub-base without deformation. Provided proper distribution, the crawler tracks of the paver placing surface course and travelling on the hot, precompacted binder layer will leave no more than minimal imprints. No adverse effect upon quality results, for neither the binder course nor the surface course.                 Well illuminated job site: The InLine Pave® train in operation at night.   “Compaction with oscillating rollers optimal for InLine Pave®”       For final compaction of binder and surface courses placed “hot on hot”, rollers with oscillation are the ideal choice. This is the result of test series carried out by HAMM AG: “We worked with a DV 90 VO roller with oscillation and a DV 90 VV vibrating roller. A comparison was made between the results and the data collected showed that the oscillation system is superior by far for compacting InLine Pave® surfaces,” explains Gerd Lenz, Applications Consultant of HAMM.     Smooth compaction of the thin surface course       This is primarily due to the two-layer structure of the InLine Pave® asphalt pavement. While a conventional pavement is made up of 8cm binder course and 4cm surface course, the ratio for two-layer InLine Pave® is 10cm and 2cm. “When applying intense pressure through vibrations, the thin surface course might risk to be displaced,” says Gerd Lenz. This risk is avoided by using oscillation: the DV 90 VO roller with oscillation achieved the specified final density after just three passes.     Compaction with oscillation: effective, fast and gentle       With oscillation, the dynamic compaction system, masses rotating in the same direction generate a specific momentum around the roller drum’s axle. The momentum changes its direction during one rotation of the mass and generates an oscillating, horizontal movement of the drum. This way, tangential shear forces are introduced into the pavement, both forwards and reverse. The result: in contrast to vibratory compaction, the vibrating load is just 10% and the compacting forces are introduced into the pavement with high accuracy. The roller drum is in permanent contact with the pavement, thus providing for rapid and homogenous compaction. Not only proved this compaction more effective, it also is gentle on both the material and the machine.                       Machine Technology for VÖGELE InLine Pave®     InLine Pave® means that the process of paving takes place by machinery working in a line, one immediately after the other. All machines feature a very compact design. The InLine Pave® train comprises 3 units: a MT 1000-1 IP Mobile Feeder, a SUPER 2100-2 IP paver for placing binder course and a SUPER 1600-2 for paving surface course. For surface course, the VÖGELE SUPER 1800-2 model can also be used as an alternative.     1. MT 1000-1 IP Mobile Feeder       The MT 1000-1 IP Mobile Feeder is the first InLine Pave® machine in the team of three. It receives binder and surface course mixes supplied by feed vehicles and transfers the mixes, by turns, either directly into the large material hopper of the paver for binder course or – via a transfer module and over this latter machine – into the hopper of the paver for surface course.     2. SUPER 2100-2 IP for Paving Binder Course       The SUPER 2100-2 IP for placing binder course is a slightly modified machine of standard design, fitted with a special transfer module for the surface course mix. The paver’s task is to place binder course of high density and with high resistance to deformation. The VÖGELE SUPER 2100-2 IP comes with a special AB 600-2 IP Extending Screed for compaction at the highest level.     3. AB 600-2 IP High Compaction Screed       The AB 600-2 IP Extending Screed, based on the unique VÖGELE pulsed-flow hydraulics, is equipped with two pressure bars. The screed is the technological gem of the InLine Pave® technology. The binder placed and compacted by the AB 600-2 IP features such a high density that the paver for surface course, following behind, can travel on the binder layer.     4. SUPER 1600-2 or SUPER 1800-2 for Paving Surface Course       A normal SUPER 1600-2 or SUPER 1800-2 is used for paving surface course. These, too, are machines of standard design, however equipped with a water spraying system for the crawler tracks and an extra material hopper insulated against loss of heat and holding a total of 25 tonnes of mix. The extra hopper is placed into the paver‘s regular material hopper.                                     InLine Pave® Increases Cost-Effectiveness     One of the biggest advantages of the InLine Pave® technology is its cost-effectiveness. Every single machine of the InLine Pave® train can be employed for conventional paving jobs at any time. The SUPER 2100-2 IP with AB 600-2 IP Extending Screed, for instance, can also be used as a stand-alone paver for placing high-density base course. The speciality in this context is that single-layer construction is possible. This saves time and money. Depending on the mix to be placed, a 18cm base, for instance, can be built in a single pass instead of two layers of 9cm each. Thanks to IP High Compaction Technology, a density between 93 and 97% is achieved. For this base course task, the paver can be used with the transfer module fitted or without it. However, when used with the transfer module equipped, the SUPER 2100-2 IP is ready immediately for subsequent two-layer paving on an InLine Pave® job site.     Quickly familiar with InLine Pave® thanks to the ErgoPlus® operating system       Comparing the InLine Pave® process of “hot on hot” paving with conventional road building techniques shows, there is no difference for the paving team as far as operation of the SUPER pavers is concerned. Both paver and screed operators quickly get to grips with the machine technology, as all vital functions are based on the VÖGELE ErgoPlus® operating concept. Mention, however, should be made that the job site logistics for InLine Pave®, such as reliable organization of mix supply, should be well planned and executed by an experienced team.               