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Slipform Paver

Technology
Overview

Construction of
History Slipform Applications
concrete roads
`

Equipment Overview
product range
History of concrete

Introduction

• Concrete road surfaces are not a new invention. They were firstly built by the Romans in towns and
on country roads over 2000 years ago when using a concrete-like layer called "Opus caementitium".

• The first concrete road surface in Germany was paved in 1888 on the Blücher Square in the town of
Breslau.

• The first concrete road in USA was built in 1894.

• In India first concrete road with slipform method was built in 1992-93 in NH-2 Agra. However the
prestigious “Mumbai-Pune expressway” paved the way for concrete roads in India.
History of concrete

1894 – First concrete road in USA 1906 – Bunzlau / Niederschlesien

Slipform paver on rails


History of concrete - India

Mumbai – Pune Expressway

THE ROAD
TO
SLIPFORM
PAVING IN
INDIA
Concrete in general

Apart from asphalt, concrete is being increasingly used as a surface for motorways, airports,
parking lots, bicycle paths and agricultural roads because some characteristics of concrete are
superior to asphalt surfaces.

• Concrete surfaces are more resistant to high & low temperatures.

• Resistance to deformation even during excessive wheel tracking.

• Effective stress distribution, Extremely sturdy even under high axle loads.

• The brightness and tyre grip of concrete have a positive effect on traffic safety.

• Concrete surfaces, when paved correctly have a life-expectancy of approx. 35 years.


Construction of Concrete Roads

- admixtures - dowel & tie bars


- curing - mesh
- material interlock

PQC second layer


PQC
single layer PQC first layer plastic
geotextile
asphalt
DLC
Drainage
treatment
analysing SOIL compaction
Construction of Concrete Roads

Basic design of concrete road:


Longitudinal dummy joint Longitudinal compressed joint

Lateral dummy joint


with dowel-bar
Dowel-bar spacing:

0
A, C = 50 cm

0
5,
B = 25-30 cm A B C

00
4

5,
 2,5 % 12 %

3.5 3.5 1.5 Concrete thickness


30 cm
DLC = 15 cm

7.0 1.5 GSB = 29 - 49 cm

Two Paved
lanes shoulder

Road surface
Construction of Concrete Roads

Method of constructing concrete roads:


SLIPFORM Paving FIXED FORM Paving
Slipform Applications

Main Slipform application Groups:


OFFSET Paving INSET Paving ROAD Paving
Slipform Applications – Offset Paving

 Curb or Curb & Gutter


 Safety Barriers
 Cross Drains
 “U” Drains
 “V” Drains
 Retaining Walls
 Sidewalks
 Bicycle Paths
 Parking Lots
 Toll Plaza
 pavements
 Profiles as per Customers
Specification.
Slipform Applications – Offset Paving
Slipform Applications – Offset Paving
Slipform Applications - Inset Paving

Paving Set up:

• 2 Tracks

• 3 Tracks with or without swing legs

Paving Methods:
• 4 Tracks with or without swing legs

• Single layer

• Double layer
- Using 2 individual machines
- Using 1 special machine.
Slipform Applications - Inset Paving

Single layer paving


with 1 machine
Slipform Applications - Inset Paving

Double layer paving


with 1 machine
Slipform Applications - Inset Paving

Double layer paving


with 2 machines
Slipform Equipment
Slipform Equipment

Spreading of concrete:

1. Spreading plough

2. Spreading Auger
Slipform Equipment

Metering Gate:

1. Controls the concrete flow in to the


compaction chamber.
ing
t er
e
2. Hydraulically controlled M te
ga
Slipform Equipment

Compaction Chamber:

1. “Compaction” is the KEY function in


the slipform paving process.

2. Vibrators:
- Electrical
- Hydraulic
1. Various size & types depending on
the application.
Slipform Equipment

Operator’s Control Panel:

1. Provided with Digital display, indicates


all paving parameters.

2. PLC controlled system.


Slipform Equipment

Concrete Mould:

1. Determines the shape, size &


smoothness of the concrete surface.

2. The mould is fixed rigidly to the


machine chassis.
Slipform Equipment

Sensors:

1. PLC controlled Electronic sensors for


both Height adjustment & Steering.

2. To be used with reference to the


string line.

3. Option: Wireless system, with radio /


laser control.
Slipform Equipment

Dowel Bar Inserter:

1. Integrated dowel bar system ensures


correct positioning of dowels in the
concrete.

2. Insertion of dowel bar while machine


moving, increased productivity.

3. PLC controlled automatic system. The


cycle of insertion & return, vibration
by a push of ONE button.
27
USE OF MACHINE INTEGRATED DBI SYSTEM
Slipform Equipment

In core test, it was observed that the Dowel Bars placed by


Automatic DBI system remained perfectly parallel to each
other in all respect
Dowel Bar Basket

Manually prepared Dowel Bar Basket for Expansion Joint


USE OF BASKETS
Dowel Bar Basket

In the core test, it was observed that the manually laid


Dowel bars got disturbed due to the pressure of the
Slipform Equipment

Side Tie Bar Inserter:

1. Side Tie Bar Inserter required while


paving multiple lanes.

