A WIRTGEN GROUP COMPANY A WIRTGEN GROUP COMPANY

JOSEPH VGELE AG
Joseph-Vgele-Str. 1
67075 Ludwigshafen Germany
Telephone: +49 (0)621 8105 0
Fax: +49 (0)621 8105 461
Vgele
marketing@voegele.info www.voegele.info
Booklet
on Paving

VGELE Booklet on Paving

ERGOPLUS, InLine Pave, NAVITRONIC, NAVITRONIC Basic, NAVITRONIC Plus, NIVELTRONIC, NIVELTRONIC Plus, RoadScan, SprayJet, VGELE, VGELE PowerFeeder, PaveDock,
PaveDock Assistant, AutoSet, AutoSet Plus, AutoSet Basic, ErgoBasic and VGELE-EcoPlus are registered Community Trademarks of JOSEPH VGELE AG, Ludwigshafen/Rhein,
Germany. PCC is a registered German Trademark of JOSEPH VGELE AG, Ludwigshafen/Rhein, Germany. ERGOPLUS, NAVITRONIC Plus, NAVITRONIC BASIC, NIVELTRONIC Plus,
SprayJet, VISION, VGELE, VGELE PowerFeeder, PaveDock, PaveDock Assistant, AutoSet, AutoSet Plus, AutoSet Basic and VGELE-EcoPlus are trademarks registered in the
US Patent and Trademark Office to JOSEPH VGELE AG, Ludwigshafen/Rhein, Germany. Legally binding claims cannot be derived from written information or pictures contained
in this brochure. Pictures may include optional extras. We reserve the right to make technical or design alterations. www.voegele.info www.voegele.info

2280299 EN/03.15
VGELE BOOKLET ON PAVING

CONTENTS

1 Design of a Road Paver 7 2.6.1 Tamper ................................................................................................................... 70

1.1 Differences between Construction Machinery and Road Pavers .................................. 8
1.2 Components of a Road Paver ..................................................................................... 10
1.3 The Floating Screed Principle .................................................................................. 12
1.4 Theoretical Outline of the Floating Screed Principle ................................................ 13
1.5 Tracked Pavers and Wheeled Pavers .................................................................... 14
1.6 VGELE Product Overview ................................................................................... 18
1.6.1 Paver Classification ................................................................................................. 20
1.7 Examples of Paver Applications ........................................................................... 22
1.7.1 Types of Paving ........................................................................................................ 22
1.7.2 InLine Pave / SprayJet Technology ........................................................................... 24
1.7.3 Paving Materials ...................................................................................................... 26
2 Screed 29
2.1 General Differences between Screeds .................................................................. 30
2.2 Extending Screeds .............................................................................................. 32
2.2.1 Components of the Extending Screed ...................................................................... 32
2.2.2 Compacting Systems Installed in Extending Screeds ............................................... 34
2.2.3 Extending Screeds and Bolt-on Extensions .............................................................. 36
2.2.4 Set-Up of the Extending Screed ............................................................................... 38
2.2.5 Mechanical Design and Maintenance of the Telescoping System ............................ 48
2.3 Fixed-Width Screeds ............................................................................................ 50
2.3.1 Components of the Fixed-Width Screed .................................................................. 50
2.3.2 Compacting Systems Installed in Fixed-Width Screeds ............................................ 52
2.3.3 Fixed-Width Screeds and Bolt-on Extensions ........................................................... 54
2.3.4 Set-Up of the Fixed-Width Screed ............................................................................ 60
2.4 Screeds for the American and Australian Markets ................................................. 62
2.4.1 VF Extending Screed (with Front-Mounted Extensions) ............................................ 62
2.4.2 VR Extending Screed (with Rear-Mounted Extensions) ............................................ 64
2.4.3 Main Applications of the VF / VR Screeds ................................................................. 66
2.5 Special Screed: AB 600 High Compaction Screed in the TP2 Plus Version ............ 68
2.6 Set-Up ................................................................................................................ 70
Contents
2.6.2 Pressure Bar(s) ....................................................................................................... 71
2.6.3 Tamper Shield ........................................................................................................ 72
2.7 Side Plates ........................................................................................................ 73
2.7.1 Mechanical-Hydraulic Side Plate ............................................................................ 73
2.7.1.1 Hydraulic Side Plate from VGELE ......................................................................... 74
2.7.1.2 Standard Side Plate from VGELE .......................................................................... 76
2.7.2 Bevel Irons ............................................................................................................. 77
2.8 Screed Heating ................................................................................................. 78
2.9 Screed Maintenance .......................................................................................... 80
2.9.1 Daily Maintenance ................................................................................................. 80
2.9.2 Weekly Maintenance ............................................................................................... 82
3 Parameters Influencing the Paving Process 85
3.1 General ............................................................................................................. 86
3.2 Paving Material ................................................................................................ 88
3.3 Paving Parameters ............................................................................................ 89
3.4 Paver Set-Up ..................................................................................................... 89
3.5 Relationship Between Tamper Speed and Pave Speed ......................................... 92
3.6 Recommended Settings for Paving Parameters .................................................... 93
3.7 Functions of the Hydraulic Rams for Raising / Lowering the Screed ...................... 94
3.7.1 Screed Float ........................................................................................................... 95
3.7.2 Screed Assist .......................................................................................................... 95
3.7.3 Screed Freeze ........................................................................................................... 95
4 Recommendations for Paving / Points to Note 97
4.1 Before Starting .................................................................................................. 98
4.1.1 Fundamentals ........................................................................................................ 98
4.1.2 Setting the Layer Thickness ................................................................................... 100
4.1.3 Weather Conditions when Paving Asphalt ............................................................ 104
4.1.4 Requirements Made on the Roadbase and its Surface .......................................... 105
4.1.5 Augers and Limiting Plates for the Auger Tunnel on an Extending Screed ............ 108

