Download or read GOMACO World Vol. 37 No. 1 in PDF format

24 Pages·2009·8.56 MB·English

by  Kelly Krueger

Vol. 37, No. 1
Introducing the NEW
IDBI Attachment for
the Commander III!
Vol. 37, No. 1
GOMACO
President and CEOGary L. Godbersen
Vice Presidents
Accounting Sharon K. Godbersen
Administration & Finance Richard E. Smith
Engineering/Research & Development
Kevin L. Klein
ManufacturingGrant Godbersen
3 GOMACO VERSATILITY SHOWCASED ON I-64 PROJECT Worldwide Sales and Marketing
Kent Godbersen
– Fred Weber, Inc., and Millstone Bangert, Inc.
General Manager of Manufacturing
7 SLIPFORMING CANAL IN NORTHERN TURKEY Dan Soellner
– Basat Elektrik Uretim & Tic. Ltd. Sti. Sales United States and Canada
Sales Manager Bob Leonard
9 DOUBLE VARIABLE BARRIER WALL ON ILLINOIS’ I-55 Sales Coordinator Brad Zobel
Assistant Sales Coordinator Mike Leinbaugh
– P.T. Ferro Construction Company
United States and Canada
11 PAVING 99 LANE MILES (159 KM) WITHOUT A GRIND District Managers
Brad Barkema – N. Central
– The Scruggs Company
Jim Hayward – Western
Kendall Kelly – S.W.
14 A HIGH-SPEED CONNECTION BETWEEN FRANCE & SPAIN Vinnie Miller – S.E.
– Eiffage Travaux Publics Len Rettinger – N.E./Central
International Sales
18 COMMANDER III POWER ON A MONO PROJECT Director Bryan Schwartzkopf
– Petra Contracting Coordinator Randy Bean
International Regional Manager
20 NEW GOMACO INNOVATIONS (Cover photo CG-030918 D14) Tim Nash – Asia Pacific
– New IDBI Attachment for the Commander III and More! Steve Bowman – Latin America
GOMACO International Ltd.
23 AROUND THE WORLD Managing Director Rory Keogh
Sales Managers John Bowden
& Andy Linham
7 11 14 20
Service Department
Manager Dennis Ernst
Service Desk DeWayne Krayenhagen
& Doug Comstock
Parts Manager John Kallin
Parts Desk Dan Ellerbusch,
Jeff Stevenson & Dean O’Tool
GOMACO University Training Center
Director Dennis Clausen
Please visit our Web site at http://www.gomaco.com
Assistant Director Rod Schneider
GOMACO Worldmagazine at http://www.gomaco.com/gomacoworld
GOMACO WorldEditor Kelly Krueger at [email protected] GOMACO Worldis produced by the
GOMACOAdvertising Department.
GOMACO Worldis published by GOMACOCorporation to inform readers of applied construction
technology utilizing GOMACOequipment as well as innovations and concerns in the construction Manager Randy Bach
industry throughout the world. All rights reserved. The contents of this publication may not be Marketing Coordinator Micki Rettinger
reproduced either in whole or in part without the consent of copyright owner. Printed in U.S.A. GOMACO WorldEditor Kelly Krueger
© 2009 GOMACOCorporation (06 CFX). All stories written by the editor unless otherwise noted.
Communications Specialist Thomas R. Grell
Address all communications to GOMACOWorldEditor. If you do not receive GOMACOWorld, Communications Specialist Bobbi L. Wonder
and would like a complimentary subscription, please contact GOMACO Corporation, PO Box 151, Advertising Coordinator Carrie J. Odgaard
Ida Grove, IA, 51445, USA, 712-364-3347 or e-mail [email protected].
Photo Lab Don Poggensee
GOMACO Corporation's Quality Management System Is
ISO 9001:2000 Certified By The American Systems Registrar.
Quality Policy: We Shall Meet Or
Exceed Our Customers’ Expectations.