Use as an InLine Pave® machine or as a standard paver: Conversion of the SUPER 2100-2 IP in just 6 hours (see pages 26/27).   Operator comfort as usual: The SUPER 2100-2 IP, too, is controlled by ErgoPlus®.                         The Advantages of VÖGELE InLine Pave® Technology at a Glance   1. Highest Evenness       The conventional method of road construction is ideal for producing pavements of highest evenness. Base course, binder course and surface course are laid in three passes. The “self-levelling” behaviour of the paver’s screed provides that the evenness is improved from layer to layer. InLine Pave® translates 100% of this principle into reality, even though paving “hot on hot“. Thanks to VÖGELE High Compaction Technology installed in the screed, the binder course reaches a density beyond 98%, as a function of mix composition. Just as if that layer would have been compacted by rolling. In other words: when applying InLine Pave®, the surface course is paved “hot on hot“ on a binder layer which, in terms of evenness and density, is on a par with a binder layer compacted in the conventional way. InLine Pave® does not make special demands on the evenness of the base course.     2. Use of Conventional Rollers       With VÖGELE InLine Pave®, the pre-compaction of the binder course achieved by the paver is so high that medium-weight rollers can follow right behind the screed to produce the final density. InLine Pave® does not call for a gradual compaction of binder and surface courses by light and heavy rollers working in echelon. This reduces the risk of destroying the pavement’s evenness behind the paver. VÖGELE High Compaction Technology applied for InLine Pave® attains such a high degree of pre-compaction that the number of roller passes required for the final density is reduced substantially. Especially when using HAMM rollers with oscillation, a perfect final density is achieved after just a few passes. The gentle compactive action of HAMM rollers with oscillation is ideal for thin surface layers like the ones placed with InLine Pave®.     3. Clear Separation of Layers       The high pre-compaction of the binder course precludes blending of binder and surface course mixes. A clear separation of layers results, which allows to obtain a high-quality surface course with optimal surface finish. In addition, measurements of layer thickness can be carried out at any point while paving. This facilitates monitoring of the layers for correct thickness considerably.                 InLine Pave® saves surface course mix and tack coat between binder and surface layers. Characteristic of the “compact pavement” structure is a thin surface course and an increased thickness of the binder course.   4. High Productive Utilization through Use of Machines Close to Standard Design       The Mobile Feeder and the paver for surface course as members of the InLine Pave® train can be employed for conventional paving jobs at any time, without a need for conversion. The transfer module of the SUPER 2100-2 IP, used for placing binder course, mounts or demounts in just a few hours. As a result, every machine of the InLine Pave® train is available for conventional paving applications at all times. This enhances the productive utilization of the contractor’s equipment pool.     5. Placing Base Course with SUPER 2100-2 IP       The SUPER 2100-2 IP with the AB 600-2 IP Extending Screed can also be used as a stand-alone paver for placing high-density base course. The speciality in this context is that single-layer construction is possible. Depending on the mix to be placed, a 18cm base, for instance, can be built in one pass instead of two layers of 9cm each. This saves time and money. For tough jobs like this, the pressure for the pressure bars of the VÖGELE High Compaction Screed is infinitely variable up to 110 bar.     6. Easy Operation for High Process Reliability       Operation of all InLine Pave® machines is to a large extent identical with usual paving. Also as far as grade and slope control is concerned, the paving teams can fall back on their knowledge gained from jobs with conventional VÖGELE equipment.                     The Wide Range of InLine Pave® Applications     Thanks to the convincing concept, more than 1.5 million m² of road were built throughout Europe using the VÖGELE InLine Pave® method in just three years. This innovative technology has been applied for single-lane and dual-lane pavement rehabilitation, as well as for new construction of motorways, highways and rural roads. Find below several examples showing the wide range of InLine Pave® applications.                 Pavement rehabilitation for rural road: Pave width 7.5m. The road was closed to traffic. For binder course, grade and slope control by means of VÖGELE Big MultiPlex Ski referencing from the milled base. Slope up to 3.5% on curved sections. Crown set to 2.5%.               Pavement rehabilitation for cross-town link: Pave width 2 x 3.2m. Rehabilitation of 950m section in single-lane width. Traffic kept flowing on the adjacent lane. Short set-up time of just 2 hours for the basic equipment configuration allows economical paving of short stretches.               Pavement rehabilitation for motorway: Pave width 4m. Rehabilitation of lorry lane. Traffic kept flowing on the adjacent lane.               Pavement rehabilitation at night: Rehabilitation of a highly trafficked motorway. Pave width 4.7m. To avoid pile-ups, the roadworks were carried out at night.               New construction of federal highway: Pave width 7.5m. Paving work carried out between 6 bridges. On the bridge decks, only surface course was laid. VÖGELE Big MultiPlex Ski used for grade and slope control.               New construction of motorway: Pave width 5m. Before placing binder and surface courses, the road base had been built with the SUPER 2100-2 IP.               Pavement rehabilitation for motorway: Pave width 3.75m. Rehabilitation of lorry lane. Ambient temperature 0 °C.               Pavement rehabilitation for motorway: Pave width 7.5m. Porous asphalt was placed in two layers.