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Wedge Joint Maker Manual

1.0 Purpose and Use of the TransTech Wedge Joint Maker The Wedge Joint Maker is used as a paver attachment tool to help construct higher density, longer lasting longitudinal joints between asphalt mats. Through several simple adjustments, the Wedge Joint Maker can help a paving crew construct various shapes of vertical and tapered mat edges. It is designed primarily to construct a precompacted, tapered mat edge with an adjustable vertical “notch” or “step”, creating a tapered edge commonly known as the “Michigan wedge joint”. The Wedge Joint Maker is typically used in a matched pair, one for the right side of the paver and one for the left side of the paver. When closing a longitudinal joint over a tapered edge, the Wedge Joint Maker is adjusted in such a way as to precompact asphalt on the closing side of the longitudinal joint in order to maximize density and quality of the resulting joint. The following instructions explain the basic installation and adjustments needed to use the Wedge Joint Maker to construct a precompacted "Michigan wedge joint”.

1.1 Caution:

HEAVY ! To Avoid Injury, Use Care When Lifting and Installing. 1

2.0 Explanation of Key Parts Joint Maker Section- precompacts the last four inches of the top of the asphalt mat. This gives higher density to the asphalt so that the edge maintains its shape and quality. Notch Section- precompacts and shapes the “notch”, the vertical drop off of the top of the asphalt mat, which is critical to the construction of a Michigan wedge joint. The depth of this notch is adjustable. Wedge Section- precompacts and shapes the wedge, or tapered section, of the mat edge. Also controls the vertical drop at the outer edge of the tapered section. The Wedge Section width is approximately 12”.

Joint Maker Section

Wedge Section Notch Section

Joint Maker Section Height Indicator- indicates the height of the Joint Maker Section above the bottom of the screed plate. Notch Section Depth Indicator- indicates the depth of the Notch Section below the bottom of the Joint Maker Section. Joint Maker Section Height Indicator

Notch Section Depth Indicator

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Joint Maker Height Adjustment Rod- controls the height of the Joint Maker Section at or above the bottom of the screed plate. Notch Depth Adjustment Rod- controls the depth of the notch section. Wedge Angle Adjustment Rod- controls the angle of the wedge, or taper section as well as the height of the vertical drop at the outer edge of the tapered section. Height Adjustment Rod

Wedge Angle Adjustment

Notch Depth Adjustment Note: All three adjustment rods are designed to move the particular section in the upward direction when the rod is turned Clockwise and in the downward direction when the rod is turned Counterclockwise. 3.0 Flexible Seals Flexible Seals- there are two flexible seals on the Wedge Joint Maker. The first is in a “Flap” shape and is positioned behind the Wedge Section. Its purpose is to prevent any asphalt material that might fall inside the Wedge Joint Maker to leak out the back of the device onto the finished tapered area. The second flexible seal is in a “Loop” shape and is attached at the outer edge of the Wedge Section. Its purpose is to prevent material leakage between the outer edge of the Wedge Section and the end gate during paving.

Flap Seal

Loop Seal

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4.0 Instructions for Installation of the Wedge Joint Maker

4.1 Tools Required Installation requires mounting holes to be installed on the screed extensions. Tools: Drill, Drill Bits, Tap, Socket Set, and in some installations it may be necessary to have a cutting torch and welding capability. Mounting hardware has been included. 4.2 Preparation of Mounting Holes The Wedge Joint Maker can be installed on the hydraulic screed extension and/or on one foot and two foot wide bolt-on screed extensions. Four mounting holes are needed for the Wedge Joint Maker. There are two mounting areas on the Wedge Joint Maker the first is the "Center Mount Location" and the second is the "Side Mount Location." •

Center Mount Location is located at approximately the center of the Wedge Joint Maker and has a pre-drilled mounting hole in the top mounting bracket and a vertical slot in the bottom mounting bracket.

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Side Mount Location is located along the edge of the Wedge Joint Maker closest to the side of the unit that will be next to the "End Gate." There is a pre-drilled horizontal slot in the top mounting bracket and vertical slot in the bottom mounting bracket. (See photo on next page.) 4

Center Mount Location

Side Mount Location

Measure and mark the 4 hole locations. Before drilling the locations check the alignment of the marked holes by placing the Wedge Joint Maker up against the screed extension and verify that the marked holes line up with the pre-drilled locations on the Wedge Joint Maker Mounting Bracket's. (helpful hint) •

It will be easier to start with the Center Mount Locations first. The Wedge Joint Maker can be temporarily mounted using the Center Mount holes and if need be the Side Mount holes can be marked for drilling after the Wedge Joint Maker is in place.

Drill and tap each hole for a 1/2 inch bolt. An alternative in case the metal in the mounting areas is too thin to tap satisfactorily is to weld a nut on the back of the hole.

Approximate Mounting Hole Locations: •

The location for the Center top mounting hole is Approx. 17 inches above the bottom of the screed plate and Approx. 6 inches in from the end gate side of the screed extension.

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The location for the Center bottom mounting hole is Approx. 9 inches above the bottom of the screed plate and approx. 6 inches in from the end gate side of the screed extension.

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The location for the Side top mounting hole is Approx. 17 inches above the bottom of the screed plate and Approx. 1 inch in from the end gate side of the screed extension.

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The location for the Side bottom mounting hole is Approx. 9 inches above the bottom of the screed plate and Approx. 1 inch in from the end gate side of the screed extension.