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VGELE BOOKLET ON PAVING

4.1.6 Definition and Preparation of the Route ............................................................... 110 5.5 Longitudinal Step ............................................................................................. 170

4.1.7 The Optimal Sensor for Every Paving Application .................................................. 111
4.1.8 Ordering Asphalt from the Mixing Plant on Call ................................................... 122
4.1.9 Preparing the Reference for Automated Grade and Slope Control ........................ 123
4.1.10 Correct Positioning of the Grade and Slope Sensors ............................................. 124
4.2 During the Paving Process ................................................................................. 125
4.2.1 Positioning the Paver ............................................................................................ 125
4.2.2 Head of Mix in Front of the Screed ........................................................................ 126
4.2.3 Joints in Asphalt Pavements ................................................................................. 127
4.2.4 Expansion Joints ................................................................................................... 131
4.2.5 Paving Hot to Cold ............................................................................................. 132
4.2.6 Paving Hot to Hot ............................................................................................... 133
4.2.7 Duties of the Paving Team During the Paving Process ........................................... 134
4.2.8 Tools for Continuous Verification of the Paved Result ........................................... 136
4.3 After Paving ...................................................................................................... 138
4.3.1 Subsequent Compaction by Rolling ...................................................................... 138
4.3.2 Rules for Rolling and Avoiding Errors ................................................................... 142
4.3.3 Measurement of Density and Surface Accuracy ..................................................... 143
4.3.4 Cleaning, Daily Maintenance and Completion of the Job Site .............................. 144
5 Imperfect Paving 147
5.1 Systematic Elimination of Paving Errors ............................................................ 148
5.2 Paving Problems / Paving Errors ........................................................................ 158
5.2.1 Irregularities when Passing over Mix .................................................................... 158
5.2.2 Pavement Irregularities due to Large Screed Planing Angle ................................. 159
5.2.3 Hump Formed when Resuming Paving ................................................................ 160
5.2.4 Short Irregularities in a Transverse Direction ......................................................... 161
5.2.5 Periodic Irregularities in a Longitudinal Direction ................................................. 162
5.3 Segregation in General ..................................................................................... 164
5.3.1 Transverse Strips ................................................................................................... 166
5.3.2 Strips in the Middle of the Pavement .................................................................... 167
5.3.3 Strips in the Lateral Areas of the Pavement ........................................................... 168
5.3.4 Patches of Mix in the Surface Texture .................................................................... 169
5.4 Imprints ........................................................................................................... 170
Contents
5.6 Non-Uniform Surface Structure due to Crushed Grains ....................................... 171
6 Paving Materials in Detail 173
6.1 General Pavement Structure .............................................................................. 174
6.2 Producing Asphalt Mix ...................................................................................... 180
6.3 Types of Pavement Layers ................................................................................. 184
6.4 Bitumen Grades Used ....................................................................................... 185
6.5 Asphalt Types and Their Composition ................................................................ 186
6.5.1 Stone Mastic Asphalt ............................................................................................. 186
6.5.2 Asphaltic Concrete (Paved Hot) ............................................................................. 188
6.5.3 Asphaltic Binder .................................................................................................... 190
6.5.4 Asphalt for Base Course ........................................................................................ 192
6.5.5 Porous Asphalt ...................................................................................................... 194
6.6 Mix Temperatures in C ..................................................................................... 196
6.7 Causes of Poor-Quality Asphaltic Concrete Mixes for Hot Paving ......................... 197
6.8 Emulsion Types ................................................................................................. 198
7 Special Equipment and Special Methods 201
7.1 Spray Technology .............................................................................................. 202
7.2 Two-Layer Paving .............................................................................................. 210
7.3 Material Feeders ............................................................................................... 218
8 Index / Notes 228

