‘Dash 5’ pavers from Vögele

Challenging noise remediation

SUPER 1900-5i lays noise-reducing surface course

Flowing traffic, strict noise control regulations: A Highway Class ‘Dash 5’ generation paver has renewed the section of the A6 motorway between Wankdorf and Muri. A working group from Frutiger AG and Marti AG laid a total of 6 km of 20 m wide noise-reducing surface course in a number of sections.

Traffic easing and noise control

Traffic jams are an everyday occurrence on the A6 near Bern. The hard shoulder was repurposed in a scheme known as a PUN in order to improve the flow of traffic and reduce noise and environmental pollution in this heavily populated area. This means that, at peak times, vehicles can also use the hard shoulders as live lanes. The aim is to create additional capacity and, at the same time, improve noise control. The working group assigned implemented a number of measures, including extending the noise barriers, renovating bridges and renewing the breakdown lanes. Another part of the project was the paving of a noise-reducing asphalt surface course on all traffic lanes of the 6 km section of road.

Paving in difficult conditions

In order to reduce inconvenience to residents and motorway users during the construction period, the work needed to be kept as low-noise as possible, with noise-reduced machines working within short time windows. Traffic in both directions also needed to be maintained.

Compared to the ‘Dash 3’ generation, Vögele has added additional noise control measures and optimised the EcoPlus low-emissions package such that the SUPER 1900-5i is now substantially quieter. The next-generation screed plate also generates significantly less noise.

SUPER 1900-5i: Especially quiet and efficient

In order to implement the measures as efficiently as possible and meet the noise control requirements, Frutiger AG opted to use a next-generation Vögele paver: the SUPER 1900-5i from the Highway Class range in conjunction with the AB 500 TV extending screed. Despite its high-performance 6-cylinder engine offering 163 kW of power at 1,700 rpm, even in ECO mode, the paver is low-consumption and especially quiet when running: Compared to the ‘Dash 3’ generation, Vögele has added additional noise control measures and optimised the EcoPlus low-emissions package such that ‘Dash 5’ machines are now substantially quieter. The next-generation screed plate also generates significantly less noise. In addition, the enhanced ErgoPlus 5 operating system of the SUPER 1900-5i means it includes all sorts of assistants and automatic functions, plus new user-friendly features and optimised management, thus meeting all the requirements for efficient, quality paving.

“Because of the strict noise control regulations and quality requirements, it was important to us that paving was efficient with as few stoppages as possible. In this context, we were blown away by the easy adjustment of the pave speed, the large material hopper with a capacity of 14 t and the material management of the SUPER 1900-5i.

Matthias Baumann, Road Construction Manager at Frutiger AG

Material management for uninterrupted paving

The Highway Class paver laid the 3 cm surface course in multiple sections, each with a width of 3.2 m. “Because of the strict quality requirements, it was important to us that paving was efficient with as few stoppages as possible,” explains Matthias Baumann, Road Construction Manager at Frutiger AG. “In this context, we were blown away by the easy adjustment of the pave speed, the large material hopper with a capacity of 14 t and the material management of the SUPER 1900-5i.” Vögele has reworked the controller for the material transport compared to the ‘Dash 3’ generation. The auger and conveyors now communicate with one another, ensuring that material feed is even more consistent and precisely coordinated. This avoids load peaks, saves fuel, enables an optimum head of mix, and so uninterrupted paving.

Efficient paving

The large material hopper and the reworked material management system ensured optimum head of mix and largely uninterrupted paving.

No assembly required

With the Light Package Plus, the LED lights are integrated into the canopy of the paver. This means no additional lights or light balloons needed to be transported and fitted.

Further developed ErgoPlus 5 operating system

Compared to the ‘Dash 3’ version, the paver operator’s console offers, among other things, improved visibility, greater comfort, better ergonomics and an optional touch-screen display.

Front view of a paver with a large material hopper

Hydraulic tamper stroke setting guarantees quality and efficiency

The new AB 500 TV extending screed also ensures excellent quality and efficiency: There are high-performance heating rods enabling even faster operational readiness than its predecessor. The hydraulic tamper stroke adjustment is also a real time-saver and very handy: “Instead of adjusting the cam by hand each time, we can simply set the optimum tamper stroke of 2 mm at the touch of a button using the Dual Power Shift function and thus achieve optimum compaction,” explains paver driver Steffen Horn.

Smart operation speeds up paving

From the crew’s point of view, the more developed ErgoPlus 5 operating system was also a plus point: “There is a logical structure to the consoles and it’s a really good solution, with no glare from the displays, these are all advantages that make paving a lot easier,” reports Horn. Compared to the ‘Dash 3’ version, the paver operator’s console offers improved visibility, greater comfort, better ergonomics and an optional touch-screen display. Vögele has made using some of the functions easier, improved the design, reduced the height to increase legroom and even incorporated drinks holders and additional storage, e.g. for mobile phones. “As we worked in several sections, the AutoSet Plus memory function was also very helpful,” explains Horn. This means you can save paving programs and recall them for the next section at the touch of a button. Process automation not only prevents paving errors, it considerably increases efficiency.

Portrait of a paver driver, including operator console

“There is a logical structure to the consoles and it’s a really good solution, with no glare from the displays, these are all advantages that make paving a lot easier,” reports Steffen Horn, paver driver.

Drinks holders

More user-friendly: Vögele has included drinks holders and other storage options in the ‘Dash 5’ pavers.

Asphalt paving with lighting under a bridge

Optimum lighting under bridges The paving team used the new Light Package Plus for the ‘Dash 5’ generation. The integrated lighting ensured optimum visibility for paving.

Integrated lighting ensured optimum visibility

As the paving team also used the paver under bridges, in tunnels and overnight, the team used the new Light Package Plus for the SUPER 1900-5i: The LED lights are integrated into the roof structure and provide optimum lighting of the paver and screed area across the entire pave width. This means no additional lights or light balloons need to be transported and fitted. “This kind of lighting at the touch of a button makes working much safer and more efficient, especially for a project like this one,” reports Baumann. “We could easily use the lighting where required, for example, when the visibility was poor under bridges or in tunnels.”

Successful construction project

The technical developments and new features of the Vögele paver made a significant contribution to the success of the A6 project: The quiet yet high-performance drive, the optimised material management, the assistants and automatic functions and the new lighting system significantly increased noise control, efficiency and safety on the construction site.

New ‘Dash 5’ generation

The ‘Dash 5’ generation road pavers set new standards in terms of user-friendliness, automation, economics and sustainability. You can find out the specific features and technical innovations behind these four focus areas on the Vögele website.

All about the ‘Dash 5’ generation