Trial of Strength at an Altitude of 4,000 Metres

It was enthusiasm at first sight! Carlos M. Salcedo de la Vega and his team decided to buy the new VÖGELE SUPER 2100-3 tracked paver at bauma 2013 in Munich, Germany. The Project Manager from Conalvias Construcciones was most impressed by the power of the drive system, as well as the versatility and robustness of the machine.

At altitudes of 4,000m, the air becomes thinner not only for humans, but also for machines. While the oxygen content at sea level is 21%, it amounts to just 12% at such high altitudes. The air pressure is also a good 40% lower than at sea level. Under such extreme working conditions, the use of a particularly powerful paver is decisive for maximizing productivity and key to the success of a road construction project. In the project involving a 206km connecting road from Ayacucho to Puquio, i.e. straight across the Andes, the innovative drive concept of the new SUPER 2100-3 set new standards in terms of performance. Indeed, it raised the bar to unheard of heights in the truest sense of the word.

“This paver represents the state-of-the-art. That’s precisely what we need in the Peruvian Andes to realize an upcoming 200km-long construction project at an altitude of 4,000m.” Salcedo de la Vega on his purchasing decision.

Mountain climber with 179kW

The SUPER 2100-3 is the most powerful paver in the new “Dash 3” generation of machines from VÖGELE. The machine is powered by an ultramodern liquid-cooled Cummins 6-cylinder diesel engine. The start-up and operating characteristics in the thin high-altitude air are extremely reliable thanks to the splitter gearbox of the VÖGELE EcoPlus package. The full performance capacity of this workhorse is ensured by the perfect cooling of the engine coolant, hydraulic oil and charge air via a large cooler assembly with innovative air routing. Powerful electro-hydraulically controlled separate drives installed directly in the sprockets of the crawler tracks translate the drive power into pave speed without loss. The 3.06m-long undercarriage provides for maximum traction and constant operating speed, even over difficult terrain. With this drive concept, the SUPER 2100-3 not only overcame the extreme conditions in the Andes with ease, but even managed to push heavy lorries up through the steep passes.

Super powerful, super intelligent, super economical

Fuel efficiency was also a convincing argument for using the new SUPER 2100-3 for the 206-km-long road construction project. Ensuring an adequate supply of fuel naturally presents a far greater logistical challenge in the Peruvian highlands than on an inner-city job site.

The innovative VÖGELE EcoPlus low-emissions package of the SUPER 2100-3 has a number of features that ensure low noise emissions and a substantial reduction in fuel consumption. In this context, all the hydraulic pumps needed for “traction”, “conveyors and augers” and “compaction” are automatically disengaged if the paver is idle for more than one minute. The combination of an energy-optimized tamper drive, engine speed-dependent variable-speed fan and controlled hydraulic oil temperature circuit allows fuel costs to be reduced by roughly 25%.

The new “Dash 3” generation has even more to offer

The list of “Dash 3” innovations is long, with the most important being these: PaveDock Assistant and PaveDock ensure a rapid and safe transfer of mix to the paver. Jolts when the feed lorry docks are effectively absorbed and communication between the feed lorry driver and paver operator greatly facilitated by a signal light system. AutoSet Plus permits quick repositioning of the paver on the job site without any settings being lost. And the new ErgoPlus 3 operating concept with colour display, side rain and wind protection, enhanced screed console and a host of other improvements allows total control over the machine and the paving process.

Paving water-bound base with high pressure

The water-bound base was placed in differing thicknesses of 10cm, 16cm and 20cm. This required pre-compaction values on the part of the paver in excess of 80%. No problem for the AB 600 Extending Screed in the TP1 version, equipped with VÖGELE high-compaction technology – tamper and pressure bar. VÖGELE high-compaction is based on the unique technology of the pressure bar driven by pulsed-flow hydraulics, yielding excellent compaction values. The calculation is quite simple: the higher the degree of compaction achieved with the paver, the lower the need for extra compaction with rollers. However, VÖGELE high-compaction screeds with pressure bar(s) are also invaluable in situations where the use of rollers is disadvantageous for technical or economic reasons. This applies to multi-layer paving, for instance, where expensive surface course material is not necessary to even out surface irregularities because the base course has been paved perfectly. This was the case in the 206-km-long road construction project in Peru. For this project, the surface course consisted of just a 1cm layer of slurry-seal asphalt, laid “on top”.

Heavy work made easier by Heavy Duty Kit

In total, 195,000m³ of water-bound base course material were paved – a great achievement for the “Dash 3” powerhouse which is extremely robust as standard, but this time was also equipped with a Heavy Duty Kit. This kit includes reinforced guards for the conveyor tunnel and the chassis, as well as modified auger blades, to withstand high abrasive wear. “The Heavy Duty version of the SUPER 2100-3 was absolutely necessary for this long and difficult project, which involved such immense volumes of water-bound base course material,” emphasised Juan Manuel Draxl from VÖGELE’s Peruvian sales partner Intermaq S.A.C., based in Lima.

The new SUPER 2100-3 – a superlative tracked paver

The new “Dash 3” generation from VÖGELE not only delivers what it promises, it actually far exceeds the high expectations of the pros. Based on the road construction project presented here, one could even reach the following conclusion: A paver that can pave effortlessly at an altitude of 4,000m can operate on any job site in the world!

Job Site Details

Construction of the north-south connection between the city of Ayacucho and the town of Puquio, Peru
Total length of the job site: 206km  
Width of the job site: up to 5.5m  
Paving Details    
Pave width: 4.5 to 5.5m  
Layer thickness: base course 10cm over 125km
    16cm over 59km
    20cm over 22km
  surface course 1cm
Base course: water-bound base of river gravel with a maximum grain size of 3.8cm, stabilized by the addition of 1% cement
Surface course: 1cm-thick asphalt layer of slurry seal with “CSS-1hp” polymer-modified asphalt emulsion and 3% SBR polymers
Equipment SUPER 2100-3 Heavy-Duty Paver with AB 600 High-Compaction Screed in the TP1 Version
  HAMM 3414 Compactor  
  HAMM GRW 15 Rubber-Wheeled Roller