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VGELE BOOKLET ON PAVING
1.3 The Floating Screed Principle
The floating working tool is the main difference distinguishing a road paver from other construction
machinery. In other words, the layer thickness only changes as a result of changes in the screeds planing
angle or changes in the height of the screed tow points. This way, irregularities in the ground are
diminished when passed over, without having to intervene through a control system.
Short irregularities in the base are levelled
out through the self-levelling property of the
Floating Screed.
When passing over long irregularities,
the height of the screed tow points changes, thus
leading to a change in the layer thickness.
Depending on the screed planing angle,
more or less mix is packed under the screed
as the paver advances, and the layer thickness
gradually changes over a longer distance.
Height of The response of the screed to such changes
Screed Tow Point depends on:
Pave speed
Change in height of the screed tow points
Properties of the mix (compactability,
Speed Properties of Mix
load bearing capacity).
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1.4 Theoretical Outline of the Floating Screed Principle
1. Design of a Road Paver
h = Height after compensation
H = Height of irregularity
a = Depth of screed plate
b = Length of screed arm
+ depth of screed plate
a
H h
b
The following rule can be derived from the example of a paver
passing over a short irregularity:
Hxa
Taking into account different lengths (b) (extending over length h =
of screed arm and depth of screed plate) for the different paver
types, an average ratio of about 5 : 1 results as far as compensation
b
of a short irregularity in the base is concerned.
Long irregularities in the base can only be levelled out by actively
controlling the height of the screed tow points.
NOTE
The evenness of the pavement must increase with every layer placed.
The magnitude of improvement depends on the quality of the layer below.
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VGELE BOOKLET ON PAVING 5

2.2 Extending Screeds

2.2.4 Set-Up of the Extending Screed

Setting Up the Screed: Prerequisites

2. Screed
1. Clearance between sliding blocks and sliding rail has been set and checked (see page 48).
2. Height adjustment: Adjusting spindles have been set and checked (see pages 42 onwards).
3. Screed has been raised and laid down on locking bolts.
4. Set both tow point rams to identical heights.
5. Crown has been set to 0%.
6. Clamping screw for height adjustment is released.
7. Height adjustment of the extending screed has been set to 0 on the scale.

