A WIRTGEN GROUP COMPANY

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.

2280299 EN/03.15

Vgele
Booklet
on Paving

Telephone: +49 (0)621 8105 0

Fax:
+49 (0)621 8105 461
www.voegele.info

VGELE Booklet on Paving

JOSEPH VGELE AG
Joseph-Vgele-Str. 1
67075 Ludwigshafen Germany
[email protected]

A WIRTGEN GROUP COMPANY

www.voegele.info

www.voegele.info

VGELE BOOKLET ON PAVING

Design of a Road Paver

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 ..................................................................
2.2
Extending Screeds ..............................................................................................
2.2.1 Components of the Extending Screed ......................................................................
2.2.2 Compacting Systems Installed in Extending Screeds ...............................................
2.2.3 Extending Screeds and Bolt-on Extensions ..............................................................
2.2.4 Set-Up of the Extending Screed ...............................................................................
2.2.5 Mechanical Design and Maintenance of the Telescoping System ............................
2.3
Fixed-Width Screeds ............................................................................................
2.3.1 Components of the Fixed-Width Screed ..................................................................
2.3.2 Compacting Systems Installed in Fixed-Width Screeds ............................................
2.3.3 Fixed-Width Screeds and Bolt-on Extensions ...........................................................
2.3.4 Set-Up of the Fixed-Width Screed ............................................................................
2.4
Screeds for the American and Australian Markets .................................................
2.4.1 VF Extending Screed (with Front-Mounted Extensions) ............................................
2.4.2 VR Extending Screed (with Rear-Mounted Extensions) ............................................
2.4.3 Main Applications of the VF / VR Screeds .................................................................
2.5
Special Screed: AB 600 High Compaction Screed in the TP2 Plus Version ............
2.6
Set-Up ................................................................................................................

30
32
32
34
36
38
48
50
50
52
54
60
62
62
64
66
68
70

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2.6.1 Tamper ...................................................................................................................

2.6.2 Pressure Bar(s) .......................................................................................................
2.6.3 Tamper Shield ........................................................................................................
2.7
Side Plates ........................................................................................................
2.7.1 Mechanical-Hydraulic Side Plate ............................................................................
2.7.1.1 Hydraulic Side Plate from VGELE .........................................................................
2.7.1.2 Standard Side Plate from VGELE ..........................................................................
2.7.2 Bevel Irons .............................................................................................................
2.8
Screed Heating .................................................................................................
2.9
Screed Maintenance ..........................................................................................
2.9.1 Daily Maintenance .................................................................................................
2.9.2 Weekly Maintenance ...............................................................................................

70
71
72
73
73
74
76
77
78
80
80
82

85

Parameters Influencing the Paving Process

3.1
General .............................................................................................................
3.2
Paving Material ................................................................................................
3.3
Paving Parameters ............................................................................................
3.4
Paver Set-Up .....................................................................................................
3.5 Relationship Between Tamper Speed and Pave Speed .........................................
3.6 Recommended Settings for Paving Parameters ....................................................
3.7
Functions of the Hydraulic Rams for Raising / Lowering the Screed ......................
3.7.1 Screed Float ...........................................................................................................
3.7.2 Screed Assist ..........................................................................................................
3.7.3 Screed Freeze ...........................................................................................................

86
88
89
89
92
93
94
95
95
95

97

Recommendations for Paving / Points to Note

4.1
Before Starting ..................................................................................................
4.1.1 Fundamentals ........................................................................................................
4.1.2 Setting the Layer Thickness ...................................................................................
4.1.3 Weather Conditions when Paving Asphalt ............................................................
4.1.4 Requirements Made on the Roadbase and its Surface ..........................................
4.1.5 Augers and Limiting Plates for the Auger Tunnel on an Extending Screed ............

