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GLOBALREPORTCONSTRUCTION EQUIPMENT 2015
www.worldhighways.com
Following its highly acclaimed launch in early 2014, The GLOBAL REPORT: Construction Equipment is back for 2015 with even bigger and better in-depth expert views on the critical factors that today’s users of construction equipment need to consider in the light of our industry’s fast-developing technological and financial parameters.
The GLOBAL REPORT: Construction Equipment 2015 will neatly fall between the two giant equipment exhibitions: Bauma China in Shanghai at the end of November 2014, and Intermat in Paris, which takes place from April 20 to 25 2015. As before, our team of EIGHT specialist construction equipment reporters will join forces with a host of industry experts to give a series of incisive insights into the most important developments and opportunities facing the market, as buyers decide which manufacturers and models to invest in.
We will look into a wide range of new technologies and focus hard on what our thought-leaders believe will be the key determining factors that buyers of construction equipment across the world will need to consider. We will showcase the opinions of the market’s most authoritative commentators and give 70,000 industry decision-makers the inside track on which new ideas are likely to prevail, and why.
Informed Authority
Publicatio
n
date:
February
2015
Digital50,000+Print20,000
aSPHaLT PaVING
aSPHaLT PaVING
A series of developments has helped push
forward the boundaries with regard
to the asphalt paving segment within
the last years. Three areas of technology
have been notable for their prominence in
recent years for the asphalt paving equipment
market with developments having been
particularly focussed on lower engine
emissions, machine control systems and
material transfer vehicles.
Asphalt paving machines do vary
considerably, depending on the markets they
are sold into. In the US, the length of highways
to be constructed meant that manufacturers
focussed on developing high production
pavers. North America and Latin America are
the main markets for these machines, while
Australia is highly unusual in that different
contractors will use either US or European
types of asphalt paving equipment. However
on a worldwide basis, the European-developed
pavers with tamper bar screeds are popular.
This screed system is also favoured by Japanese
and Chinese manufacturers, while for both
types, electric heating is becoming the most
widely accepted system.
A lot of the innovation for asphalt pavers
of all types has come from the power source.
Engine firms have invested a great deal of
effort in developing new low emissions
technologies to meet the phased set of
regulations set out for North America and
Europe. These have resulted in new engines
that produce far lower levels of NOx and
particulates, with the regulations being
introduced in a series of stages. For 2014
comes the first step in the introduction of the
Tier 4 Final/Stage IV legislation for North
America and Europe, the most stringent
yet with regard to exhaust emissions and
operating noise.For the asphalt paver manufacturers
supplying equipment to North America
and Europe, this has required an enormous
investment in engineering development.
Paver manufacturers have had to research
the technologies the engine suppliers have
developed and select the most suitable for
their respective ranges. And this has not been
an easy task as, in some instances, engine
firms have changed the emissions solutions
they have used from what was originally
predicted. The machines themselves
have had to be redesigned to allow the
installation of these new engines as well as
the aftertreatment systems they employ. At
the same time, care has been taken to ensure
that sight lines from the paver decks have
not been obscured, a significant challenge
given the size of some of the necessary
aftertreatment components as well as the
additional cooling these new generation
engines require. For customers, pavers fitted with the latest
engines will certainly be quieter running and
smoke-free. The cost of the extra research
and development and technology required
to make these diesels so much more clean-
running is not inexpensive though. However
the engine companies have managed to
address running costs in many instances,
increasing the times required between service
intervals and also cutting fuel consumption
significantly. This last point is something all the
major asphalt paver manufacturers have
also prioritised for their new generation
machines. Combining the new generation,
low emission, low fuel consumption engines
with improved load-sensing hydraulics
governed by sophisticated electronic
management systems has helped cut fuel
consumption. This fuel economy is further
improved by intelligent engine speed
reduction systems that activate when the
machine is running at low load. Several of the
major European, Japanese and US firms such
as Ammann, BOMAG, Caterpillar, Dynapac,
Roadtec, Sumitomo, Vögele and Volvo CE
offer this kind of economy mode. For the
customer, while new engines may have
added to the purchase price of equipment,
fuel economy gains of around 15%, will help
offset the costs, particularly in markets such
as Europe, where fuel costs are high.
However asphalt paver manufacturers sell
machines in a much wider range of territories
than Europe and North America. As a result,
their new paver designs have also had to be
designed so as to allow the installation of
diesels for lower emissions targets such as
Tier 3/Stage IIIA and Tier 2/Stage II.
For the contractor, a significant efficiency
saving will come with the utilisation of new
machine control systems. A new generation
of machine control systems is now being
offered to the asphalt paving sector, with
companies such as Topcon, Trimble and also
MOBA, offering an array of systems to the
sector. In many cases these can be plugged
straight into the new electronic controls
that run proprietary software that paver
manufacturers such as Ammann, BOMAG,
Caterpillar, Dynapac, Roadtec, Sumitomo,
Vögele and Volvo CE have installed on their
latest machines. These also can be connected
to the advanced telematics systems now fitted
to pavers from various firms, which help with
machine maintenance and diagnostics, as well
as monitoring performance.
Both Topcon and Trimble have developed
machine control systems for the asphalt
paving market. These are based around
proven technology that originates from
the earthmoving sector, offering higher
performance and increased efficiency. Asphalt
paving controls from these firms feature
colour graphical displays, sonic trackers and
slope sensors and can be used to monitor
elevation and slope values for the screed.
Meanwhile the sophisticated MOBA
PAVE-IR system plays an important role as it
can ensure that asphalt temperature remains
within tolerance during paving and
compaction. This is a highly critical factor as
compaction cannot be carried out if the
asphalt temperature drops below tolerance.