3 4

6 7

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VGELE BOOKLET ON PAVING
2.2 Extending Screeds
2.2.4 Set-Up of the Extending Screed
Preparation
Support the screed on large wooden blocks
or pallets to compensate for any unevenness
of the ground.
Flange surfaces must be clean, i.e. free from
asphalt.
TIP
Before mounting a bolt-on extension, the
tamper shafts of both the screeds extending
unit and the bolt-on extension must be set
so that the arrow on the coupling points to
the gap in the gearwheel (see photo).
Easy and Fast Attachment with
Quick-Fitting Aid
The bevelled quick-fitting aid makes it possible
to raise a bolt-on extension without tightening
down the screws.
This allows an extension to be fitted even on
an uneven base.
TIP
The front and rear eccentric bolts must be set
to zero position (uppermost position). This is
important later on for aligning the extending
unit with the basic screed.
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2. Screed
Height Adjustment
of the Bolt-on Extension
The height of the extending unit and bolt-on
extension in relation to one another is adjusted
via the eccentric bolts so that the trailing edges
of the screed plates are flush while the leading
edges are between 0.5 and 1mm higher.
0mm
1mm (maximum)
Fitting the Braces
The frames of the screeds extending unit and
of the bolt-on extension must be joined.
Then fit the braces stabilizing the bolt-on
extensions. These braces must be adjusted
so that a light downwards pressure is exerted
onto the extension.
TIP
The pressure is correct if the brace can be
turned slightly. If it cannot, the pressure
is too high.
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VGELE BOOKLET ON PAVING

2.5 Special Screed:

AB 600 High Compaction Screed in the TP2 Plus Version

2. Screed
Pressure Valve Pressure Sensor

Constant Oil Flow

Pulsed Oil Flow

Gear Pump
Pulse Generator

Return Pipe

Pressure Adjusting Unit Tank Pressure Bar

The VGELE high-compaction process begins with the pulse generator.
It generates high-frequency pressure pulses. The pressure bar(s),
in contrast to the beating tamper bar, remain in permanent contact
with the material, thus forcing it down for a prolonged period of time.
Thanks to the high density achieved by the pressure bar(s),
fewer passes are required for subsequent compaction by rolling.
T he pressure bar(s) driven by pulsed flow hydraulics are the core
of VGELE High-Compaction Technology.
T hanks to this unique technology, VGELE High-Compaction Screeds
in the TP1, TP2 or TP2 Plus versions bring about the highest degree
of density a road paver can achieve.

In recent years, the AB 600 in the TP2 Plus version has been developed further and perfected to meet the
special requirements of hot to hot paving. On an InLine Pave contract, it achieves an extraodinarily high
degree of precompaction. Depending on the paving material used, the resultant compaction comes very
close to the final density.
The AB 600 Extending Screed in the TP2 Plus Version at a Glance
Uses: for hot to hot paving of binder and base courses, as well as thick roadbase packages.
Maximum pave width 8.5m. T = Tamper P1 = Pressure Bar 1 P2 = Pressure Bar 2 T = Tamper P1 = Pressure Bar 1 P2 = Pressure Bar 2
Supplementary weight for additional compaction. The pressure bars P1 and P2 are the last elements in the process of A
 separate control is provided for each compacting system installed
Innovative tamper geometry: modified tamper shield so that material is drawn under the screed compaction as a whole. Logically, they are located in the rear area of in a VGELE High-Compaction Screed.
VGELE HPC screeds. Only in this location can the highest possible
more effectively. compacting effort be achieved, as the mix is prevented from yielding
F ine control of the pressure for the pressure bar(s) allows VGELE

Variable tamper speed up to 1,800rpm. to the front. Nor can it yield to the sides, where it is constricted by the
High-Compaction Technology to be used for paving surface courses
as well.
Special tamper stroke settings 4, 7 or 9mm. screeds side plates.

2 pressure bars with infinitely variable pressure from 40 to 120 bar each. A change from high compaction to conventional compaction and
vice versa can easily be made from the ErgoPlus 3 operating consoles.
This allows the screed to be used for highly varied applications.

