Resurfacing a motorway in Brazil

Bird’s-eye view of a two-lane motorway surrounded by fields of sugar cane. The SUPER 2100-5 X resurfacing one carriageway with workers standing next to it.

October 2026 | Time to read: 7 min

New large paver in action to repair rain damage

The SUPER 2100-5 X proves its worth on the Anhanguera motorway

Unusually heavy and persistent rainfall has had a severe impact on the Anhanguera motorway in the Brazilian state of São Paulo. One of the biggest construction companies in Brazil was awarded the contract for resurfacing it – and used the SUPER 2100-5 X “Dash 5” paver from Vögele for the first time.

The Anhanguera motorway is a major traffic artery in the state of São Paulo. Almost 500 km long, it connects the rural and industrial North East with key sales markets on the coast and in the city of São Paulo. Commuter traffic is correspondingly dense, with heavy goods vehicles especially prevalent.

Following heavy rainfall, construction company Val Rocha Engenharia was commissioned to resurface several sections of the motorway near São Simão. The project was for the company to mill a depth of 10 cm off the carriageway to a width of up to 3.6 m and build it back up with new binder and surface courses in order to restore evenness, driving comfort and traffic safety.

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Première for the SUPER 2100-5 X

Val Rocha Engenharia has been working in heavy infrastructure projects for over 20 years and specialises in demanding, complex road-building and civil engineering projects. Its machine park includes several Vögele pavers and other Wirtgen Group machinery. The company furthermore has two Ciber asphalt mixing plants of its own to secure high-quality material and short routes to its job sites.

For this particular motorway resurfacing project, the company used one of its two new large SUPER 2100-5 X pavers combined with the AB 600 TV extending screed. The paver is particularly suitable for the projects in which Val Rocha is primarily involved, because as a Highway Class paver, the SUPER 2100-5 X is designed, among other things, for paving motorways and for other demanding large-scale projects. Featuring an engine output of 187 kW, it achieves a maximum pave width of 14 m and a laydown rate of up to 1,100 t/h. “The ErgoPlus 5 operating concept makes it really simple and intuitive to operate, despite its size”, says Otair Castro de Melo, paver operator at Val Rocha Engenharia. “The application experts at Vögele trained us and showed us the new functions. The rest was more or less self-explanatory.” The new automation solutions and Comfort functions of the “Dash 5” generation give users extra support.

Rapid commissioning at the touch of a button

The sections of the heavily-used Anhanguera, totalling 1.6 km in length, had to be resurfaced within a short time. The main challenge was to pave each short section as quickly as possible, but to a high standard - so the paving crew exploited one benefit of the “Dash 5” generation right from the start: rapid, simple commissioning using Paver Access Control (PAC). The control unit located on the screed enabled operators to activate all the initial steps from ground level at the touch of a button.

Paver Access Control (PAC) allows the paver to be commissioned and shut down at the touch of a button – conveniently from ground level using the screed control unit.

Operators can control all the initial commissioning steps from the control unit on the screed.

The many sections requiring paving with identical requirements made the Pave Assist Plus function particularly helpful. It simplifies paver repositioning, as well as saving and calling up paving programs.

Ready for operation straight away: the screed control units of the ErgoPlus 5 operating concept can be connected with the system up and running - Quick Connect means no cable is required.

Clearly arranged ErgoPlus 5 paver operator’s console with touch display and practical storage facilities

Worker stands behind the SUPER 2100-5 X and operates Paver Access Control (PAC) from the screed control unit.
Screed control unit
Oblique view from the rear of the SUPER 2100-5 X paver with a truck in front of it.
Worker operating the screed control unit on the operator’s platform.
View of the ErgoPlus 5 paver operator’s console from above.
Picture of André Machado, engineer at Val Rocha Engenharia

“Our clients generally have very strict requirements, which is why we rely on the latest engineering technology - like the Vögele SUPER 2100-5 X paver here in São Simão”.

André Machado, engineer at Val Rocha Engenharia

Rapid repositioning between sections

So as not to waste any time when switching between paving sections, the team also used the Pave Assist Plus function. Vögele developed this assistance system for situations just like Anhanguera, as well as for others. It simplifies repositioning between sections: the paving team set the paver to Travel mode at the touch of a button. This automatically raises the augers, hydraulic hopper front flap and the deflectors in front of the crawler tracks to their top positions. The screed and tow point rams are also set to Travel mode. At the start of the next section, the paving team then activated Pave mode and thus automatically returned all the components to their original operating positions. As the requirements were identical from section to section, the team also saved all the relevant paving settings - such as pave width, paving thickness and laydown rate, type of course, type of material and tamper stroke - and called them back up just as simply for subsequent sections using the Execute button. This facilitated consistent quality and maximum efficiency across all sections.

New extending screed reduces setup time and noise

The new-generation extending screed, the AB 600 TV with tamper and vibrators as compacting systems, ensured a high degree of precompaction and surface quality. Hydraulic tamper stroke setting allowed operators to select the right tamper stroke quite simply at the touch of a button. Compared to mechanical adjustment, this saves time and is very practical, especially when layer thickness varies. At the same time, the screed operates more quietly than its predecessor, noticeably improving working conditions. Additional elements of the paver’s Comfort package - including the ergonomic seat and the sound insulation in the hardtop - help the operator, in particular, maintain concentration throughout a long shift. With great success: as the team was able to start work on this section before daybreak, it was possible to complete it on time.

“Dash 5” logo

The key features of the “Dash 5” generation:

  • Convenience Package: rapid, straightforward commissioning and shutdown using Paver Access Control (PAC) as well as sound-insulated sunshades, luggage nets in the hardtop, ergonomic heated seat and drinks holder
  • Integrated Light Package and Light Package Plus for optimum illumination with no assembly required
  • ErgoPlus 5 operating concept with improved overview, practical storage facilities and optional touch display
  • Assistance systems:Grade Assist controls the paving profile, whilst Pave Assist Plus automates paver repositioning as well as saving paving programs and calling them back up
  • The AutoTrac and Smart Pave automation solutions control the direction and width of the paver
  • Digital job site documentation with WPT Paving
  • Organised Logistic Plus boxes for storing auger and screed components

Discover the wide range of benefits of the “Dash 5” generation:

Find out more

Otair Castro de Melo, paver operator at Val Rocha Engenharia, is delighted with the simple, intuitive operation of the new SUPER 2100-5 X.

The team from Val Rocha Engenharia achieves a high degree of precompaction and surface quality with the new-generation extending screed, the AB 600 TV.

Service Team support: The application experts from Vögele train operators on site and demonstrate the new functions of the “Dash 5” generation.

Picture of Otair Castro de Melo, paver operator at Val Rocha Engenharia, standing in front of the SUPER 2100-5 X.
Oblique view from below right of the paver and extending screed, with the paver operator controlling precompaction.
Service staff explaining the paver operator’s console to two workers.
Facts and figures:
Location:
Country:
Brazil
State:
São Paulo
Motorway:
Anhanguera, SP030
Paving data:
Total distance paved:
1.6 km
Pave width:
3.6 m
Total pave thickness:
10 cm
Motorway with traffic, SUPER 2100-5 X working in the foreground.