When the asphalt is cold, compaction can
crush the aggregate in the material while air
voids will remain and the surface will not
meet specification and will be subject to early
failure. The MOBA PAVE-IR features a high-speed
scanner that monitors the temperature of the
mat during the asphalt paving process and
this provides full electronic documentation
for later analysis and recording purposes. The
improved system allows a contractor to
optimise operations from the moment the
asphalt is fed into the paving train until the
compaction rollers make their final passes
over the freshly laid surface.
The firm’s earlier system was used by a
number of contractors, particularly in the US,
and proved the efficiency of the concept.
However the original design featured heat
sensors mounted on a bar
that restricted the movement of the paving
crew around the screed, so the company
opted to develop this more effective unit
with its temperature scanning unit raised out
of the way.The sophisticated scanner measures the
temperature across the mat and can be set for
widths of up to 8m. The system can check the
temperature at several points, with an
accuracy of +/-2°C and displays this
temperature profile in real-time. By
monitoring progress, the operator can
identify cold or hot spots and take
New techNology is driviNg
AsphAlt pAviNg towArds true
optimum efficieNcyNovel asphalt paving technologies are coming to market – Mike Woof writes
globAl report construction equipment 2014
34
globAl report construction equipment 2014 35Above: Machine control technologies
ensure optimum paving efficiency
below: Improvements in asphalt paver
design have made newer machines easier
to operate, with far better visibility of the
screed and better controls
left: Screed designs vary considerably
between European and North American
marketsbelow: Using a materials transfer
vehicle minimises the risk of material
segregation in the mat as well as providing
a more homogenous heat gradient for the
surface, while also delivering a continuous
material flow to the paver
➔
Market intelligence
Market intelligence
global report construction equipment 201412global report construction equipment 2014 13
the current construction cycle in Malaysia has reached its peak, with construction activity in Q2 2013
seeing the lowest pace of expansion since Q4 2011, according to the latest Malaysia Infrastructure Report by Business Monitor, a leading independent business research consultancy covering 195 countries and 24 industry sectors.
BM says it expects this slowdown to intensify, primarily due to falling demand for residential and non-residential buildings, as well as concerns about Malaysia’s fiscal position. These concerns are said to have increased financing risks for public-funded projects, particularly within the infrastructure sector. As a result, BM has
maintained its construction growth forecasts for 2013 (10.1%) and 2014 (6.7%), but revised down its longer-term forecasts, from an annual average of 5.0% to 4.5% between 2015 and 2017.
In July 2013, BM states, the Malaysian Highway Authority stated that the government was considering plans to construct a new coastal highway along the east coast of Peninsular Malaysia, from Kota Bahru in the state of Kelantan to Pengerang in Johor. There is a need to improve connectivity and accessibility in the eastern coast of the country, while most parts in the western coast areas are well-connected and served with roads and highways. BM says the project is expected to create economic spillover effects and open new growth centres in the east coast areas.
The Asia-Pacific region is set to have the largest share of global demand for construction equipment in the five-years to 2015, according to the Freedonia Group. Construction machinery sales are expected by Freedonia to increase almost 7% a year until 2015, fuelled by a higher degree of mining output and construction spending. Although China will, say Freedonia, represent nearly 40% of new construction machinery demand to 2015, growth will also accelerate in Indonesia and Malaysia. Within overall construction equipment demand, fellow independent market analysis firm Timetric notes that Asia-Pacific’s share of overall global demand for earthmoving equipment will rise to 64.5% in 2016, compared to 57.8% of the $78.7 billion market value in 2011.
The Indonesian construction sector has benefited greatly from soaring fixed
investment, according to a VDMA study using data from Timetric. The research states that investment in construction has grown by 7.4% on an annual average basis in real terms over the past 10 years, well above the GDP growth rate of 5.9%.
In nominal output terms, the VDMA study reports that the sector will grow by 15% a year in the next five years, supported by urbanisation, rising incomes and the government’s effort to improve infrastructure as part of the Master Plan for the Acceleration and Expansion of Indonesia’s Economic Development. The study reports that in order to attract investment for the
master plan, set to see spending of up to US$428 billion from 2011-25,
the Indonesian government is taking steps to strengthen public-private partnership (PPP) regulations.
Infrastructure construction will be the leading sector for growth,
according to the VDMA study, but other construction
sectors, especially residential and commercial construction, will also see
healthy growth given the positive economic forecast and the expansion of the country’s middle class.
Singapore’s construction industry recorded a CAGR of 4.14% from 2008-12, reports Timetric. This rise was supported by public and private investments in Singapore’s infrastructure, commercial and institutional construction markets. The outlook for construction is favourable, says Timetric, due to the government’s focus on infrastructure and residential construction. Timetric state that the construction industry’s output is expected to record a CAGR of 5.04% over the period 2013-2017.