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VGELE BOOKLET ON PAVING

3.5 Relationship Between Tamper Speed and Pave Speed 3.6 Recommended Settings for Paving Parameters

While paving, an equilibrium of forces is reached between the screed and the paving material. Type of

3. Parameters Influencing the Paving Process

Any change in the pave speed or the tamper speed immediately results in a change of the screeds Pavement

Vibrator Speed (rpm)

Pave Speed (m/min.)
floating behaviour.

Tamper Speed (rpm)

Tamper Stroke (mm)
Layer Thickness (cm)

Pressure Bar(s)
Pressure (bar)
Material
Tamper speed and pave speed are very strongly
dependent on one another. Any change in pave
Asphalt: AC 32 T 10 - 60 2 - 4 4 - 7 1,500 - 1,800 2,600 - 3,000 90 - 110
speed without changing the tamper speed and Base Course
position of the screed tow point rams will affect
AC 22 T 6 - 10 2 - 5 4 - 7 1,000 - 1,400 2,100 - 2,400 70 - 100
precompaction of the mix. If the pave speed is
increased without simultaneously increasing the
Asphalt: AC 22 B 6 - 10 2 - 5 4 1,000 - 1,400 2,100 - 2,400 70 - 100
tamper speed, the load bearing capacity of the
Binder Course
mix will be reduced and the screed lay a thinner
8m/min. 4m/min. AC 16 B 4 - 8 2 - 6 4 600 - 1,000 1,800 - 2,100 50 - 80
layer at a steeper planing angle.
AC 11 B 4 - 6 3 - 6 4 600 - 800 1,600 - 1,800 50 - 70
Low Precompaction
High Precompaction Paving with Automated Grade Asphaltic AC 11 D 4 - 6 3 - 6 4 600 - 900 1,600 - 1,800 50 - 80
and Slope Control Concrete:
Wearing Course
If automated grade and slope control is used AC 8 D 2 - 4 3 - 6 2 - 4 600 - 900 1,300 - 1,600 50 - 70

Pave Speed for paving, the desired elevation of the screed

can be maintained by increasing the planing AC 5 D 2 - 4 3 - 6 2 - 4 600 - 900 1,200 - 1,500 Off
8m/min. 4m/min.
angle, but precompaction will not remain
constant. SMA 11 4 - 6 3 - 6 4 600 - 1,500 1,600 - 1,800 50 - 80

SMA 8 2 - 4 3 - 6 2 - 4 600 - 1,500 1,300 - 1,600 50 - 70

SMA 5 2 - 4 3 - 6 2 - 4 600 - 1,500 1,200 - 1,500 Off

After Compaction by Rolling Asphalt:

Combined Base/ AC 16 TD 8 - 16 2 - 6 4 1,200 - 1,800 2,200 - 3,000 80 - 110
When the roller passes over the mix, the Wearing Course
Pave Speed amount of extra compaction will differ on
8m/min. 4m/min. account of varying precompaction and result Asphalt: 1 - 3 3 - 10 2 500 - 1,400 1,000 - 1,200 Off
Thin Layer
in irregularities in the surface.

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VGELE BOOKLET ON PAVING

4.1 Before Starting

4.1.7 The Optimal Sensor for Every Paving Application

Short Ski

4. Recommendations for Paving / Points to Note

Length 0.3m

TIP
Should only be used for tight bends
or for deliberately copying irregularities
from the base.

Long Ski
Length 0.8m

TIP
Used when paving large bends
Big MultiPlex Ski or straight sections.
By arranging 3 sonic grade sensors in a row, it is possible to tap the physical reference at several
points lying far apart from each other. Based on the values picked up by the sensors, Niveltronic,
the VGELE System for Automated Grade and Slope Control, calculates a virtual reference. In this way, Averaging Beam
the system is much more precise for levelling out long irregularities than a single level sensor.
Length 7m

TIP
TIP
Used when paving surfaces requiring
Ideal for levelling out long irregularities when an absolute reference is not available. high evenness.

