3. 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
4. 1894 – First concrete road in USA 1906 – Bunzlau / Niederschlesien
Slipform paver on rails
History of concrete
6. 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.
• Concrete surfaces, when paved correctly have a life-expectancy of approx. 35 years.
• The brightness and tyre grip of concrete have a positive effect on traffic safety.
Concrete in general
• Effective stress distribution, Extremely sturdy even under high axle loads.
• Resistance to deformation even during excessive wheel tracking.
7. Construction of Concrete Roads
SOIL
analysing
treatment
compaction
DLC
PQC
single layer
PQC second layer
PQC first layer plastic
geotextile
asphalt
Drainage
- admixtures
- curing
- dowel & tie bars
- mesh
- material interlock
8. Concrete thickness
30 cm
Lateral dummy joint
with dowel-bar
Dowel-bar spacing:
A, C = 50 cm
B = 25-30 cm A B C
DLC = 15 cm
4
Two
lanes
Paved
shoulder
3.5
3.5 1.5
7.0 1.5
Road surface
GSB = 29 - 49 cm
2,5 %
Longitudinal dummy joint Longitudinal compressed joint
Basic design of concrete road:
Construction of Concrete Roads
9. Construction of Concrete Roads
Method of constructing concrete roads:
SLIPFORM Paving FIXED FORM Paving
14. Slipform Applications - Inset Paving
Paving Set up:
• 2 Tracks
• 3 Tracks with or without swing legs
• 4 Tracks with or without swing legs
Paving Methods:
• Single layer
• Double layer
- Using 2 individual machines
- Using 1 special machine.
22. 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.
24. Slipform Equipment
Concrete Mould:
1. Determines the shape, size &
smoothness of the concrete surface.
2. The mould is fixed rigidly to the
machine chassis.
25. 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.
26. 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.
29. In core test, it was observed that the Dowel Bars placed by
Automatic DBI system remained perfectly parallel to each
other in all respect
Slipform Equipment
32. In the core test, it was observed that the manually laid Dowel
bars got disturbed due to the pressure of the concrete
Dowel Bar Basket
33. 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.
34. 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.
35. 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.
36. 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.
37. Slipform Equipment
Surface Treatment:
1. Texturing of the concrete slab
- Transversal
- Longitudinal
2. Curing compound – protection
against surface drying out.
38. SP 150 SP 250 SP 500 Vario SP 850 Vario SP 1500 Side feeder ISF
Texture curing
machine TCM
SP 500 SP 850 SP 1200 SP 1500 L SP 1600
Product Range
39. SP 150 (3 crawlers)
Output:
Engine speed:
Displacement:
Paving speed:
Travelling speed:
60 kW / 80HP
2.500 min-1
3.100 cm³
0.5-10 m/min
0-20 m/min
Machine data:
1.000 – 1.500 mm
300 mm
1.500 mm
1.000 mm
Concrete paving kit:
Working width min-max:
max. paving thickness:
max. working width offset mould:
3 crawlers
max. working height offset mould:
3 crawlers:
Product Range
55. 55
SP 500 (3 / 4 crawlers)
Output:
Engine speed:
Displacement:
Paving speed:
Travelling speed:
131 kW / 176 HP
2.100 min-1
6.057 cm³
0-5 m/min
0-17 m/min
Machine data:
2.000 mm
4.250 mm
6.000 mm
400 mm
3.000 mm
1.900 mm
16 / 18
3 %
Concrete paving kit:
Working width min:
Working width max (3 crawlers):
Working width max (4 crawlers):
max. paving thickness:
max. working width offset mould:
max. working height offset mould :
max. number of vibrators: hydr./elec.
max crowning angle:
55
Product Range
70. 70
SP 1500 / SP 1500 L
Output:
Engine speed:
Displacement:
Paving speed:
Travelling speed:
272 kW / 370 PS
2.100 min-1
10.300 cm³
0-5 m/min
0-19 m/min
Machine data:
5.000 mm
15.250 mm
450 mm
48
2,5 %
Concrete paving kit:
Working width min:
Working width max:
max. paving thickness:
max. number of vibrators:
max crowning angle:
70
Product Range
71.
72.
73. 73
SP 1600
Output:
Engine speed:
Displacement:
Paving speed:
Travelling speed:
317 kW / 425 PS
2.100 min-1
12.000 cm³
0-5 m/min
0-20 m/min
Machine data:
5.000 mm
16.000 mm
450 mm
48
3 %
Concrete paving kit:
Working width min:
Working width max:
max. paving thickness:
max. number of vibrators:
max crowning angle:
73
Product Range
74.
75. Questionnaire for compiling an offer
WIRTGEN Slipform Paver
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
76. A1. Width of concrete surface ____ m
Thickness of concrete surface ____ cm
Length of concrete surface ____ m
Crown profile YES
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
A4. Is the surface to be produced by
single layer paving YES
double layer paving YES
** CTB = cement
treated base
A. Paving concrete surfaces
Questionnaire for compiling an offer
NO
77. A5. Are dowel-bars required in the lateral joints ?
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 ?
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
A. Paving concrete surfaces
Questionnaire for compiling an offer
NO
YES
NO
YES
78. A8. Is continuous reinforcement required ?
If yes :
Weight of mats per m²: _____ kg/m²
A. Paving concrete surfaces
A9. Is a side feeder unit required ? YES
If yes :
Is side feeding carried out by tipper trucks YES
or is side feeding carried out by mixer trucks YES
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
NO
NO
NO
NO
YES
79. B1. Profile data for paving moulds (offset or inset) or
channel mould between crawler tracks:
________________________________________
(Please supply profile sketches with dimensions)
B. Paving concrete profiles
B2. Where will the crawler units run during paving ?
_________________________________________
(Please supply cross-section drawing showing paving position when necessary)
Questionnaire for compiling an offer
80. C1. Is an offer required for general information only ?
YES
C. General questions for project monitoring
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 : _________________
Questionnaire for compiling an offer
81. 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 …..
82. MANUFACTURER NOS MARKET
SHARE
G&Z 6 6.45%
GOMACO 6 6.45%
POWER PAVER /
POWER CURBER
18 19.35%
CMI 1 1.07%
WIRTGEN 63 66.66%
TOTAL 94
OVERALL POPULATION
SP TRAIN - INDIA
83. SLIPFORM 2010 – YTD JUL
MANUFACTURER NOS MARKET
SHARE
G&Z 0 0%
GOMACO 0 0%
POWER CURBER 0 0%
WIRTGEN 6 100%
TOTAL 6