Infrastructure construction will be
the leading sector for growth, according to
the VDMa study
rest of asIa
aboVe left: Concerns about Malaysia’s fiscal position are contributing to slower expansion left: The Sila Sanon limestone quarry in Thailand is playing a key role in providing high quality aggregates for the growing Thai construction industrybeloW: Thailand’s roads feature heavy congestion, especially in urban areas, with more work being carried out to expand the system and improve flow
2017*
china 29% north America 17% europe 12% india 7% Japan 6% rest of World 29%
2012
china 38% north America 14% europe 13% india 5% Japan 5% rest of World 25%
2007
china 18% north America 28% europe 20% india 3% Japan 8% rest of World 23%
0
20
40
60
80
100
120
Year 2007 2011 2012 2013* 2017* rest of World $32.3 $32.1 $29.0 $29.0 $30.3 Japan $4.6 $3.2 $4.3 $4.5 $4.5 india $1.9 $3.1 $2.4 $2.2 $3.9 europe $19.6 $12.0 $12.4 $11.1 $12.7 north America $28.2 $20.3 $25.3 $23.2 $27.8 china $11.2 $37.1 $24.3 $22.6 $25.6
Changing Structure of Demand, 2007-2017* (% of Total) source: off-Highway research*Forecast
Global Equipment Sales, 2007-2017* ($Billion)source: off-Highway research*Forecast
Articulated Dump trucks 2.4
rigid Dump trucks 4.5
Wheeled Loaders 24.3
Global Value of Construction Equipment, by Type 2012 ($Billion)source: off-Highway research
crawler excavators 38.8
Asphalt Finishers 0.8
mini excavators 6.0
Backhoe Loaders 5.6
crawler Dozers 5.2
others 0.8
Wheeled excavators 2.5
skid-steer Loaders 2.6
telescopic Handlers 3.2
motor Graders 3.4
GLOBALREPORTCONSTRUCTION EQUIPMENT 2014
UNIQUE CONTENT AND INSIGHTFUL OPINIONS ON THE SHIFTING MOVEMENTS WITHIN THE MARKET BY THE INDUSTRY’S MOST INFORMED AND INFLUENTIAL SOURCES
www.worldhighways.com I www.aggbusiness.com
Informed Authority
GLOBAL REPORT CO
NSTR
UCTIO
N E
QU
IPM
EN
T 2014
We could tell you about the new innovative features on the Roadtec Shuttle Buggy™ MTV like 38% more auger surface area or how all of the conveyor floors are made of chromium carbide plate. We could talk about our stronger chains with newer sprockets. But the thing that really separates us from the others is how we backed it up with the industry leading EDGE™ extended warranty; A 3 year, 3,000 hour unlimited warranty that isn’t prorated. Roadtec will reimburse you for your labor and covers everything but wear parts. That’s how we DARE TO BE DIFFERENT.
WE DARE TO BE DIFFERENT,SO YOU CAN BE YOUR BEST.
Standard Warranty: 1 YEAR OR 1,000 HOURS EDGE™ Extended Warranty:3 YEARS OR 3,000 HOURS EDGE™ Engine Warranty: 5 YEARS OR 6,000 HOURS
Total circulation:70,000
GLOBALREPORT
CONSTRUCTION EQUIPMENT 2014UNIQUE CONTENT
AND INSIGHTFUL
OPINIONS ON
THE SHIFTING
MOVEMENTS
WITHIN THE
MARKET BY
THE INDUSTRY’S
MOST INFORMED
AND INFLUENTIAL
SOURCES
www.worldhighways.com I www.aggbusiness.com
Informed Authority
GLOBAL REPORT CO
NSTR
UCTIO
N E
QU
IPM
EN
T 2014
We could tell you about the new innovative features on the Roadtec
Shuttle Buggy™ MTV like 38% more auger surface area or how all
of the conveyor floors are made of chromium carbide plate. We
could talk about our stronger chains with newer sprockets. But the
thing that really separates us from the others is how we backed it
up with the industry leading EDGE™ extended warranty; A 3 year,
3,000 hour unlimited warranty that isn’t prorated. Roadtec will
reimburse you for your labor and covers everything but wear parts.
That’s how we DARE TO BE DIFFERENT.
WE DARE TO BE DIFFERENT,
SO YOU CAN BE YOUR BEST.
Standard Warranty:
1 YEAR OR 1,000 HOURS
EDGE™ Extended Warranty:
3 YEARS OR 3,000 HOURS
EDGE™ Engine Warranty:
5 YEARS OR 6,000 HOURS
THIS DEFINITIVE AND FORWARD-LOOKING PUBLICATION WILL BE CIRCULATED TO THE TOTAL CONSTRUCTION EQUIPMENT DATABASE OF ROUTE ONE PUBLISHING, MAKING IT A PARTICULARLY COST-EFFECTIVE ADVERTISING OPPORTUNITY AT THE START OF THE YEAR.
Market intelligence
Market intelligence
The Global Report
Construction Equipment
2014 has been written by a
team of expert journalists
from World Highways
and Aggregates Business,
as well as leading figures
from the industry itself.
In this piece, on the global outlook for the
world’s leading road construction equipment
manufacturers, we are pleased to include an
expert view from Paul Howard, a consultant
with Off-Highway Research. Despite the
global economic crisis and a government-led
slowdown in China, cautious optimism is
creeping back.
It’s been a tough few years for the world’s
construction equipment manufacturers.
Despite the fallout of the global
economic crisis over the last five years,
there has been cautious optimism among
many senior figures of the world’s leading
equipment manufacturers during equipment
launches and media interviews at the
biggest industry trade shows. The latest
construction equipment unit sales forecast
from Off-Highway Research (OHR), an
international construction equipment
industry management consultancy, backs
such restrained optimism. After global sales
of US$97.8 billion in 2012, OHR tips sales of
$104.8 billion in 2017 – a rise of 6.6%.
Within the overall figures, however,
some key regional markets are predicted
by respected industry analysts and national
associations to fare much better on future
unit sales and levels of production than others.
Markets such as Africa, the Middle East,
parts of South America such as Brazil, and
Asian countries such as Indonesia are already
flourishing as governments and private
investors invest and the likes of The World
Bank continue to loan hundreds of millions
of dollars for vital new transport and other
infrastructure.
Read on for a region-by-region look at the
fast-changing global construction equipment
industry world.
Meanwhile, OHR has
tipped average annual
Europe construction machine
sales to average 115,400 units a
year from 2013-2017 – down from
an 118,589 unit average 2008-2012.
On sales by machine, OHR forecasts little
change between 2012 and 2017. Of 2012
machine sales, 33% were mini excavators;
19% were telescopic handlers; 16% of sales
were of crawler excavators; another 16%
were wheeled loaders; 6% were wheeled
excavators; 3% of sold units were skid steer
loaders; a further 3% of sales were of backhoe
loaders; and 4% of sales were made up of
other machines.
In 2017, OHR predicts that the only
change in machine percentage sales changes
will be a 1% dip in telescopic handler sales
(to 18%), and a 1% rise in
backhoe loader sales (to 4%).