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VGELE BOOKLET ON PAVING

4.2 During the Paving Process 4.2 During the Paving Process
4.2.2 Head of Mix in Front of the Screed 4.2.3 Joints in Asphalt Pavements1

4. Recommendations for Paving / Points to Note

RULES
A joint describes the connecting seam between two adjacent strips (longitudinal joint). Joints
are found when working with several pavers in echelon (hot to hot) or when placing a single
lane alongside an existing lane (hot to cold). A transverse joint is produced when resuming
work on the previous days section or between paving sessions. In all cases, the two areas must
The head of mix in front of the screed should be durably connected to prevent surface water seeping into the pavement.
be uniformly spread over the full pave width.
The use of limiting plates for the auger tunnel
and of strike-off plates is strongly recommended.
Longitudinal Joints
Paving Hot to Hot
Paving with two or more pavers working in echelon is ideal for an integral bond between asphalt strips.
Points to be noted:
The distance between the individual pavers should be kept as short as possible so that the joint face
of the first strip is still sufficiently hot.
The first rollers following each paver should be of the same size. The rollers start rolling towards the
Mix is not spread adequately from the inside joint from the outer pavement edge inwards. Compaction ends approx. 15cm beside the longitudinal
outwards, with the result that there is too much joint on either side. The joint is then the last strip to be compacted by the rollers. This way a tight bond
mix in front of the screeds basic unit: between the pavement strips is obtained.
Reduce conveyor speed.
Check / adjust position of sensor for augers.

Road Axis

Asphalt Wearing Course

Asphalt Binder Course

Asphalt Base Courses

The conveyors do not deliver sufficient mix:
Increase conveyor speed.
Fit limiting plates for auger tunnel. Longitudinal Joint
Joints should be offset in the individual pavement layers and produced with oblique faces.
Check / adjust position of sensor for augers.
1 T ext and diagrams on pages 127 - 130 in accordance with the asphalt LEITFADEN: Ratschlge fr den Einbau von Walzasphalt (Asphalt Manual, Guidelines
for Paving Hot Mix), published by DAV Deutscher Asphaltverband e.V. (German Asphalt Association), 2nd edition, July 2007, pages 35 - 40.

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VGELE BOOKLET ON PAVING

4.3 After Paving

4.3.4 Cleaning, Daily Maintenance and Completion of the Job Site

10 Steps after Paving: Time Required 30 Minutes (approx.)

4. Recommendations for Paving / Points to Note

Step 1: B efore the paver is supplied with material from the last feed lorry, switch off
screed heating and spray the material hopper and auger with cleaning agent.

Step 2: Before raising the screed, switch off automatic grade and slope control
and set both screed tow point rams to the same height.

Step 3: Raise the screed and set it down on the locking bolts.

Step 4: Empty the material hopper and conveyor tunnel.

Step 5: Extend the screed completely and select operating mode N (neutral).

Step 6: C lean those parts of the tractor unit and screed which cool rapidly
(side plates, deflector plates, centre auger box, limiting plates for
the auger tunnel and push-rollers).

Step 7: Select Positioning mode and activate Cleaning.

Step 8: S pray all paver parts in contact with the mix with cleaning agent
(tamper must be sprayed from the back, pressure bar(s) from above).
Step 9: Retract the screeds extending units, switch off the engine and the ignition.
Step 10: R emove the sensors for grade and slope control, as well as the screed consoles.
Put cover onto the paver operators console to prevent vandalism.
TIP
After Work on the Job Site
The following tasks should also be performed when the work on site is complete:
1. Technical check of the machine.
2. Make sure that the machine has been properly parked.
3. Protect the machine against vandalism.
4. Add up the delivery notes for mix for the day just ended.
5. Check that everything has been prepared on site for the next working day
(is sufficient fuel available, has asphalt been ordered from the mixing plant
for the next day, etc.).

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 VGELE BOOKLET ON PAVING

5.1 Systematic Elimination of Paving Errors

Possibilities for Detecting Paving Errors on the Basis of Descriptions 13. Has the ratio of maximum grain size to layer thickness been taken into account or has

Formation Impressions in the Asphalt
of Undulations Pavement, Starting Humps,
Insufficient Compaction
5. Imperfect Paving
aggregate been shattered? (Since this effect is enhanced by the Screed Assist function,
it should not be used when paving wearing course.)
14. Is the Screed Float valve working correctly?
15. Can the side plate move freely?
16. Have the braces (horizontal / vertical) been fitted correctly when paving large widths?