GOMACO Versatility Showcased on I-64 Project
One of the most unique projects in slipformed by GOMACO equipment. Paving for Fred Weber, said. “That
Missouri history is currently in its Fred Weber and Millstone Bangert machine will do anything you ask it to
second phase on Interstate 64 through have brought their fleet of GOMACO do. It’s just amazing what it can do, as
St. Louis. The design-build project, the equipment onto the project. That fleet small as it is.”
city’s first, is a complete replacement includes three 9500 trimmer/placers,
Paving the Mainline –
of approximately 10 miles (16 km) of an RTP-500 placer, four Commander III
But let’s start at the beginning of
the interstate right through the heart four-tracks, and a GHP-2800 paver.
the project and the removal of the
of the city. One-half of the 10 miles It’s a lot of equipment, but the variety
existing roadway. All of the material
(16 km) is completely shut down to of applications the equipment is
on the project was recycled. The
traffic while work takes place. The slipforming is astounding.
concrete was crushed and used again
unprecedented move is taking years The Commander IIIs are
for the base material. The base for the
off the completion date and creating a slipforming shoulders, medians,
I-64 project consists of 10 inches
safer environment for the construction variable-width ramps, inside median
(254 mm) of six inch (152 mm) minus
workers. barrier wall, outside barrier wall,
rock, capped with two inches (51 mm)
The project is being built by a retaining wall, roundabouts, bridge
of Type 5 rock. The top layer is
consortium called Gateway parapet, truck lanes, half-shaped
trimmed to the accurate, final grade
Contractors, which involves barrier wall against MSE
with a GOMACO 9500 with an 18 foot
contractors Granite Construction; (mechanically-stabilized earth)
wide (5.5 m) trimmerhead.
Fred Weber, Inc.; and Millstone wall, and moment slabs for the
Millstone Bangert is responsible
Bangert, Inc. The two-year sound wall. That’s over 10 different
for all of the mainline paving on the
project involves 200,000 cubic applications that one machine is
project and are using their GOMACO
yards (152,912 m3) of concrete. capable of slipforming.
four-track GHP-2800 paver. Project
All of the concrete will be “In my opinion, the Commander III
smoothness specifications require a
is the best machine around and you
reading of under 30 and Millstone
can’t beat it for versatility,” Jim
Bangert is consistently running
Jackson, Operations Manager of
D4
G-100819
C
ger
Krue
Kelly
by
Photos
A GOMACO 9500 feeds concrete onto the belt of a four-track Commander III slipforming barrier wall on a project in St. Louis.
3
“In my opinion,the Commander III is the
best machine around and you can’t beat
it for versatility,”Jackson said.“That
machine will do anything you ask it to
do.It’s just amazing what it can do,as
small as it is.”
between 10 and 12 on the zero-blanking band.
Smoothness, according to Ron Dibler, Millstone
Bangert’s PavingSuperintendent, begins with
the base.
“Good ride is a process that begins from the
ground up,” Dibler said. “You have to have good
string, consistent mix and try to keep the paver D14
mtahnoodvu rignuhgn, witsh ieath pg moavoiednri ms’so ultirmda c tskrtisom.p”ms. eMd obsats iem tpo opratavnet on FT-100801
A 9500 trims grade for the mainline portion of the paving project. The
Each paving pass with the GHP-2800 is nine or
trimmer is equipped with an 18 foot (5.5 m) wide trimmerhead.
10 inches (229 to 254 mm) thick and 25 feet (7.6 m)
wide. They’re building four new lanes of interstate,
Retaining Wall –
for both the eastbound and westbound sides. Paving
production averages between 2500 to 3000 cubic
yards (1911 to 2294 m3) per day.
All of the concrete for the project is being
supplied by two on-site batch plants. Concrete is
delivered to the paving site by tandem-axle dump
trucks. The concrete is a Missouri Department of
Transportation (MDOT) approved mix with an
average slump of 1.5 inches (38 mm).