In terms of percentage
of machine sales by country,
UK machine sales are tipped to
increase from 20% of all Europe sales
in 2012 to 21% in 2017; and Germany sales
to dip from 27% in 2012 to 24% of overall
European sales by 2017. French machine
sales are forecast to fall from 21% of all-
Europe sales in 2012 to 19% of sales in 2017;
and Italy machine sales from 7% of all the
continent’s machine sales in 2012 up to 9%
in 2017. Other countries combined sales are
tipped to rise from 25% of all-Europe sales to
27% of total sales.
OHR has reported a 29.7% fall in
the average annual level of European
construction machines produced from 2008-
2012 (to 134,996 units a year), compared to
192,167 a year average production levels from
2003-2007.The Russian construction industry
recorded a nominal Compound Annual
Growth Rate (CAGR) of 9.68% from 2007–
2012, reports Timetric, the independent
business research analysts. Understanding
how modernising infrastructure can lead
to long-term growth, the government has
announced large-scale investment in road
and rail infrastructure. Timetric notes that
construction related to the 2014 Winter
Olympic Games in Sochi and the 2018 FIFA
World Cup is anticipated to support growth
in all construction markets. In particular,
infrastructure construction is projected to
remain the fastest-growing construction
market to 2017.
A brIghter future?
The global construction equipment manufacturing industry is still recovering from
the dramatic impact of the 2008 world financial crisis - Guy Woodford reports
globAl report construction equipment 2014
6
globAl report construction equipment 2014 7
european construction machine exports
fell 15.8% between January 1 and
May 31 2013 to €11.049 billion from
€13.096 billion over the same period of 2012,
according to new CECE (Committee for
European Construction Equipment) figures.
Germany was the biggest Europe-based
export market for European construction
machines importing €1.107 billion worth
of machinery – down 14.1% on €1.288
billion over the same period the previous
year. France was the second biggest Europe
export market importing €832.51 million
of construction machines over the first five
months of 2013, a fall of 14.8% on €977.14
million in 2012. Exports into the UK fell
less sharply (-3.8%) to €449.48 million from
€467.28 million. Other key export nations
for European construction machines were
the US, importers of €1.08 billion worth of
equipment – down 23.4% on €1.42 billion
worth of machines imported in the 2012
recording period. Russia imported €792.55
million of European construction machines,
compared to €931.15 million between
January 1 and May 31 2012. Australian
imports of European exported construction
machines were worth €343.73 million – down
41.2% on the €584.32 million of machines
the previous year. European exports to China
were worth €228.08 million January 1 to
May 31 2013 – a fall of 28.1% on the €317.02
million worth of machines exported in the
first five months of 2012.
the Association of Equipment
Manufacturers (AEM) say US
construction machinery exports
dropped 21% during the first half of
2013, with US$10.8 billion shipped to
global markets compared to $13.7 billion
in H1 2012.
The AEM report that nearly all
world regions recorded double-digit
declines, except Central America with a
double-digit gain.
Construction machinery
exports to Europe in H1
2013, compared to H1 2012,
declined 20% for a total
$1.4 billion, with exports to
Canada down 15% to a total
value of $3.7 billion. Exports
to Asia decreased 24% to
$1.2 billion, while exports to
Central America gained 15%
to $1.2 billion. Exports to South
America dropped 13% to $1.9 billion.
In other key US export markets, Australia/
Oceania’s export purchases fell 62% to $750
million, while Africa took delivery of $654
million worth of construction equipment,
down 20% on exports during the first half of
2012.The five countries buying the most US
made construction machinery during the
first half of 2013 were: (1) Canada - $3.7
billion, down 1%; (2) Mexico - $1 billion, up
18%; (3) Australia - $715 million, down 63%;
(4) Brazil - $513 million, up 17%; and (5)
Chile - $475 million, down 38%.
The AEM off-road equipment
manufacturing trade group consolidates
US Commerce Department data with
other sources into global trend reports for
members.OHR has reported that while the
North American construction machine
manufacturing industry is still fragile, there
are positive signs of recovery. It paints
a more encouraging picture of
North American machine sales
over the next few years. Sales
averaged 118,233 units a
year from 2008-2012, but
that is forecast by OHR to
rise to 161,595 units a year
from 2013-2017 – reaching a
high of around 180,000 units
sold in 2016.
Combined sales of machines
outside crawler dozers, skid steer
loaders, backhoe loaders, crawler excavators,
mini excavators, wheeled loaders, telescopic
handlers, are tipped by OHR to rise from 8%
of overall North American machine sales in
2012 to 13% of overall sales in 2017.
On a less positive note, OHR has
illustrated how North American construction
machine production has fallen dramatically
in recent years. While the number of units
manufactured from 2003-7 averaged 184,734
a year, that average fell to 98,803 units a year
from 2008-2012 – a fall of 46.5% compared
to 2003-7, reaching an annual low of around
55,000 units in 2009, a year after the start of
the global financial crisis.