2. Semi - automatic operation, accurate


insertion of tie bar in to the concrete
slab.

3. Extreme fast & smooth operation,


does not damage the paved surface.
Slipform Equipment

Central Tie Bar Inserter (option):

1. Central Tie Bar Inserter required


while paving the entire slab in single
pass.

2. PLC controlled fully automatic


operation.
Slipform Equipment

Oscillating Beam:

1. Heavy duty oscillating beam restores


the concrete surface, disturbed by
the dowel bar insertion.

2. Oscillating movement over full width


of the concrete slab & achieves good
surface texture even with the dry
concrete.
Slipform Equipment

Super Smoother:

1. Aluminium alloy metal generally 3-4


metre long moves entire width of the
slab.

2. Final process of surface finishing of


the concrete slab.
Slipform Equipment

Surface Treatment:

1. Texturing of the concrete slab


- Transversal
- Longitudinal

2. Curing compound – protection


against surface drying out.
Product Range

Texture curing
SP 150 SP 250 SP 500 Vario SP 850 Vario SP 1500 Side feeder ISF machine TCM

SP 500 SP 850 SP 1200 SP 1500 L SP 1600


Product Range

SP 150 (3 crawlers)

Machine data: Concrete paving kit:


Output: 60 kW / 80HP Working width min-max: 1.000 – 1.500 mm
Engine speed: 2.500 min-1 max. paving thickness: 300 mm
Displacement: 3.100 cm³ max. working width offset mould:
Paving speed: 0.5-10 m/min 3 crawlers 1.500 mm
Travelling speed: 0-20 m/min max. working height offset mould:
3 crawlers: 1.000 mm
Profiles by SP150
Profiles by SP150
Profiles by SP150
Profiles by SP150
Profiles by SP150
Profiles by SP150
Profiles by SP150
Product Range

SP 250 (3 / 4 crawlers)

Machine data: Concrete paving kit:


Output: 79 kW / 107 HP Working width min-max: 1.000 – 3.500 mm
Engine speed: 2.300 min-1 max. paving thickness: 300 mm
Displacement: 3.900 cm³ max. working width offset mould:
Paving speed: 0-7 m/min 3 crawlers / 4 crawlers: 1.800 mm / 2.500 mm
Travelling speed: 0-20 m/min max. working height offset mould:
3 crawlers / 4 crawlers: 1.300 mm / 1.800 mm

47
47
Profiles by SP250
Profiles by SP250
Profiles by SP250
Profiles by SP250
Profiles by SP250
Slipform Special Applications
Slipform Special Applications
Product Range

SP 500 (3 / 4 crawlers)

Machine data: Concrete paving kit:


Output: 131 kW / 176 HP Working width min: 2.000 mm
Engine speed: 2.100 min-1 Working width max (3 crawlers): 4.250 mm
Displacement: 6.057 cm³ Working width max (4 crawlers): 6.000 mm
Paving speed: 0-5 m/min max. paving thickness: 400 mm
Travelling speed: 0-17 m/min 3.000 mm
max. working width offset mould: 1.900 mm
max. working height offset mould : 16 / 18
max. number of vibrators: hydr./elec. 3%
max crowning angle:
55
55
Slipform Applications – City Roads
Slipform Applications – City Roads
Slipform Applications – Rural Roads
Slipform Special Applications

Airport

Train Track

Canal Bed
Reinforcement (continuous)

60
Reinforcement (continuous)

61
Slipform Special Applications
Slipform Special Applications
Slipform Special Applications
Product Range

SP 500 Vario

Machine data: Concrete paving kit:


Output: 131 kW / 176 PS Working width min: 2.000 mm
Engine speed: 2.100 min-1 Working width max: 6.000 mm
Displacement: 6.057 cm³ max. paving thickness: 400 mm
Paving speed: 0-5 m/min 16 / 18
Travel speed: 0-17 m/min max. number of vibrators: hydr./elec.

65
65
Product Range

SP 850

Machine data: Concrete paving kit:


Output: 224 kW / 305 HP Working width min: 2.500 mm
Engine speed: 2.100 min-1 Working width max: 9.000 mm
Displacement: 8.300 cm³ max. paving thickness: 450 mm
Paving speed: 0-6 m/min 24
Travelling speed: 0-23.5 m/min max. number of vibrators: 3%
max crowning angle:

66
66
Product Range

SP 1200

Machine data: 224 kW / 305 HP Concrete paving kit:


Output: Working width min: 3.500 mm
2.100 min-1 Working width max: 12.000 mm
Engine speed:
Displacement: 8.300 cm³ max. paving thickness: 450 mm
0-6 m/min
Paving speed: 36
0-29 m/min max. number of vibrators: 3%
Travelling speed:
max crowning angle:

68
68
SP 1200
Product Range

SP 1500 / SP 1500 L

Machine data: Concrete paving kit:


Output: 272 kW / 370 PS Working width min: 5.000 mm
Engine speed: 2.100 min-1 Working width max: 15.250 mm
Displacement: 10.300 cm³ max. paving thickness: 450 mm
Paving speed: 0-5 m/min 48
Travelling speed: 0-19 m/min max. number of vibrators: 2,5 %
max crowning angle:

70
70
Product Range

SP 1600

Machine data: Concrete paving kit:


Output: 317 kW / 425 PS Working width min: 5.000 mm
Engine speed: 2.100 min-1 Working width max: 16.000 mm
Displacement: 12.000 cm³ max. paving thickness: 450 mm
Paving speed: 0-5 m/min 48
Travelling speed: 0-20 m/min max. number of vibrators: 3%
max crowning angle:

73
73
Questionnaire for compiling an offer

WIRTGEN Slipform Paver

Questionnaire for compiling an offer

A) Should concrete surfaces be paved (PCC surfaces*) ?

B) Should concrete profiles be paved ?

C) General questions concerning project supervision

* PCC = Portland cement surface


Questionnaire for compiling an offer

A. Paving concrete surfaces

A1. Width of concrete surface ____ m


Thickness of concrete surface ____ cm
Length of concrete surface ____ m
Crown profile YES NO

A2. Are other paving widths required for later construction work ?
If yes:
______ m

A3. Maximum width of available lanes (or CTB**) for crawler units
next to concrete surface (e.g. on HGT):
Left side : _____ cm Right side : _____ cm
** CTB = cement
treated base
A4. Is the surface to be produced by
single layer paving YES
double layer paving YES
Questionnaire for compiling an offer

A. Paving concrete surfaces

A5. Are dowel-bars required in the lateral joints ?


YES NO
If yes :
Tie-bar dimensions : ___________ Diameter: _____ mm Length: _____ mm
Spacing between tie-bars (provide drawing if spacing irregular) : _____ mm
Is tie-bar inserter for automatic vibration of tie-bars into fresh concrete required ?

A6. Are tie-bars required in the longitudinal joints ? YES NO


If yes :
Tie-bar dimensions : __________ Diameter: _____ mm Length: _____ mm
Distance between lateral joint and first tie-bar : ______ mm
Distance between the tie-bars : _____ mm

A7. Are reinforcement mats required in addition to dowel-bars in lateral joints ?


YES If yes :
Dimension of mats : _____m x _____ m
Weight of mats per m²: _____ kg/m²
Questionnaire for compiling an offer

A. Paving concrete surfaces

A8. Is continuous reinforcement required ? YES NO


If yes :
Weight of mats per m²: _____ kg/m²

A9. Is a side feeder unit required ? YES NO


If yes :
Is side feeding carried out by tipper trucks YES NO
or is side feeding carried out by mixer trucks YES NO

A10. Paving performance :


Required paving performance : _____ m³/hour or _____ m2/hour
Concrete mixer for project :
Make / Type : ______________________/_______________________
Rated output : _____m³/hour
Mixing method : Plate mixer Force-feed mixer Free-fall mixer
Questionnaire for compiling an offer

B. Paving concrete profiles

B1. Profile data for paving moulds (offset or inset) or


channel mould between crawler tracks:
________________________________________
(Please supply profile sketches with dimensions)

B2. Where will the crawler units run during paving ?


_________________________________________
(Please supply cross-section drawing showing paving position when necessary)
Questionnaire for compiling an offer

C. General questions for project monitoring

C1. Is an offer required for general information only ?


YES

C2. Is an offer required for a defined project for which bidding invitation has already
been published ? YES
If yes:
Which project : _____________________________
Publication date of bidding invitation : ____________________
Planned starting date of machine on site : ______________________

C3. Is the offer required for a project for which the customer has already
received an order ? YES
Date of order issue was : ______________
Date for delivery ex works : _________________
WIRTGEN POPULATION
SP TRAIN

MODEL QTY SHARE

SP 150 9 14.5%

SP 250 3 4.8%

SP 500 21 32.3%

SP 850 13 21%

SP 1200 7 11.3%

SP 1500 1 1.6%

SP 1600 9 14.5%

TOTAL 63
And many more to come …..
OVERALL POPULATION
SP TRAIN - INDIA

MANUFACTURER NOS MARKET


SHARE
G&Z 6 6.45%

GOMACO 6 6.45%

POWER PAVER / 18 19.35%


POWER CURBER

CMI 1 1.07%

WIRTGEN 63 66.66%

TOTAL 94
SLIPFORM 2010 – YTD JUL

MANUFACTURER NOS MARKET


SHARE
G&Z 0 0%

GOMACO 0 0%

POWER CURBER 0 0%

WIRTGEN 6 100%

TOTAL 6
THANK YOU
For your attention