All of the Wall –
Slipping the Outside Barrier Wall – The profiles D1
fsoimr tilhaer ,i nbusitd teh aen odu tosuidtsei dbea rbraierrr ihera sw saolulsn adr ew vaellry G-040813
C
mounted to the top of it. ACommander IIIis used d
to slipform a moment slab with a rebar grid. The m Hel
steel for the wall is tied to the rebar grid in the by To
moment slab. With the steel in place, the spacing for Photo
the sound wall is meticulously plotted and the Two rebars at a time are hydraulically inserted into the top of this barrier.
anchoring bolts for each post are carefully set.
Another wall will be slipformed on top to form a retaining wall on the project.
“The sound wall posts have to be put in the
exact location, because each panel is made to fit a
certain area,” Dibler said. “After the cages are built,
we dry run the steel to make sure everything is
going to work and it’s all set to the right height.”
The concrete trucks dump their loads into an
RTP-500, which then feeds the belt on the
Commander III. The central mix concrete, according
to Dibler, gives their concrete more consistency and
allows them to run a drier mix for their barrier
work.
Behind the Commander III, workers have to
locate the anchoring bolts for the sound wall, dig
D3
tinhsetmal loeudt aafntedr etxhpe ocsoen tchreetme hsoa st hceu rpeods.t s can be G-100843
Center Median Barrier –A9500 placer feeds C
d
another four-track Commander III as it slipforms Hel
m
the variable-height center median barrier. The To
h7.e2i5g hfet eotf ( t2h.2e mw)a.l l varies from four feet (1.2 m) to Photo by
A roundabout on the project was slipformed 20 feet (6.1 m) wide with
4 integral curb around a 45 foot (13.7 m) radius.
“We’ve been able to slipform variable
Non-variable Barrier –
pavement widths very easily,and that’s
been a big help on this project,”Dibler
said.“The new roller frame on the
Commander III and the transition
sensors go right through the width
changes without a problem.”
The non-variable height barrier has 10
longitudinal bars fed into the front of the mold for
wall reinforcement. The variable-height barrier is
slipformed over a steel cage in the lower half of the
wall. They are inserting six longitudinal bars into
D19 the front of the mold for the top section of the wall.
G-100820 costR-seatvaiinngin mg eWasaulrle – oTnh teh ec opnrsoojertcitu bmy esntagciknienegr etdw ao
C
Ten longitudinal bars are fed into the front of the mold on the slipformed walls on top of each other instead of
putting in MSE wall. The first retaining wall varies
Commander III for the non-variable barrier wall.
in height between three feet (0.9 m) and six feet
(1.8 m). Two rebars are hydraulically inserted
vertically into the 24 inch (610 mm) wide top of the
wall and vibration is applied to the rebar during
insertion. The wall is allowed to cure, and then
backfilled. The roadway is brought up to grade, and
then another section of wall is slipformed on top of
the existing wall.
“The slipformed retaining wall replaces MSE
walls shorter than nine feet (2.7 m) in areas that
would retain dirt,” Dibler explained. “Rather than
building a costly MSE wall, we were able to
slipform retaining walls.”
Side-mounted Shoulder and Medians –
All of the shoulder and medians on the project
are slipformed with a side-mounted mold on the
G-100822 D3 C((11o..82m mtmo) a3 wn mdide),er .oI SrII h8. o.M5u efldedeeitar sn( 2sv. 6aa rrmye )sf rliiofp mtfho efrormeu erids t oas i1bx0a f refreeieet tr
C
The Commander III is equipped with a variable-height mold for wall on it. Zero-clearance paving against the MSE
slipforming both the variable and non-variable center median barrier. wall was accomplished after modifying their mold.
“We had an idea of moving the sideform
cylinders and mounting structure from the outside
of the mold to the inside of the mold and
minimizing the thickness of the sideform,” Dibler
said. “We were able to get that down to about two
inches (51 mm), which allows us to slipform closer
to the walls, and that’s been a big help on this job.”