98
98
100
104
105
108

Contents

CONTENTS

 4.1.6 Definition and Preparation of the Route ...............................................................

4.1.7 The Optimal Sensor for Every Paving Application ..................................................
4.1.8 Ordering Asphalt from the Mixing Plant on Call ...................................................
4.1.9 Preparing the Reference for Automated Grade and Slope Control ........................
4.1.10 Correct Positioning of the Grade and Slope Sensors .............................................
4.2
During the Paving Process .................................................................................
4.2.1 Positioning the Paver ............................................................................................
4.2.2 Head of Mix in Front of the Screed ........................................................................
4.2.3 Joints in Asphalt Pavements .................................................................................
4.2.4 Expansion Joints ...................................................................................................
4.2.5 Paving Hot to Cold .............................................................................................
4.2.6 Paving Hot to Hot ...............................................................................................
4.2.7 Duties of the Paving Team During the Paving Process ...........................................
4.2.8 Tools for Continuous Verification of the Paved Result ...........................................
4.3
After Paving ......................................................................................................
4.3.1 Subsequent Compaction by Rolling ......................................................................
4.3.2 Rules for Rolling and Avoiding Errors ...................................................................
4.3.3 Measurement of Density and Surface Accuracy .....................................................
4.3.4 Cleaning, Daily Maintenance and Completion of the Job Site ..............................

110
111
122
123
124
125
125
126
127
131
132
133
134
136
138
138
142
143
144

147

Imperfect Paving

5.1
Systematic Elimination of Paving Errors ............................................................
5.2
Paving Problems / Paving Errors ........................................................................
5.2.1 Irregularities when Passing over Mix ....................................................................
5.2.2 Pavement Irregularities due to Large Screed Planing Angle .................................
5.2.3 Hump Formed when Resuming Paving ................................................................
5.2.4 Short Irregularities in a Transverse Direction .........................................................
5.2.5 Periodic Irregularities in a Longitudinal Direction .................................................
5.3
Segregation in General .....................................................................................
5.3.1 Transverse Strips ...................................................................................................
5.3.2 Strips in the Middle of the Pavement ....................................................................
5.3.3 Strips in the Lateral Areas of the Pavement ...........................................................
5.3.4 Patches of Mix in the Surface Texture ....................................................................
5.4
Imprints ...........................................................................................................

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148
158
158
159
160
161
162
164
166
167
168
169
170

5.5 Longitudinal Step ............................................................................................. 170

5.6
Non-Uniform Surface Structure due to Crushed Grains ....................................... 171
6

Paving Materials in Detail

173

6.1
General Pavement Structure ..............................................................................
6.2
Producing Asphalt Mix ......................................................................................
6.3
Types of Pavement Layers .................................................................................
6.4
Bitumen Grades Used .......................................................................................
6.5
Asphalt Types and Their Composition ................................................................
6.5.1 Stone Mastic Asphalt .............................................................................................
6.5.2 Asphaltic Concrete (Paved Hot) .............................................................................
6.5.3 Asphaltic Binder ....................................................................................................
6.5.4 Asphalt for Base Course ........................................................................................
6.5.5 Porous Asphalt ......................................................................................................
6.6
Mix Temperatures in C .....................................................................................
6.7 Causes of Poor-Quality Asphaltic Concrete Mixes for Hot Paving .........................
6.8
Emulsion Types .................................................................................................

174
180
184
185
186
186
188
190
192
194
196
197
198

Special Equipment and Special Methods

201

7.1
7.2
7.3

Spray Technology .............................................................................................. 202

Two-Layer Paving .............................................................................................. 210
Material Feeders ............................................................................................... 218

Index / Notes

228

Contents

VGELE BOOKLET ON PAVING

VGELE BOOKLET ON PAVING

1.4

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.

h =
H =
a =
b =

Theoretical Outline of the Floating Screed Principle

1. Design of a Road Paver

1.3

Height after compensation

Height of irregularity
Depth of screed plate
Length of screed arm
+ depth of screed plate

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.

The following rule can be derived from the example of a paver

passing over a short irregularity:
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.
The response of the screed to such changes
depends on:

Height of
Screed Tow Point

Speed

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Properties of Mix

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Pave speed
Change in height of the screed tow points
Properties of the mix (compactability,
load bearing capacity).

Taking into account different lengths (b) (extending over length

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
of a short irregularity in the base is concerned.

Hxa
h =
b

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.

13

VGELE BOOKLET ON PAVING

2.2

Extending Screeds

2.2.4

Set-Up of the Extending Screed

2. Screed

Setting Up the Screed: Prerequisites

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.

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39

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.

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.

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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1mm (maximum)

0mm

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.