europe
unIted StAteS
of 2012 machine
sales, 33% were
mini excavators
fAr left: The world’s largest tunnelling
machine was used on Italy’s important road
connection between Bologna and Florence
left: In Finland, a new motorway link
being built as a green highway will link
Europe to Russia
north American
construction machine
production has fallen
dramatically in
recent years
AboVe top: Many existing US roads and
highways are now ageing and do not
meet current standards
AboVe loWer: The demolition of Doyle Drive
in April 2012 was part of the ongoing Presidio
Parkway project in San Francisco, California
AsphAlt pAvement Recycling
AsphAlt pAvement Recycling
global report construction equipment 2014
44
global report construction equipment 2014 45
laid back down in two layers of 200mm and 130mm thickness using a conventional paving machine. Next, this base will be covered with an asphalt surfacing layer only 50mm thick. The sections recycled in 2011 are still performing in excess of expectations.Also, the cold recycling projects carried out back in 2003/2004 involving foam bitumen in Greece, on the highways between Iliki – Corinth – Athens, have demonstrated their high performance over the past 10 years in spite of carrying significant traffic levels of 40,000 vehicles/day, with 25% being heavy goods vehicles. To achieve results of this kind requires extensive studies of the entire road pavement in advance, as well as a detailed examination as to whether the mixing material is suitable for use with foam bitumen. Wirtgen sends its road construction engineers to accompany such projects all over the world, and also provides consulting to assist local road construction experts. Application experts from Wirtgen are available directly on the ground with their equipment, expertise and experience for preliminary investigations of materials, intensive surveys of the road pavement and even carrying out the construction work themselves.Cold recycling offers several key cost and materials benefits. These include the reduction of transport to the job site by up to 90%, savings for binding agents of up to 30%, conserving resources by up to 90% and the avoidance of the need for waste disposal of up to 100%. Cold recycling offers other advantages too including environmental benefits, as full use is made of the material in the existing pavement while the volume of new material that needs to be imported from quarries is minimised. As a result, haulage is drastically reduced, as is the damage caused
by heavy vehicles travelling on existing roads in the vicinity of the project. The overall energy consumed by recycling is also significantly less compared to all other rehabilitation options.It is important to note that the quality of the recycled layer can be maximised. Consistent, high quality mixing of the in-situ materials with water and stabilising agents is achieved using modern recyclers. Micro-processor controlled spraying systems
road building firms over recent years, as illustrated by two projects in Germany and Italy. Alongside the further development of its machines, Wirtgen is also continuously optimising the cold recycling process. For example, its experts developed the downcut process for in-situ cold recycling. In this concept, not only can the milling drum rotate opposite to the travel direction in the upcut process, but also with downcut milling. This allows the recycled material to be loaded directly off the rear onto a road paver which immediately paves and compacts it. Following that, drums carry out the final compaction. The downcut process allows for precise monitoring of the particle sizes during material preparation – especially in very heavily fractured, old asphalt roads.
The new process also simplifies material guidance and has already been used successfully for in-situ cold recycling in North America, while there is additional
potential for it to be used in other markets.Cold recycling is the future of road rehabilitation according to Wirtgen. The global road infrastructure faces excessive demands and onerous challenges in the 21st century. High population growth in developing countries coupled with a need for improved infrastructure to stimulate economic growth, form but a few of these challenges.“In-situ cold recycling offers the most economical alternative for repairing the structure of roads. Often, roads merely undergo ‘cosmetic’ rehabilitation – involving the uppermost structure or simply renewing the asphalt surfacing – which frequently only delivers a temporary improvement and masks the true condition of a road’s construction. The requirement for sustainable road construction technologies is unavoidable,” said Diekmann.The cold recycling process has proved its effectiveness worldwide and can withstand even the heaviest traffic loadings, as shown by the example of the Ayrton Senna Highway in Brazil. It is one of the busiest roads in the world, carrying in excess of 250,000 vehicles/day with a heavy traffic proportion of more than 15%.
During the rehabilitation, the milled material previously extracted from the existing asphalt package was recycled with foam bitumen in a cold mixing system, then
route 17 in Hamptonthis uS project on route 17 in the state of Hampton used a Wirtgen 3800Cr rear load model. the recycling width was 3.8m and was carried out to a depth of 120mm. the mix used a cement content of 1% as well as a foamed bitumen content of 2.2%. the machine achieved a production rate of 520tonnes/h and ran at an average working speed of 8.5m/min. For this job, the inside lane was recycled across its full width in a single pass, with truck traffic on route 17 running in the adjacent lane.
Cold recycling offers several key cost and
materials benefits
“In-situ cold recycling offers the most economical alternative for repairing the structure of roads”martin Diekmann
0
5
10
15
20
25
30
35
paving 0.1
Asphalt 2.2
Bitumen 4.9
raw materials 0.9
recycler 0.4
transport 0.9
removal 0.2
paving 0.4
Asphalt 14.3
Bitumen 6.8
raw materials 3.5
recycler 0
transport 4.9
removal 0.2
Conventional Method kgCO2/m2
Cold Recycling kgCO2/m2
The CO2 balance sheet provides a comparison between conventional repair and the recycling process
sum 9.6
sum 30.1
beloW: The Wirtgen WR 4200 cold recycling machines on a construction project in China
➔
➔
both the in-situ cold recycling process and machine development have benefited from rapid advances during the past three decades. “but the road industry has underestimated bSm technology. With the right mix design and construction technique, it is a user-friendly technology, but practitioners shouldn’t underestimate various points,” said prof Kim Jenkins of Stellenbosch university in South africa. He said it is crucial that when dealing with the variability of in-situ materials, supporting conditions, field moisture, rap percentage and quality and existing layer thicknesses. these need to be systematically dealt with. He added that there also needs to be a strong understanding of the key performance properties of the mix, such as shear properties of bSms and resistance against permanent deformation. prof Jenkins added that it is important to understand that the mechanisms of stiffness and strength change over time, such as with curing after construction. He said that for a project it is key to know how materials should be designed, such as the stiffness values that should be used. another important issue, is understanding the mechanisms of bSms to resist moisture damage and how to test this, as it cannot be carried out with asphalt type tests.most of these aspects have been addressed through research. “but practitioners think that this is an easy material to use and they don’t need to understand what really makes the material perform well,” said prof Jenkins.
novel reCyCling metHod
interState i-81, virginathis project used a Wirtgen 3800Cr in a downcutting operation on interstate i-81 in the uS State of virginia. the recycling width was 3.8m and the work was carried out to a recycling depth of 120mm. the mix featured a cement content of 1% and a foamed bitumen content of 2.5%, with the work being carried out over a 6km stretch of road. While work was being carried out, traffic at interstate 81 was guided past the construction site on the adjacent, previously recycled right-hand lane.
• MARKET INTELLIGENCE: What are the most important trends in construction equipment sales and what sort of materials are being specified? Graphs and charts will give readers a vital update on what is being bought, and why.