Open-Textured Surface
Segregation Other Problems
Formation of Undulations
A) Formation of undulations at irregular intervals over the full width while paving
1. Do the undulations also occur without automated grade and slope control?
If not, continue with step 5.
2. Check the sensitivity of Niveltronic and set up Niveltronic anew.
3. Inaccurate reference (wire wrongly tensioned, uneven base).
4. Check the choice of sensors (sonic sensors react to changes in temperature
due to wind or rain).
5. Slack in the mechanism for height adjustment of the extending units
or in the telescoping tubes?
6. Are the tractor unit / screed arm and fishplate tightly connected?
7. Slack in the torque restraint system?
8. Bolt-on extensions have a negative screed planing angle.
9. Tamper speed is too high for the set pave speed.
10. Check the setting of the pressure bar(s) (height and pressure).
11. Pave speed is not constant.
12. Supply of mix is not constant. Have the sensors for the conveyors and augers
been set correctly?
B) Formation of undulations at regular intervals over the full width while paving
1. Do the undulations also occur without automated grade and slope control?
If not, continue with step 5.
2. Check Niveltronics sensitivity and set up Niveltronic anew, if necessary
(exchange components).
3. Inaccurate reference (uneven base or wire wrongly tensioned: distance between stakes = 6m).
4. Has the required precompaction been achieved behind the paver or are the undulations due
to rolling errors?
5. Slack in the height adjustment mechanism of the extending units or in the telescoping tubes?
6. Slack in the torque restraint system?
7. Bolt-on extensions have a negative screed planing angle.
8. Tamper speed is too high or too low for the set pave speed (for approx. 3 m/min = 700rpm,
for approx. 5 m/min = 1,000rpm, for approx. 10 m/min = 1,800rpm).
9. Supply of mix is not constant. Have the sensors for the conveyors and augers been set correctly?
10. Have the braces (horizontal / vertical) been fitted correctly when paving large widths?
C) Undulations only form under the left or right extending units
1. Do the undulations also occur without automated grade and slope control?
If not, continue with step 5.
2. Check Niveltronics sensitivity and set up Niveltronic anew, if necessary
(exchange components).
3. Inaccurate reference on one side (uneven base or wire wrongly tensioned:
distance between stakes = 6m).
4. Are the hydraulic ram for raising / lowering the screed, the Screed Float valve and the shutoff
valves working properly?
5. Slack in the mechanism for height adjustment of the extending units or telescoping tubes?

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6.8 Emulsion Types

Overview of Emulsion Types for Noise Absorbing Thin Overlay What happens when bitumen emulsion breaks?

6. Paving Materials in Detail

The type and handling of bitumen emulsion used is a matter of great importance when paving When heating the bitumen emulsion to 70 - 80 C
thin overlay. Among other things, it is important to ensure that the emulsion is applied constantly and spraying it onto the base, the majority of the 4
at the required rate over the entire surface so that the water contained in the emulsion can evaporate. water contained in the emulsion evaporates.
The remaining water evaporates spontaneously
For this reason, a semi-permeable asphalt is normally used when paving thin overlay, as it allows
when the emulsion comes into contact with asphalt
the remaining moisture to escape through the asphalts open structure after paving. In this way,
heated to more than 100 C. In this way, the
water is extracted from the emulsion, leaving only a film of bitumen. Professionals refer to this
emulsion breaks when using SprayJet technology
process as emulsion breaking.
from VGELE.
1. Prepared base: milled surface or freshly laid
binder course.

Type of Emulsion Nominal Content Breaking Class On Contact 2. Hot bitumen emulsion at a temperature between
Bitumen in % by Weight with the Base 70 and 80 C is applied by the spray paver.