45

2. Screed

VGELE BOOKLET ON PAVING

VGELE BOOKLET ON PAVING

Special Screed:
AB 600 High Compaction Screed in the TP2 Plus Version
Pressure Valve

2. Screed

2.5

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.
Supplementary weight for additional compaction.
Innovative tamper geometry: modified tamper shield so that material is drawn under the screed
more effectively.
Variable tamper speed up to 1,800rpm.
Special tamper stroke settings 4, 7 or 9mm.
2 pressure bars with infinitely variable pressure from 40 to 120 bar each.

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T = Tamper

P1 = Pressure Bar 1

P2 = Pressure Bar 2

The pressure bars P1 and P2 are the last elements in the process of
compaction as a whole. Logically, they are located in the rear area of
VGELE HPC screeds. Only in this location can the highest possible
compacting effort be achieved, as the mix is prevented from yielding
to the front. Nor can it yield to the sides, where it is constricted by the
screeds side plates.

T = Tamper

P1 = Pressure Bar 1

P2 = Pressure Bar 2

A
 separate control is provided for each compacting system installed
in a VGELE High-Compaction Screed.
F ine control of the pressure for the pressure bar(s) allows VGELE
High-Compaction Technology to be used for paving surface courses
as well.

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.

69

VGELE BOOKLET ON PAVING

Vibrator Speed (rpm)

2 - 4

4 - 7

1,500 - 1,800 2,600 - 3,000

90 - 110

AC 22 T

6 - 10

2 - 5

4 - 7

1,000 - 1,400 2,100 - 2,400

70 - 100

AC 22 B

6 - 10

2 - 5

1,000 - 1,400 2,100 - 2,400

70 - 100

AC 16 B

4 - 8

2 - 6

600 - 1,000 1,800 - 2,100

50 - 80

AC 11 B

4 - 6

3 - 6

600 - 800

1,600 - 1,800

50 - 70

AC 11 D

4 - 6

3 - 6

600 - 900

1,600 - 1,800

50 - 80

AC 8 D

2 - 4

3 - 6

2 - 4

600 - 900

1,300 - 1,600

50 - 70

AC 5 D

2 - 4

3 - 6

2 - 4

600 - 900

1,200 - 1,500

Off

SMA 11

4 - 6

3 - 6

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

Asphalt:
Combined Base/
Wearing Course

AC 16 TD

8 - 16

2 - 6

1,200 - 1,800 2,200 - 3,000

80 - 110

Asphalt:
Thin Layer

1 - 3

3 - 10

500 - 1,400 1,000 - 1,200

Off

Asphalt:
Binder Course

Pressure Bar(s)
Pressure (bar)

10 - 60

Tamper Speed (rpm)

AC 32 T

Asphalt:
Base Course

Low Precompaction
High Precompaction

Pave Speed
8m/min.

4m/min.

Paving with Automated Grade

and Slope Control
If automated grade and slope control is used
for paving, the desired elevation of the screed
can be maintained by increasing the planing
angle, but precompaction will not remain
constant.

After Compaction by Rolling

Pave Speed
8m/min.

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4m/min.

When the roller passes over the mix, the

amount of extra compaction will differ on
account of varying precompaction and result
in irregularities in the surface.

Asphaltic
Concrete:
Wearing Course

93

3. Parameters Influencing the Paving Process

4m/min.

Type of
Pavement
Tamper Stroke (mm)

8m/min.

Tamper speed and pave speed are very strongly

dependent on one another. Any change in pave
speed without changing the tamper speed and
position of the screed tow point rams will affect
precompaction of the mix. If the pave speed is
increased without simultaneously increasing the
tamper speed, the load bearing capacity of the
mix will be reduced and the screed lay a thinner
layer at a steeper planing angle.

Recommended Settings for Paving Parameters

Pave Speed (m/min.)

While paving, an equilibrium of forces is reached between the screed and the paving material.
Any change in the pave speed or the tamper speed immediately results in a change of the screeds
floating behaviour.

3.6

Layer Thickness (cm)

Relationship Between Tamper Speed and Pave Speed

Material

3.5

VGELE BOOKLET ON PAVING

4.1

Before Starting

4.1.7

The Optimal Sensor for Every Paving Application

4. Recommendations for Paving / Points to Note

Short Ski
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
Big MultiPlex Ski
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,
the system is much more precise for levelling out long irregularities than a single level sensor.