Variable-width ramps with the V2 mold –
Two of the Commander IIIs on the project are
equipped with V2 variable-width molds. The V2s
have the optional auto-width adjustment package to
allow the mold to make on-the-go width changes
and produce a tapered slab. Asecond stringline is
set to follow the desired tapered slab, and sensors
on the paver use that second stringline to control
the cylinders that extend or retract the frame and
CG-100825 D13 sstriydasnetes-smithi ioofntn t ahanued tmo tmhoelad tm.i cTo whldeh aeodnpj euarpsatptsor troo as citmhheipn nlgye twphu ep twsa vtidhinetgh
The V2 mold is making on-the-go width changes from 15 feet (4.6 m)
down to 12 feet (3.7 m), and 18 feet (5.5 m) down to 12 feet (3.7 m). 5
D13
G-100838
C
The Commander III slipforms barrier next to a section
of already finished sound wall.
D14 D8 D3
G-100833 G-100833 G-100836
C C C
The first step to the sound wall is slipforming a moment slab. The slab features extra steel reinforcing slipformed into the concrete. The
steel caging for the barrier wall is anchored to the steel in the slab. Extra supports for the sound wall are incorporated into the wall’s
steel cage. The posts that support and hold the sound wall panels are then bolted to the supports after the concrete wall has cured.
width automatically. You don’t have to worry about radius. Fred Weber decided to pave the
Width changes on the ramps anything else. It gives us such first roundabout in two separate pours.
include transitions from 15 feet (4.6 m) flexibility and different options. It’s The first was 10 feet (3 m) wide and
down to 12 feet (3.7 m) wide, and just a very smooth transition.” the second was the same width with a
18 feet (5.5 m) down to 12 feet (3.7 m) It allows them to pave at different three inch (76 mm) mountable curb.
wide. The transitions are made on-the- widths, with one machine, all in the “The tight radius intimidated us a
go, with no need to stop and adjust same day. On a project like this, it’s a bit on the first roundabout,” Jackson
the paver width. necessity and a huge time savings. said. “The second one though, we
“This is something I’ve been “We’ve been able to slipform decided to pour the full 20 foot (6.1 m)
looking forward to for a long time,” variable pavement widths very easily, with the curb on it. It worked out just
Jackson said. “We’ve always had to and that’s been a big help on this fine, and we accomplished it all in one
stop paving and add or take out a project,” Dibler said. “The new roller pour, instead of two.”
section, and that takes time. Then, frame on the Commander III and the To finish out the roundabout, a
when we first got our V2 mold, we transition sensors go right through the lane was slipformed inside of its
had to set our stringline like normal width changes without a problem.” radius. The lane, which is used to
and paint a line where we wanted our assist trucks through the roundabout,
Roundabouts –
transition. Aworker would stand was nine inches (229 mm) thick, and
Another cost-saving measure on
there with the remote in hand and try 10 feet (3 m) wide with a six inch
the project included building two
to follow that line manually. (152 mm) vertical curb.
roundabouts instead of entrance and
“Now with this new package The I-64 project is scheduled to
exit ramps. The 20 foot (6.1 m) wide,
and the extra cylinder and stroke, have traffic back on the finished
eight inch (203 mm)thick roundabouts,
we can set our second stringline and second phase by the end of this year.
with integral curb on one side, had to
the transitions follow the stringline. It’s a deadline the consortium is
be built around a 45 foot (13.7 m)
confident they’ll make.
6
D18
W-090816
H
Moser
Ric
by
Photos
The GP-2600 with a front-mounted chain trimmer slipformed a new canal between Amasya and Tasova in northern Turkey.
Slipforming Canal in Northern Turkey
Water has always been a precious paver to slipform three kilometers 150 millimeters (5.9 in) thick. The
commodity in the Amasya Province of (1.9 miles) of new canal between the GP-2600 has the capabilities of
northern Turkey. Afamous canal, the cities of Amasya and Tasova. paving canal profiles between six to
Ferhat Water Canal, was first carved The new canal has a top width 9.9 meters (19.7 to 32.5 ft) wide.
into the mountains during the late of 22.3 meters (73.2 ft), bottom width At the start of the project,
Hellenistic Age and early Roman of 6.7 meters (22 ft), and 9.3 meter over 2.5 million cubic meters
Period, approximately 2000 years ago. (30.5 ft) side slopes that are (88,286,188 ft3) of material had to be
It was constructed using the water
balance system by opening tunnels on
the carved rocks and forming vaulted
walls using the natural slope of the
land to make the water flow to the
ancient city of Amasya.
