Newcomb_-_101_Ideas - Rocky Mountain Asphalt Conference

(Part II – The Paving Site)
36th Annual
Rocky Mountain
Asphalt Conference & Equipment Show
February 18-20, 2009
Use Common Sense
Train for and Implement Best Practices
Focus on Quality and Customer Service
Include Employees
Be Willing to do Things Differently!
Account for predictable traffic patterns in
scheduling – Know traffic patterns to job. Rush
hours, special events, school and factory
hours. Adjust routes and timing.
On mill and fill projects, use delivery trucks to
back haul RAP – Save on trucking. May need
release agent at paving site.
Mill different layers separately to allow more
flexibility in RAP use – Different layers may have
different materials. E.g., milling surface layer with
high friction aggregates will provide RAP for
surface mixes. Evaluate costs of extra pass and
separate stockpiles.
Sort milling teeth by the amount of wear to
reuse less worn teeth – When replacing worn
milling teeth, sort them by the wear. They can be
used together to obtain smooth milling. Saves on
number of teeth used each year.
Install weigh bridge on milling machine
conveyor to maximize truck load – Minimize the
number of trucks during the day.
Position trucks side-by-side in front of milling
machine to keep continuous operation. – Save
time in truck exchange.
Minimize water spray during milling to keep
RAP dryer – Minimizing cooling water reduces
delays in re-filling tank and reduces moisture in the
RAP, reducing plant fuel consumption.
Calibrate electronics on distributor truck every
day – Important to obtain proper coverage and
Install plate at the end of distributor spray bar
to avoid overspray of curb and gutter – Avoids
cleanup and keeps customers happy.
Make sure each paving crew has a wooden
level to check the screed (daily), transverse
joints, and mat behind the screed – Identify
warped screeds, smooth transverse joints and proper
Install a bumper in back of the spray bar on
distributor truck - Protects the spray bars, avoids
down time.
Investigate use of trackless tack –Reduces the
time for an emulsion tack to break. This can
increase productivity and reduce tracking.
Attach a magnetic grade gauge on the back of
the paver ($55 each) – Provides a check of crossslope control on paver.
Provide paving crew and roller operators with
daily feedback on smoothness and density –
Allows the team to know the score.
Share bonus with employees on bonus jobs,
when successful – Get buy-in from employees on
the importance of quality.
Keep biodegradable release agent on board
paver for tool and paver clean up - Keep tools
and paver parts clean, saves time and avoids using
Assign one member of crew to look after the
electronics and store them in a dry, safe place One person responsible for the care and storage of
the electronics to avoid costly malfunctions..
Install hooks, buckets, and bins on pavers for
tools (e.g. putty knives, wood level, 30’ tape,
100’ tape, gloves, 12’ straight edge, whisk
broom for tacking pavement edges) - Having all
of the tools needed saves time. Tools should be
inventoried, cleaned and placed back on the paver at
the end of every shift.
Use MTV in places requiring hand work or
when trucks can’t get to paver - This helps to
deliver mix to the paver in places where trucks
cannot reach or stay in contact with the paver. It
can also be helpful in depositing mix in areas
requiring hand work.
Cut off feeders and run augers to avoid piling
at end of paver pulls –Cutoff the feeders and run
the augers properly to avoid piling mix at the end of
the pull.
Use a paint marker system on pickup truck
instead of string line –Improves productivity by
speeding job layout and improves safety by keeping
employees away from traffic.
Have auger and tunnel extensions available on
site– Auger and tunnel extensions reduce
segregation and improve longitudinal
joints. Waiting for them or proceeding without
them hurts productivity or quality.
Check tire pressures on pneumatic rollers often
– Important to the ability of pneumatic rollers to
obtain density.
Purchase a “vibe tachometer” for each
vibratory roller to ensure proper frequency
($500 each) – Assures proper roller operation for
compaction and smoothness.
Always stop roller only on cool pavement at an
angle – Avoids bumps in the pavement for
maximum smoothness and to avoid re-work.
Inspect scrapers, wipers, and cocoa mats on
rollers and have spares available – Keep drums
and tires clean to avoid pick-up. Avoids mat
blemishes and improves smoothness.
Install small rubber bumpers on all perimeter
frame rollers – Protects the sheet metal from
Fill roller water tanks and check the water
spray system at the beginning of each shift –All
equipment should be fully functional prior to
beginning paving to avoid time delays and quality
issues. Stopping to fill or repair rollers may affect
density and require stopping paving operations.
Have welder wire available to clean roller
water spray nozzles and have extra water
spray nozzles available - Welder wire is an easy
and cheap way to clean clogged nozzles. Nozzles
should be checked periodically to avoid down time.