• CHINA: How will Asia’s biggest superpower push forward into the global construction equipment market and take on the established machinery and technology suppliers in the West? Will there be more emphasis on finance and insurance deals to keep the customer feeling safe? How important is the maintenance and spare parts offering to buyers with increasing standardisation of components? Will it all come down to doing the best deal, taking account of resale values, or will added-value services make the difference?
• MACHINE CONTROL: How are the leading equipment integration systems starting to make a difference, and do their benefits accrue in equal measure to large and small sites? Is machine control technology making mixed fleets more competitive?
• TELEMATICS: In addition to helping fleets operate more efficiently, telematics are now being widely used to help individual machines, and not just new ones, perform at a consistently higher level. Is it all about performance optimisation, or can the fast-moving world of telematics really change behaviour and make our industry a better place to work?
• NON-OPERATED PLANT AND AUTONOMOUS CONTROL: How far can we go with this hands-off approach? What are the main benefits and where will the technology go next?
• SITE MANAGEMENT SOFTWARE: When will we get to maximum efficiency, or is it just a dream? Welding together huge amounts of data in real time with the sort
of communication that flows through a big project is a major challenge – what is the latest thinking on how to get it right?
• THE MINT ECONOMIES: Take a tour of Mexico, Indonesia, Nigeria and Turkey and find out what influence this next group of emerging powerhouse economies can have on the overall construction market.
• THE SUPPLY CHAIN: If you cannot get the right equipment and materials in the right place at the right time at the right cost, your project will fail and your costs will spiral out of control. What is happening in the construction equipment supply chain and what is driving change? Big infrastructure projects need a tight chain of construction equipment owners, investors, designers, constructors, suppliers, financiers, engineers, maintenance staff and spare parts delivery networks to keep everything on the move. Who does it well, and why?
• THE TREND TOWARDS RENTAL: Should you buy or should you rent? Is the old idea of writing capital equipment off during the course of a big project yesterday’s way of doing things?
• NEW VERSUS USED: How reliable is used equipment? When and how should you consider used equipment? What are the key factors and the most important entry points in this equation?
• EUROPE: Where do CECE and CEMA think the market is heading in Europe? Will it be new regulations on the environment, emissions or safety that will push Europe ahead, and oblige contractors to renew their fleets, or does the continent still face another year of slow sales?
Our experts will be analysing a wide range of key topics including:
aSPHaLT PaVING
aSPHaLT PaVING
to make these diesels so much more clean-running is not inexpensive though. However the engine companies have managed to address running costs in many instances, increasing the times required between service intervals and also cutting fuel consumption significantly. This last point is something all the major asphalt paver manufacturers have also prioritised for their new generation machines. Combining the new generation, low emission, low fuel consumption engines with improved load-sensing hydraulics governed by sophisticated electronic management systems has helped cut fuel consumption. This fuel economy is further improved by intelligent engine speed reduction systems that activate when the machine is running at low load. Several of the major European, Japanese and US firms such as Ammann, BOMAG, Caterpillar, Dynapac, Roadtec, Sumitomo, Vögele and Volvo CE offer this kind of economy mode. For the customer, while new engines may have added to the purchase price of equipment, fuel economy gains of around 15%, will help offset the costs, particularly in markets such as Europe, where fuel costs are high.However asphalt paver manufacturers sell machines in a much wider range of territories than Europe and North America. As a result, their new paver designs have also had to be designed so as to allow the installation of diesels for lower emissions targets such as Tier 3/Stage IIIA and Tier 2/Stage II. For the contractor, a significant efficiency saving will come with the utilisation of new machine control systems. A new generation of machine control systems is now being offered to the asphalt paving sector, with companies such as Topcon, Trimble and also MOBA, offering an array of systems to the sector. In many cases these can be plugged straight into the new electronic controls that run proprietary software that paver manufacturers such as Ammann, BOMAG, Caterpillar, Dynapac, Roadtec, Sumitomo, Vögele and Volvo CE have installed on their latest machines. These also can be connected to the advanced telematics systems now fitted to pavers from various firms, which help with machine maintenance and diagnostics, as well as monitoring performance.Both Topcon and Trimble have developed machine control systems for the asphalt paving market. These are based around proven technology that originates from the earthmoving sector, offering higher performance and increased efficiency. Asphalt
paving controls from these firms feature colour graphical displays, sonic trackers and slope sensors and can be used to monitor elevation and slope values for the screed.Meanwhile the sophisticated MOBA PAVE-IR system plays an important role as it can ensure that asphalt temperature remains within tolerance during paving and compaction. This is a highly critical factor as compaction cannot be carried out if the asphalt temperature drops below tolerance. When the asphalt is cold, compaction can crush the aggregate in the material while air voids will remain and the surface will not meet specification and will be subject to early failure.
The MOBA PAVE-IR features a high-speed scanner that monitors the temperature of the mat during the asphalt paving process and this provides full electronic documentation for later analysis and recording purposes. The improved system allows a contractor to optimise operations from the moment the asphalt is fed into the paving train until the compaction rollers make their final passes over the freshly laid surface. The firm’s earlier system was used by a number of contractors, particularly in the US, and proved the efficiency of the concept. However the original design featured heat sensors mounted on a bar that restricted the movement of the paving crew around the screed, so the company opted to develop this more effective unit with its temperature scanning unit raised out of the way.The sophisticated scanner measures the temperature across the mat and can be set for widths of up to 8m. The system can check the temperature at several points, with an accuracy of +/-2°C and displays this temperature profile in real-time. By monitoring progress, the operator can identify cold or hot spots and take appropriate action to ensure that compaction processes are carried out efficiently. As the temperature gradient data is merged with GPS position information and can be downloaded using a USB stick, the contractor can use this data within MOBA’s PAVE Project Manager software to assess paving quality. The temperature and GPS data can also be sent remotely using a GSM connection to a server, with internet connectivity allowing the data to be used for analysis and quality management. Another important tool in ensuring even asphalt temperatures at the screed comes in the
shape of the material transfer vehicle. This has an added bonus in that it can also minimise the risk of material segregation, providing a more homogenous surface both in terms of temperature gradient and aggregate sizes. Material transfer vehicles are of particular importance for large highway paving jobs, where a consistent material supply is required, without the risk of interruptions. A discontinuous asphalt supply can result in cold spots that are hard to compact and may leave bumps, showing exactly where the supply of material into the paver from one truck ended, and the next began.