Water is still a precious
commodity in northern Turkey and
the modern city of Amasya. The city is
home to over 350,000 people. The
entire province of Amasya is very
agricultural and is famous for its
apple crops. They also produce
tobacco, peaches, cherries and okra.
Amore modern method of
building canals is currently underway
near the city. Basat Elektrik Uretim & D17
TTuicr.k Letyd, .i sS tui.s,i nbags ae dG oOuMt oAfC IOsta GnPbu-2l6,00 W-090817
H
The GP-2600 paved each of the canal slopes are 9.3 meters (30.5 ft) wide.
77
D3
W-090818
H
Concrete was discharged into the concrete feeding system with an auger and baffles that fed it down the slope of the canal.
excavated to build the new canal. A trimming up to 50 millimeters (2 in) of into a concrete distribution system
fleet of crawler dozers and excavators fine grade material. mounted to the front of the paver. The
worked on the project getting the Concrete for the canal was distribution system is an auger system
canal to the proper profile. produced at an on-site mobile batch with baffles that run along the slope
The GP-2600 was equipped with plant. Ready-mix trucks delivered the of the canal. An auger moves the
a chain trimmer to trim down any concrete to the paver. Slump averaged concrete down the slope, while the
high spots in the crushed-gravel 50 millimeters (2 in). baffles collect the concrete to keep it
grade. The trimmer is capable of The ready-mix trucks discharged from sliding down to the bottom of
the 1.5:1 slope of the canal wall.
Behind the paver, a transverse
joint cutter and two longitudinal disk
wheel cutters cut the joints. Each is
spaced three meters (10 ft) apart and
the joint, itself. is 10 millimeters
(0.4 in) wide. Finishers stood on a
work bridge mounted to the back of
the paver and applied a trowel finish
to the surface of the canal and around
the joints. Paving production
averaged around 170 cubic meters
(222 yd3) per hour.
Basat Elektrik’s portion of this
canal is nearly finished. They plan on
keeping their GP-2600 paver busy in
the future on more canal work on 28
different hydroelectric projects. The
D15 work will be carried out over the next
W-090818 fTiuvrek yeey.ars throughout the country of
H
The chain trimmer on the GP-2600 is capable of trimming up to 51 millimeters
8 (2 in) of fine grade material in the canal.
Double Variable
Barrier Wall on
Illinois’ I-55
P.T. Ferro Construction Company first
started work in 1964 as utility contractors in
Joliet, Illinois. Since that time, they’ve taken
on a variety of challenges as they expanded
their business. They added a GOMACO
GT-3600 curb and gutter machine in 2004
and started slipforming their own curb on
their projects.
The Illinois Department of
Transportation (IDOT) let a barrier wall
project on Interstate 55, just west of their
Joliet location. They had never slipformed
barrier wall before, but weren’t afraid of the
challenge. They consulted with their
GOMACO distributor, Finkbiner Equipment
Company, and with GOMACO engineers to
find the right machine and mold profile to
complete the 22,000 lineal feet (6706 m) of
variable height, center median barrier.
They purchased a Commander III with
a four-track barrier package assembly. The
mold was built with double variable
capabilities so each side of the wall could
be adjusted up to 30 inches (762 mm) to
meet project specifications in a single
slipforming pass.
Choosing the right machine was an
important decision in the project’s early
phase. P.T. Ferro was working under a tight
deadline for completing a portion of the
work before winter weather moved in.
