Level Control

Runway Asphalt Laydown & Compaction 1 For Base & Binder courses
Stringline & Joint-matching Shoe or averaging beam
2 For wearing course
David H Moloney August 2011 Method using 2 # Pavers working in Echelon Set paver screed to achieve a compacted thickness of 40mm
Contract:- Muscat Airport Expansion new Runway
References - 1 Method Statement # 40 Level Tolerances Spec Series 400, page 34
2 Specification Series 400 Asphalt Paving Surface +/- 6mm

3 ITP for Bituminous Pavement Activities SE-CTJ-01CW-PLN-00006 Under Straight edge 3mm with 3 m long beam

Main Parts Level Equipment Marini Asphalt Batching plant

1. Cold bins
2. Cold feed gate
3. Cold Elevator
4. Dryer
5. Dust Collector
6. Exhause stack
7. Hot elevator
8. Screening unit
9. Hot Bins
Lead Paver 2 # stringlines Model - Top TOWER 4000 P
10. Weight box
11. Mixing unit - pugmill
Trailing Paver 1 # stringline & joint-matching shoe Plant Capacity - 300 tonnes per hour
12. Mineral Filler storage Pins set at 10 centres with wire 100mm over finish level Mixer batch Capacity - 3.5 tonnes
13. Hot asphalt cement storage
14. Asphalt weight bucket Hot mix Storage - 126 tonnes
Joint Pattern across runway

South Finish Rolling

Intermediate Rolling for removing marks,
for further compaction creases & to polish
surface
Wibau Asphalt Batching plant
Initial aka
Asphalt Batching Plant Schematic Plant Capacity - 180 tonnes per hour
Breakdown Rolling Hot mix Storage - 100 tonnes
Mixer model - WKM 250-4
250 tonne with 4# screens

Batching Plants Capacity

Marini 300 t / hr (TopTower 4000 P)
Wibau 250 t / hr
Total 550 t / hr
Take output @ 450 t / hr
Roller Pattern to be determined by Compaction Test Strip for checking
density & smoothness, detailing sequence of rollers, # of passes, speed of
rollers and vibratory or static passes. Vogele Super 1900-2 tracked Pavers
Testing Extending Screed type AB 600-2 TP
Levels by Engineers level
Prime Coat - apply by lorry with spray bar @ 90 *C & allow to cure for 24 to 48 hours Smoothness by Straight Edge
Compaction by Cores
Surface Preparation - remove loose material & dirt with mechanical brush Ingredients by Sample to Lab
Temperature by Digital Thermometer
Asphalt Paving - Outputs & Pave Speed
Lorry 35t Round-trip Cycle Time Length of runway appro 5,000 m Train of Laydown & Compaction Plant PTR - Pneumatic Tyre Roller
Lorry Tonnes
Loads unload Lorry load 34 t metres Exerts both vertical & horizintal force to knead the
Thickness 7.5m strip t/m per hour Pave Speed
Travel from batching plant to site Av 5km 10 minutes per hour cycle per hour per Paver Delivery :- Tippers & Tractor units with trailers asphalt for high compaction, Tyre pressures can be
altered for different applications
Queue, Reverse, Unload & Pull out 10 minutes Wearing Course 40 mm 7.5m x 1m x 0.04m x 2.6t/cm 0.78 t/m 6.6 # 9 min 43 m / load 290 m 225 t / hr 5 m/min Pavers:- Asphalt Paver - Vogele Super 1900-2
Return to batching plant 10 minutes Binder Course 50 mm 7.5m x 1m x 0.05m x 2.6t/cm 0.98 t/m 6.6 # 9 min 34 m / load 225 m 225 t / hr 4 m/min Site Pave width 7.5 m Capacity 225 t / hr / paver
Mix & Load 10 minutes Base Course 70 mm 7.5m x 1m x 0.07m x 2.6t/cm 1.365 t/m 6.6 # 9 min 24 m / load 160 m 225 t / hr 2.6 m/min Rollers :- PTR Pneumatic Tired Roller - Bomag BW 25 RH 25 tonne
Total 40 minutes Prime Coat MC70 Applied to CABC surface - 0.5kgs to 0.6 kgs per m2 Application temperature 90*C +/-5*C PTR Pneumatic Tired Roller - Bomag BW 24 R 24 tonne
=> 10 # Lorries capacity 35t required Tack Coat SS-1 Between asphalt layers - 0.2kgs per m2 to 0.35 kgs per m2 Application temperature 20*C to 70*C Tandem vibratory Roller - Bomag BW161 AD-4 10 tonne
Compaction of Asphalt Roller Pattern - Temp 121 to160*C Temperatures
For 7.5m wide strip & Output 225t/hr Rate of paving 290 m per hr or 5 metres per minute Paver :- Vogele Super 1900-2 Tracked Paver Storage of Bitumen 150*C
Aim - to achieve target density and smoothness of surface Mixing 165*C Incidental Plant & Equipment Steel Tandem Drum Roller
Initial or Breakdown Rolling Intermediate Rolling Finish Rolling Laying 150*C Mechanical Suction Brush
Initial Rolling min 150*C Roller with cutting wheel for longitudinal joints
Cut longitudinal Joint max 80*C Road Saw for transverse Joints
Water Bowzer & Welfare Facility with Toilet
Lorry mounted Bitumen Sprayer c/w hand lance for
Roller type : Steel Tandem RTR Steel Tandem cold joint sealing
Pneumatic Tyre Roller Ballasted to 20 tonne
Typical Crew
Make & model : BW 161 AD-4 BW 25 RD BW 161 AD-4 Engineer Tandem Roller Operatives Environmental Issues - Wastage & Efficiency
# of Rollers 1 # per 7.5m strip 1 # per 7.5m strip 1 # per 2 x 7.5m strips Supervisor Paver Operator Material Waste - Keep tight control by reconciling daily the quantity Road Planer
# of Passes : 4# 6# 2# Foreman Rake Hand x 2# of bitumen used at the batching plant and asphalt mix used on site,
against the theorical to establish the daily waste factors.
Vib / Static : 2 # Static & 2 # Vibration Static 2 # Vibration & 2 # Static Extending Screed type AB 600-2 TP Setting-out Surveyors Labourer x 4#
Weight ballasted 10 tonne 25 tonne 10 tonne Varible Pave Width 3m to 6m , with bolt on extensions to 9.5m Screw man Levels x 2#
Speed : 5 Km/hr 4.5Km/hr 8 Km/hr PTR Roller Operator x 2# Banksman Ensure level of aggregate layer under the asphalt base course is not
Tyre Pressure : 60 lbs/in Pass is "one coverage" by the roller in one direction Breaks for meals 30 minutes maximum low. As the daily crew cost if fixed, seek ways to improve the daily
output without compromising quality.
Pneumatic Tyre Roller (PTR) used to knead the mix and achieve most compaction.

Joints Construction Details:- 1 Traverse : Temporary ramp to allow rollers to pass, prior to restart vertical joint cut, stagger joints across adjacent strips by 3 metres. Ingredients Approximate Weights

2 Longitudinal : Add extra 100mm width to pave width for cutting back, offset joints by 300mm, cut with roller wheel when asphalt is below 80* C . Paint joints with tack coat Bitument 60/80 = 4.8% of mix weight Lorry tanker for Prime & Tack Coat
Compaction Requirement :- 94% of Gmm ie Max theroretical Note :- Vertical joint surfaces sprayed with tack coat, particular attention paid to ensure compaction on hot side of joint. Polymer 3.8 kgs per tonne of mix
Phoenix Model FC 8000 with spray bar, pressure pump
and devise to measure rate of application