The latest generation of material transfer vehicles feature automatic controls that allow them to follow the paver closely, without impeding progress. Many of these machines are also available with conveyors that can be swung into position to allow side loading if required.Roadtec has led the field for material transfer vehicles for many years, with its highly successful Shuttle Buggy. This machine is well accepted in many international markets, so much so that its use is even written into the client specification for a paving job in some instances. Having developed this lead, Roadtec has been keen to maintain its position and the Shuttle Buggy has been through successive upgrades, with this latest version featuring critical wear components made from materials that should last up to 50% longer. These improvements will help cut downtime for maintenance, with improvements to the overall structure also increasing reliability and productivity, and a low emission engine offering reduced fuel consumption.Also wheel-mounted, the Weiler E2850 material transfer vehicle is said to offer efficient remixing of materials, with a capacity of 22.5tonnes. Power comes from a Caterpillar diesel and in a novel move this machine is now available through Caterpillar dealers in some territories. It can be supplied as part of a paving train to go along with Caterpillar pavers and the dealers will also supply service and support. Initially this was for the North American market but has now been broadened to include Australia, Russia and Mongolia.
One sophisticated competitor to Roadtec’s Shuttle Buggy is a very different machine in concept. Vögele’s MT-3000-2 material transfer vehicle is a crawler machine with a transfer capacity of up to 1,200tonnes/hour. This replaced the firm’s earlier machine in the global report construction equipment 2014
36
global report construction equipment 2014 39
the lastest forecast from the Freedonia group suggests that worldwide sales of construction aggregates will expand by 5.8% per annum to 53.2 billion tonnes in 2017. Following recent declines from 2007-2012, aggregates demand is expected to rebound in North america and Western europe. eastern europe is also expected to register faster growth. the global market will continue to be driven by above average growth in the large asia/pacific and africa/Mideast regions,” says Freedonia analyst gleb Mytko.the non-building market
for construction aggregates is expected to outperform the building segment through 2017, as many countries will invest heavily in their public infrastructures. Crushed stone is expected to account for over one-half of all new product demand generated between 2012-2017. these and other trends are presented in World Construction aggregates, a new study from the Freedonia group, a Cleveland, USa-based industry market research firm.between 2012-2017, more than 50% of all additional construction aggregates demand
will be attributable to China, where massive gains in building and non-building construction activity will stimulate sales. as the Chinese market matures, growth is expected to decelerate noticeably from the breakneck pace of the last decade. aggregates consumption in India, the asia/pacific region’s second largest market, will expand at a somewhat faster pace than China through 2017.the construction aggregates markets of eastern europe, North america and Western europe are projected to expand between
3-5% per annum through to 2017. as these regions recover from financial and fiscal crises, residential, commercial and public works construction activity will rebound, generating additional demand for aggregates. eastern europe and North america will record somewhat faster growth than Western europe during the 2012-2017 period. In terms of major countries, Spain, russia, the United States and Italy are expected to perform particularly well, due to a considerable amount of pent-up aggregates demand in these markets.
WorldWIde CoNStrUCtIoN aggregateS prodUCtIoN WIll booM by 5.8% per aNNUM to 2017
World Construction Aggregates Demand (Million Metric Tonnes) source: Factfish*Forecast 2007
20122017*
30.300
40.150
53.200
north America 3.800 Western europe 3.275 Asia/pacific 17.350 other regions 5.875
north America 3.050 Western europe 2.550 Asia/pacific 27.000 other regions 7.550
north America 3.750 Western europe 3.000 Asia/pacific 36.500 other regions 9.950
north America -4.3% Western europe -4.9%
Asia/pacific 9.2% other regions 5.1%
-6 -4 -2 0 2 4 6 8 10
2007-2012
north America 4.2% Western europe 3.3%
Asia/pacific 6.2% other regions 5.7%
0 1 2 3 4 5 6 7 8 9 10
2012-2017
➔
roadtec has led the field for material transfer vehicles for many years
asphalt plants
therefore expect a global market in decline
– in terms of volume (number of asphalt
plant and linked equipment units sold) but
above all in terms of billing. This profession,
like many others, needs to strike a new
balance linked to globalisation: maintaining
its European centres of competence while
managing two very different markets (Europe
and the Rest of the World).”
Despite the inherent complexities associated
with operating commercially in a globalised
market, Bonvallet believes sales opportunities
are there for all asphalt plant and associated
technology manufacturers in “all countries
characterised by dense population –
particularly in urban areas – which are also
experiencing significant, constant growth over
several years, and are stable politically.”
Of the increasing use of RAP in asphalt
plant mixes, he says, “It is not solely the
result of legislation, but also the high price
of bitumen – which has risen by 250% over
seven years.” Bonvallet claims that Marini-
ERMONT is very competitive in this area due
to the firm’s control of continuous techniques,
which, he says, “enables simple, economical
recycling up to 50%.” He continues, “We have
13 recycling solutions that can be put into
practice, but we believe that the simplest,
least expensive solutions are often the best.
Marini has just commissioned a highly
versatile plant in Singapore, equipped with
three recycling systems, producing hot-mix
and warm-mix asphalt and boasting an
impressive storage of finished products. As
the most modern plant in the Asean zone,
this is proof that the markets are multiple,
and that in a mostly emerging zone, in
countries including Philippines, Indonesia
and Thailand, hi-tech demand can go hand in
hand with low-cost solutions.”
