Milling the Mall

A high-profile job

One of the first tasks of a start-up road contractor with new Wirtgen W 207 Fi cold mill, Vögele SUPER 2000-3i paver with VF 600 screed, and asphalt compactors from Hamm was to resurface streets along Washington, D.C.'s historic National Mall.

At work on 17th St. on National Mall

In summer 2021, working night shifts, Highway and Safety Services Inc. cold-milled 17th Street and Independence Avenues, repaired failed concrete joints on 17th St., and then placed two lifts of hot mix asphalt, all in the shadow of the Washington Monument, Lincoln Memorial, the World War II Memorial, and other sites.

The pavement was milled between Independence Ave. on the south and Constitution Ave. on the north. This was accomplished with H&SS's new Wirtgen W 207 Fi, a high-performance cold milling machine with standard 7 ft. 3 in. drum, and maximum milling depth of 13 in.

"The first phase was to mill 17th Street from 4 to 6 in. down to the concrete sub-base, and expose the needed concrete repairs."

Bradley Gardner, director of paving operations, Highway and Safety Services, Inc., Gaithersburg, Md

Work shifts were limited in time

On the first section, on 17th St., 3,800 tons of reclaimed asphalt pavement (RAP) were removed. Failed PCC joints were jackhammered and sawn, and repaired with new dowels and wire mesh. All work – milling, paving and compaction – had to be done between 8 p.m. and 4 a.m., so the work shifts were limited in time.

"We repaired the concrete and put a wedge-and-level base course on top of the concrete," Gardner says. "We are proceeding with intermediate and surface courses containing PG 76E 9.5mm mix, which is an FHWA high-polymer content mix spec, a total 4 in. of material in two 2-in. lifts."

Level Pro

W 207 Fi Level Pro leveling system provides superior cut smoothness.

Illumination

Operator's platform illumination ideal for night work.

W 207 Fi

Across from U.S. World War II Memorial W 207 Fi is refilled with water.

A 10-ft. Vögele SUPER 2000-3i paver with VF 600 screed was being used for the paving, followed by a Hamm HD+ 120 VV HF in breakdown position and an HD+ 90 VV HF for secondary and finish compaction. A smaller Hamm HD 14 VV roller was used for close work around manholes, storm sewer inlets and other appurtenances. H&SS's Hamm compactors were attaining 95 to 96 percent density.

"The Vögele VF 600 front-mount screed is a both a flexible and rigid screed."

Terry Cays, district sales manager for Wirtgen America

"The Vögele VF 600 front-mount screed is a both a flexible and rigid screed," says Terry Cays, district sales manager for Wirtgen America. "It has the flexibility to move in a parking lot for crowns and inverts and make quick adjustments, moving in and out quickly for getting around obstructions. But it has rigidity between the extensions and the main screed. So when the extension goes out, it stays true to the main. While being superior for those applications, they absolutely also can pave mainline highways and roads."

New 10-ft. Vögele SUPER 2000-3i paver with VF 600 screed of HSS places first course on 17th St. adjacent to World War II Memorial.

While the failed concrete joints and their reflecting through to 17th St.'s driving surface required removal of the entire asphalt pavement there, Phase II was to involve milling 2 in. of Independence Avenue, about 3,000 tons of RAP, and paving back with 2 in. of the polymer-modified mix.

Concrete base repairs were unnecessary. The contract from FHWA's Federal Lands Division involves placement of a total of 6,500 to 6,800 tons of polymer-modified HMA.

Hamm HD+ 120 VV HF

Hamm HD+ 120 VV HF compacts 17 St. lift to over 95 percent density

W 50 Ri cold mill

Smaller W 50 Ri cold mill ideal for trimming around manholes and other tight work.

"Highway and Safety Services began in 1987 with the intent of serving the needs of larger general contractors," says Kyle McPherson, division president and part-owner, Highway and Safety Services Inc., Gaithersburg, Md.

McPherson joined seven years ago after the business was sold. In 2019 the start-up paving division was launched. The experience of Gardner and McPherson with Wirtgen Group products led to their choice of Wirtgen cold mill, Hamm compactors, and Vögele paver for the greenfield launch of H&SS's paving division.

In establishing its fleet of paving equipment, the two work closely with Wirtgen distributor Elliott & Franz, Inc., Jessup, Md., its president Bob Schaeffer, and territory manager Terry Jacobs. "They've been a great asset to me and Kyle in getting started, providing a great support system along with Wirtgen personnel," Gardner says.

"The technology of Hamm, Vögele and Wirtgen America is so advanced ahead of every other manufacturer, that they're eight to 10 years ahead of the game," Gardner says. "I was amazed at the power and the technology built into the W 207 Fi, including the safety features.

"The technology of Hamm, Vögele and Wirtgen America is so advanced ahead of every other manufacturer, that they're eight to 10 years ahead of the game."

Bradley Gardner, director of paving operations, Highway and Safety Services, Inc., Gaithersburg, Md

"The Vögele 2000-3i integrates all controls into a single box for the screed operator, one on each side of the paver, and they replicate what's at the operator's station above," he adds. "It's a very smooth machine to run, very user-friendly. We still are learning all the computer screens available to us but this winter we will send our guys to the Wirtgen Center for Training and Technology at the Nashville headquarters to learn more."

"As Vögele has grown we've listened to customers, and we've made changes that the customers wanted," Cays says. "On the previous screen console, we had a lot of screens that you had to navigate. With the Dash 3 series, we made this easier, with pop-up menus. When I press AUGER, the screen pops up to the auger page. And if I press the CROWN button, the crown pops up on the page. All the screens are still there, but Vögele's made it easier for the operator to get to them."

Likewise, the Hamm compactors enhance H&SS's productivity. "The Hamm rollers are very user-friendly and I get really good compaction out of them," Gardner says. "I'll get a 94, 95 percent density with three passes, where with another roller it'll take me four or five passes. I'm saving a lot of time and money and fuel. They definitely increase my productivity."

Waiting for dusk and the National Mall job to begin are Frank Barosio, milling application specialist for Wirtgen America; Terry Jacobs, territory manager for Elliott & Franz; Bradley Gardner, director of paving operations, Highway and Safety Services, Inc.; and Terry Cays, district sales manager, Wirtgen America.