C60BP1S 60 1 breaks rapidly

C40BF1S 40 1 breaks rapidly
C67BP5DSHV 67 5 breaks very rapidly

C67BP5DSHV ist is a cationic polymer-modified bitumen emulsion with class 5 breaking effect,
meaning that the emulsion breaks very rapidly when it comes into contact with the base. The breaking
effect and high bitumen content make this emulsion ideal for paving thin overlay on spray seal,
hot to hot (DSHV).

1 2 3

3. Paving of a binder or surface course. 4. Any water still remaining in the emulsion
The bitumen emulsion breaks immediately evaporates through the open pores of the
as the hot asphalt causes the water to evaporate, asphalt overlay.
leaving a firmly adhering film of bitumen.

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 VGELE BOOKLET ON PAVING
7.1 Spray Technology
The spray nozzles are opened and closed pneumatically.
A compressed air system is integrated into the
SprayJet module for this purpose.
A very low spray pressure of no more than 3 bar
allows absolutely uniform spreading of bitumen emulsion
and a clean result when spraying along kerbs.
The SUPER 1800-3i SprayJet is equipped with
five spray bars. The front spray bar has six spray
nozzles and is located between the machines
crawler tracks right behind the push-rollers.
An articulated spray bar installed on each side of
the paver comes with 7 nozzles per side. Finally,
a short spray bar with two nozzles is provided right
behind each crawler track. This arrangement of
206 | www.voegele.info
the spray bars allows full coverage of the existing
surface with emulsion, even when the pave
width varies. The rate of spread can be selected
accurately within the range of 0.3 and 1.6kg/m.
The SprayJet nozzles do not spray the emulsion
continuously, but operate instead in pulsed
mode. The frequency of the spray pulses is
adjusted automatically as a function of the
selected rate of spread, pave speed and pave
width. As a result, complete coverage of the
existing surface with a uniform film of emulsion
is achieved, without any overlaps.
7. Special Equipment and Special Methods
250 mm
120 120
The nozzles do not spray the emulsion continuously,
but operate instead in pulsed mode. The frequency
of the spray pulses is adjusted automatically as a function
of the selected rate of spread, pave speed and pave width.
The particularly high quality of the spray nozzles
guarantees perfect spraying.
Emulsion is applied at an exceedingly low spray
pressure of no more than 3 bar. In combination
with the high-quality spray nozzles, this allows
the emulsion to be sprayed cleanly and without
burdening the environment.
207
A WIRTGEN GROUP COMPANY A WIRTGEN GROUP COMPANY

JOSEPH VGELE AG
Joseph-Vgele-Str. 1
67075 Ludwigshafen Germany
Telephone: +49 (0)621 8105 0
Fax: +49 (0)621 8105 461
Vgele
marketing@voegele.info www.voegele.info
Booklet
on Paving

VGELE Booklet on Paving

ERGOPLUS, InLine Pave, NAVITRONIC, NAVITRONIC Basic, NAVITRONIC Plus, NIVELTRONIC, NIVELTRONIC Plus, RoadScan, SprayJet, VGELE, VGELE PowerFeeder, PaveDock,
PaveDock Assistant, AutoSet, AutoSet Plus, AutoSet Basic, ErgoBasic and VGELE-EcoPlus are registered Community Trademarks of JOSEPH VGELE AG, Ludwigshafen/Rhein,
Germany. PCC is a registered German Trademark of JOSEPH VGELE AG, Ludwigshafen/Rhein, Germany. ERGOPLUS, NAVITRONIC Plus, NAVITRONIC BASIC, NIVELTRONIC Plus,
SprayJet, VISION, VGELE, VGELE PowerFeeder, PaveDock, PaveDock Assistant, AutoSet, AutoSet Plus, AutoSet Basic and VGELE-EcoPlus are trademarks registered in the
US Patent and Trademark Office to JOSEPH VGELE AG, Ludwigshafen/Rhein, Germany. Legally binding claims cannot be derived from written information or pictures contained
in this brochure. Pictures may include optional extras. We reserve the right to make technical or design alterations. www.voegele.info www.voegele.info

2280299 EN/03.15