Averaging Beam
Length 7m

TIP

TIP
Ideal for levelling out long irregularities when an absolute reference is not available.

116 |

Used when paving large bends

or straight sections.

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Used when paving surfaces requiring

high evenness.

117

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

RULES

The head of mix in front of the screed should

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.

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
be durably connected to prevent surface water seeping into the pavement.

Longitudinal Joints
Paving Hot to Hot
Paving with two or more pavers working in echelon is ideal for an integral bond between asphalt strips.

Mix is not spread adequately from the inside

outwards, with the result that there is too much
mix in front of the screeds basic unit:

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
joint from the outer pavement edge inwards. Compaction ends approx. 15cm beside the longitudinal
joint on either side. The joint is then the last strip to be compacted by the rollers. This way a tight bond
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.
Check / adjust position of sensor for augers.

Longitudinal Joint
Joints should be offset in the individual pavement layers and produced with oblique faces.
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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127

4. Recommendations for Paving / Points to Note

VGELE BOOKLET ON PAVING

VGELE BOOKLET ON PAVING

4.3

After Paving

4.3.4

Cleaning, Daily Maintenance and Completion of the Job Site

144 |

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.

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4. Recommendations for Paving / Points to Note

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

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

Systematic Elimination of Paving Errors

Possibilities for Detecting Paving Errors on the Basis of Descriptions

Formation
of Undulations

Impressions in the Asphalt

Pavement, Starting Humps,
Insufficient Compaction
Open-Textured Surface

13. Has the ratio of maximum grain size to layer thickness been taken into account or has
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?

B) Formation of undulations at regular intervals over the full width while paving

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?

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5. Imperfect Paving

5.1

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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Emulsion Types

Overview of Emulsion Types for Noise Absorbing Thin Overlay

What happens when bitumen emulsion breaks?

The type and handling of bitumen emulsion used is a matter of great importance when paving
thin overlay. Among other things, it is important to ensure that the emulsion is applied constantly
at the required rate over the entire surface so that the water contained in the emulsion can evaporate.

When heating the bitumen emulsion to 70 - 80 C

and spraying it onto the base, the majority of the
water contained in the emulsion evaporates.
The remaining water evaporates spontaneously
when the emulsion comes into contact with asphalt
heated to more than 100 C. In this way, the
emulsion breaks when using SprayJet technology
from VGELE.

For this reason, a semi-permeable asphalt is normally used when paving thin overlay, as it allows
the remaining moisture to escape through the asphalts open structure after paving. In this way,
water is extracted from the emulsion, leaving only a film of bitumen. Professionals refer to this
process as emulsion breaking.

6. Paving Materials in Detail

6.8

1. Prepared base: milled surface or freshly laid

binder course.
Type of Emulsion

Nominal Content
Bitumen in % by Weight

Breaking Class

On Contact
with the Base

C60BP1S

60

breaks rapidly

C40BF1S

40

breaks rapidly

C67BP5DSHV

67

2. Hot bitumen emulsion at a temperature between

70 and 80 C is applied by the spray paver.

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).

3. Paving of a binder or surface course.

The bitumen emulsion breaks immediately
as the hot asphalt causes the water to evaporate,
leaving a firmly adhering film of bitumen.

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3
4. Any water still remaining in the emulsion
evaporates through the open pores of the
asphalt overlay.

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Spray Technology

250 mm

120

120

The spray nozzles are opened and closed pneumatically.

A compressed air system is integrated into the
SprayJet module for this purpose.

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.

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 particularly high quality of the spray nozzles

guarantees perfect spraying.

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

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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.

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

7. Special Equipment and Special Methods

7.1

A WIRTGEN GROUP COMPANY

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.

2280299 EN/03.15

Vgele
Booklet
on Paving

Telephone: +49 (0)621 8105 0

Fax:
+49 (0)621 8105 461
www.voegele.info

VGELE Booklet on Paving

JOSEPH VGELE AG
Joseph-Vgele-Str. 1
67075 Ludwigshafen Germany
[email protected]

A WIRTGEN GROUP COMPANY

www.voegele.info

www.voegele.info