Bonvallet believes Europe “took the lead”
on warm-mix asphalt plant production in
the early 2000s, after the first production
using Fayat foam began in Holland in 1999.
“Curiously, it took more than 10 years for
the European market to take off, structure
itself and gain credibility. Warm-mix
asphalt production in the US did not get off
the ground until years later – but by 2012
accounted for 20% of total production.
We note that the bulk of this American
production is done with foamed bitumen,
unlike in Europe where lots of company-
specific solutions still jostle for space.”
The cause of a “cyclical lag” in Europe
on warm-mix asphalt production does
not lie, says Bonvallet, in the fact that one
process is better than another, but in the fact
that there are multiple specifications and
different objectives, specific to companies and
contractors alike. “Processes are now clarified
with several countries having published
guides, and we therefore predict that warm-
mix asphalt production will now experience
double-digit growth. This development
concerns Europe, as well as China which is
taking environmental constraints into ever
greater consideration.” All warm-mix asphalt
solutions, whether chemical, mechanical or
based on foam, are available, says Bonvallet,
through the Fayat Group.
According to Bonvallet, asphalt emulsion
cold mixes may finally be developed after
20 years of “relatively stagnant production”.
He believes these solutions – which he
stresses are certainly more difficult to put
into practice with virgin aggregates – are
ideally suited to recycling, and therefore
to RAP. “RAP production is rising sharply
and not everything will be processed hot.
The company SAE has the most expertise
on the subject in Europe – and is part of the
Fayat Group. The combination of this centre
of competence’s resources and the FAYAT
Group’s logistics and international standing
are undeniable assets.”Although the latest Eurobitume figures on
European bitumen consumption, which show
a fall across the continent from 14.94 million
tonnes consumed in 2011, to 12.917 million
tonnes in 2012, support concerns raised by
leading asphalt plant sector figures such as
Bonvallet, one leading industry research
organisation is offering a more positive
outlook on overall worldwide bitumen
demand.A market report published mid-2013
by Transparency Market Research (TMR)
titled Bitumen (Paving, Oxidized, Cutback
and PMB) Market For Roadways, Roofing,
Adhesives and Insulation-Global Industry
global report construction equipment 201460
global report construction equipment 2014 61
➔
beloW: The sun rises on the Marini Top
Tower 4000 plant being used by Lane for
runway paving at the Midfield Terminal
Complex in Abu Dhabi, UAE
“RAP production is rising sharply and
not everything will be processed hot”
Jacques Bonvallet
asphalt plants
The Global Report Construction Equipment
2014 has been written by a team of expert
journalists from World Highways and
Aggregates Business, as well as leading figures
from the industry itself. In this piece, on the
way in which the world’s emerging economies
are helping to push forward the development
of new asphalt plant technologies, we are
pleased to present expert views from Bernd
Benninghoven, the managing director of
Benninghoven, and Jacques Bonvallet, sales
and marketing director of Fayat. These two
industry authorities take a look into the
future of the asphalt plant and outline the
key drivers of change, in a comprehensive
overview of issues like the use of RAP
(Recycled Asphalt Pavement), the use of LEP
(Lignite Energy Pulverised) and the relative
benefits of hot and cold mixing.
Falling world bitumen consumption;
the commercial and environmental
advantages and disadvantages of opting
for warm or cold mix, rather than traditional
hot mix asphalt plant production; the use and
percentage of use of RAP (Recycled Asphalt
Pavement) in a mix; and the growing use
of Lignite Energy Pulverised (LEP) during
asphalt plant production are set to remain
among key talking points within the asphalt
plants sector of the construction equipment
industry for the foreseeable future.
Last year saw the world’s leading asphalt
plants manufacturers release new plants
and linked technology in response to all
these crucial sector debates. So what does
the future hold for asphalt plant and related
equipment manufacturing?
According to Jacques Bonvallet, Fayat
sales and marketing manager, whose France-
headquartered construction equipment
manufacturing group owns Italian asphalt
plant and associated technology manufacturer
Marini, there has been a “structural transition”
in the asphalt plants sector.
“World bitumen consumption has been
falling sharply ever since a peak in 2007,
before the (2008) global economic crisis.
If we reincorporate the share of bitumen
contained in recycled material in the
economic cycle, which could account for
10% of the total in mature markets, at the
very most we have stagnation in global
asphalt production, with major variations
between mature markets, BRIC and emerging
markets,” says Bonvallet.
“The market is segmented between
European countries – some of which are
equipped or over equipped with asphalt
plants and related equipment - where partial
(asphalt plant and linked equipment)renewal
is taking place and production means are
being concentrated, while other (non-
European) countries are building their road
networks often with mobile equipment,
generally to lower level standard. We
emerging economies push design into a greener and more eFFicient FutureAsphalt plant and linked technology manufacturers are keen to offer more efficient
and greener production and seek out big commercial opportunities in countries
with ambitious plans to develop new or upgrade decaying highways’ infrastructure.
But there are many key factors to ponder in this sector, as Guy Woodford reports
aboVe: ADM EX Series: ADM’s EX Series
asphalt plants produce 90.71 to 385.55tonnes
per hour at a very low cost per tonne.
The US firm claim the plants also have the
longest aggregate drying and mixing times
in the industry
➔
The GLOBAL REPORT: Construction Equipment 2015 will be circulated to a total of 70,000 qualified decision-makers worldwide and provide carefully-researched, well-written and authoritative articles on the most important engineering and technological developments affecting our industry.
Incisive and engaging, The GLOBAL REPORT: Construction Equipment 2015 will give readers a first-class insight into the sort of innovations that will affect their purchasing decisions in the years to come. This glossy annual will have a long shelf life and claim its place as one of the industry’s most important “state of the nation” reviews.
MANUEL BATTISTAEmail: [email protected]: +44 1322 612069Mobile: +44 7768 876463
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