Install infrared sensors on rollers or equip
operator with infrared gun and set temperature
targets for each type of roller - Assures rolling
temperatures are correct. It keeps the operators
aware that they are working in the right
temperature zone.
Equip all rollers with high-intensity discharge
xenon lights for night work - Important safety
and quality issue.
Explore intelligent compaction for rollers – This
technology could help quality and productivity on
paving jobs.
Select rollers to match paver and planned
production rates - Roller selection is part of the
daily planning. The wrong type and number rollers
can mean the difference between high production
and quality, and wasted time.
Have a printed daily maintenance check list for
equipment operators and truck drivers – Avoids
downtime and holds them accountable for the
equipment they operate.
Have parts “uptime” kits for pavers and rollers
–Have high wear and repair parts in stock or on site
so they can be available at a moments’ notice.
Install pre-cleaners in front of air filters on
rollers and pavers – Improves fuel economy, and
improves engine and filter life.
Set start time for operations and meet it - Start
time for paving crews should mean when the first
truck dumps into the paver. There is a 20 to 30
minute lag (while the paver warms up and the crew
gets ready) between the “start time” and when the
pave starts moving.
Stagger start times for crews on long days to
avoid loss of momentum – Not all employees
need to start at same time. Different members of
plant and paving crew can start and quit at
different times.
Outline tools on tool racks in utility trucks so
they are kept in the same place all the time –
Saves time when people know where to get the tool
they need and when a tool is missing and needs to
be replaced.
Tape a list of tools contained in toolboxes and
periodically inventory – Saves time by knowing
that key tools are available.
Install ice machines for employees at each yard
to avoid stopping to buy ice – Crews stopping at
convenience stores wastes time.
Install common key locks on all equipment to
avoid waiting for lost keys –Time can be lost
looking for the correct key or waiting for someone to
show up with it.
Plan each day’s production and paving in
detail – Every days’ production needs to be planned
in every detail for maximum productivity.
Equip dump man, paver operator, and MTV
operator with radio headsets, especially at
night, for better communication. (one ear
phone, not voice activated) - These are an
inexpensive way to coordinate between the dump
man, MTV operator and paver operator and can
result in higher production and greater safety.
Avoid unusually long shifts for employees –
Tired employees are more likely to make mistakes
affecting quality and safety. Longer hours do not
mean more productivity.
Keep cooler of water and electrolyte drinks
with drinking cups on paver at all times – This
is a safety issue. Dehydration can reduce good
judgment and result in heat exhaustion or heat
Enhance safety at every opportunity – Improved safety
reduces insurance costs and improves
productivity. Examples: “X” on back of safety vests means
“I’m not facing you,” distinctive red headgear for new
employees to indicate they are new, backup cameras on all
trucks, reversible flashing arrows on front of tack truck to
indicate direction for oncoming traffic, orange flags on the
ends of distributor spray bars, flashing strobe lights on
pavers, rollers and other equipment.
 Provide an incentive plan for employees for safety,
quality and cleanliness – Safety and quality affect your
bottom line. Cleanliness can affect safety and presents a
better image to your customers.
Establish a training program for paving company
customers – Value the customers and it will improve the
quality of their work, reducing the number of bad jobs and
conflicts. Provide attendance incentives such as food and
giveaways. Keep them informed on future changes in
company and industry, and emphasize the importance of best
Cross train people in critical positions – If a critical
employee does not show up, another should be trained to take
their place.
Motivate employees to do the right things. Explain
how it benefits them – Use bonuses and commendations to
motivate employees. Point out how quality affects the
bottom line.
Have a regular training program for employees –
Training affects quality and reduces employee
turnover. Examples of training include: toolbox talks,
regular training sessions, on-line training, equipment
manufacturers’ schools, and using professional trainers.
 Provide “train the trainer” classes for
superintendents and foremen – This will make them
more effective in teaching others how to do their jobs.
Have an employee appreciation day at least
once a year – Shows your employees that you value
the work they do, improving morale and
Call on customers - Increases customer
satisfaction and helps maintain repeat customers.
Make sure job is done right the first time to
avoid expensive call backs – Never take shortcuts
or accept marginal material to get the job down. It
is much more expensive to remove and replace
materials than it is to do it right the first time.
Put paving crews in uniforms so they look and
act professional – This provides and better image
to your customers and the general public. It can
also instill pride in your workers.
Have a person responsible for site clean-up
throughout the day – This assures that the site is
kept clean since one person is responsible.
Provide accessible trash bags on pavers and other
equipment to keep job site neat – This portrays a better
image to your customers and the general public. It may
also prevent trash from ending up in the mat.