“This job had an interim completion
date that included a penalty,” Phil Hess,
19 inches 19 inches President of P.T. Ferro, said. “We were
(483 mm) (483 mm)
under the gun to buy a machine, and get
2500 feet (762 m) of barrier wall slipformed
before winter set in.”
chesmm) chesmm) Their new Commander III was
D11 42-78 inches42-78 inches067-1981 mm)067-1981 mm) 32-62 inches32-62 inches813-1575 mm)813-1575 mm) (71 732 ini8n c(813 mhems) (71 7i8n c32 inmhem(813 s) 62 inches(1575 mm) 42-78 inches067-1981 mm) dpNiwan renoacolllveijluvew,e decmb trelu eabdcdtnoe narmeo lo 1nsapto5n lto. edi tnmTth ilohoeyep ne eo fe’ncisnnno ti diimOnrsaeghcpt ietpluno erfpgbtooi ejortterh hnct e2ah td 2teob a. s faytTe reaechradtieierdo rwin n agos f
Kelly Krueger CG-100732 (1(1 3-39 inches(76-991 mm) 3-39 inches(76-991 mm) (1 iwtfnroaetrei nPor“.sinOTntl.agny tF, ce”nee ret Eotrehro dite,cre s adCZaf foioaidmcl .ac amo,“ guTGaaphenilennde .e oe orrpaf e IldI rSIaauatyiprsnr egiorv fisenydtse, tnedmesnt
by on the GT-3600 and the Commander IIIare
Photos
39.25 inches 39.25 inches 9
(997 mm) (997 mm)
very similar, so it was easy for our “In a normal work day, we always Finishing work was kept to a
people to learn. Because of the exceeded our estimated production minimum with only a light broom
background we already had and the rates,”Zola said. “We were emptying finish applied behind the
ease of using the GOMACO concrete trucks every 14 minutes... Commander III.
equipment, I’d say we were up to that’s a lot of concrete. Our concrete P.T. Ferro finished their first
maximum production within a couple supplier, Welsch Ready-Mix, did an portion of interstate within the time
of days.” excellent job for us. allowed. They went back and
On the first day of their barrier “The key was getting the concrete completed the second portion of the
pour, IDOT had a review team on site to the site at the right slump, having project and impressed everyone at
to witness the slipforming. the vibrators set correctly and then IDOT with their slipformed barrier.
“They were impressed with the just having great personnel out there.” “It was a massive wall within a
quality of our wall and our total The concrete mix design was an restricted area, but it worked well for
production,” Zola explained. “And it IDOT approved mix with slump us,”Hess said. “From Marty Ahrendt
was just our first day. It only got averaging between 0.5 to 0.75 inch at Finkbiner Equipment to
better from there on out.” (13 to 19 mm). P.T. Ferro used nine GOMACO... everybody was just top
The barrier’s profile featured a straight vibrators placed at strategic notch.
39.25 inch (997 mm) wide base, and a locations in their barrier mold. They “The key, besides the equipment
19 inch (483 mm) wide top, with both also equipped their Commander III and the people, is good concrete... The
of the side walls varying in height with a 24 inch (610 mm) long concrete is crucial. Because of this
from 3.5 to 6.5 feet (1.1 to 2 m). Every conveyor extension. Zola felt the experience, we’re looking forward to
14 feet (4.3 m) of wall required a new extension made it easier to get doing more wall work with our
mixer truck, carrying a 10 cubic yard concrete from the trucks into the mold Commander III in the near future.”
(7.6 m3) load of concrete. to aid their overall production rate.
D28 D15
G-100728 G-100732
C C
P.T. Ferro’s barrier mold is built with double variable Slipforming successful wall, according to P.T. Ferro, is having
capabilities so each side of the wall can be adjusted for height. the right concrete mix design delivered at the correct slump.
D5 D13
G-100723 G-100732
C C
Stringline is set underneath the Commander III The wall has a 19 inch (483 mm) wide top, is 39.25 inches (997 mm) wide
10 and out of the way of the finishers. at the base and its sidewalls vary in height from 3.5 to 6.5 feet (1.1 to 2 m).