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4.3 Installation of Wedge Joint Maker •

Insert a bolt and washer into the "Center " top bracket mounting hole and tighten.

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Insert a bolt and washer into the "Center" bottom bracket slot and finger tighten. The bottom bracket needs to be able to move up and down until final adjustment.

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Repeat the process using the "Side" Mount locations.

When all four bolts are in, the Wedge Joint Maker is ready to be adjusted to a height of 1 inch above the bottom of the screed. •

Rotate the Joint Maker Section Adjustment Rod until the Joint Maker Section is level with the bottom of the screed plate. Clockwise rotation moves the Joint Maker Section up and counterclockwise rotation moves the Joint Maker Section down.

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The Joint Maker Section Height Indicator must now be adjusted to the proper position. Loosen the bolt and washer holding the Joint Maker Section Height Indicator in place.

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Slide the Joint Maker Section Height Indicator up or down to position the first indentation (at the bottom of the indicator) level with the top edge of the Wedge Joint Maker’s lower mounting plate.

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Tighten the bolt to secure the Joint Maker Section Height Indicator in its proper position.

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Each indentation represents one inch of travel of the Joint Maker Section

During normal paving conditions, the bottom edge of the Joint Maker Section should be approximately one inch above the bottom of the screed plate. •

Rotate the Joint Maker Section Height Adjustment Rod clockwise to raise the Joint Maker Section until the Joint Maker Section reaches one inch above the bottom of the screed plate.

• Tighten all four mounting bolts. (See photo on next page.)

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The wedge section has not been lowered it is at "0" position

Joint Maker Section is set 1" above the bottom of the screed.

The notch section has not be lowered it is at "0" position.

The Wedge Joint Maker is now mounted!!!

Note: At no time should the Joint Maker Section be adjusted to extend below the bottom of the screed plate it should be 1" above the bottom of the screed.

"End Of Installation Section of Manual."

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"Using the Wedge Joint Maker for Paving" 5.0 Instructions for Adjustment of Wedge Joint Maker During Paving 5.1 Positioning the Wedge Section Once the Paving Operation begins, and full mat depth has been reached, the Wedge Section should be adjusted to create the angle of taper and the height of the vertical drop on the outer edge of the taper. One adjustment controls both. Then the Notch section can be lowered to create the notch or step. •

Wedge Adjustment:

1. Rotate the Wedge Angle Adjustment Rod (clockwise for up and counterclockwise for down) until the Wedge Section is level with the bottom edge of the Notch Section. In this position, there is no angle to the resulting taper. If a downward angle is desired, rotate the Wedge Angle Adjustment Rod counterclockwise so that the outer edge of the Wedge Section is lowered to the desired level. It is advisable that the outer edge of the Wedge Section always be kept at a height greater than the size of the largest stone size in the asphalt mix being paved. This avoids dragging of the stone and deformation of the taper. Make sure that during adjustment of the Wedge Section that the “Flap” seal remains in proper position between the outer edge of the Wedge Section and the end gate. See the section “Constructing a Notched, Tapered Edge with the Wedge Joint Maker” for guidance on adjusting the Wedge Section for different paving conditions. 5.2 Positioning the Notch Section The Notch Section of the Wedge Joint Maker precompacts and shapes the “notch”, the vertical drop off of the top of the asphalt mat, which is critical to the construction of a Michigan wedge joint. The Notch Section is lowered below the level of the Joint Maker Section by rotating the Notch Section Adjustment Rod counterclockwise. The Notch Section Depth Indicator is preset to indicate the depth of the Notch Section below the bottom of the Joint Maker Section. Each indentation on the Notch Section Depth Indicator indicates one inch of travel below the bottom of the Joint Maker.

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Lowering the Notch Section by one indentation of the Notch Section Depth Indicator shows that the Notch Section is one inch below the bottom of the Joint Maker Section. When the Joint Maker Section is properly adjusted to one inch above the bottom of the screed plate, then the first indentation of the Notch Section Depth Indicator will position the Notch Section even with the bottom of the screed plate. In order to create a notch in the pavement behind the paver, the Notch Section will have to be lowered below the bottom of the screed plate. Each additional indentation in the Notch Section Depth Indicator will position the Notch Section one additional inch below the bottom of the screed plate. •

Notch Adjustment:

1. Rotate the Notch Adjustment Rod (clockwise for up and counterclockwise for down) until the Notch begins to form in the mat behind the screed. Increase the depth of the notch as needed to ensure a step is present after the break down rolling. As the notch is lowered it may be necessary to adjust the taper up to create the taper and prevent dragging of material at the edge of the taper. See the section “Constructing a Notched, Tapered Edge with the Wedge Joint Maker” for guidance on setting the depth of the Notch Section for different paving conditions. 6.0 Constructing a Notched, Tapered Edge with the Wedge Joint Maker During the compaction process, the thickness of the asphalt mat is reduced as it is rolled. This is often referred to as “rolldown”. A rule of thumb commonly used is that the thickness of an uncompacted asphalt mat will reduce by 25%, or one quarter inch for every inch of thickness. For example, a 3.0 inch uncompacted mat will be reduced by a full three-quarter inch (.75 inch) during rolldown, or .25 inch for every inch of thickness. The resulting mat would be 2.25 inches thick. The amount of rolldown is often different for different asphalt mixes. When constructing a notched, tapered edge on an asphalt mat, consideration of rolldown is very important. Rolldown effects the tapered edge in two ways. First, the depth of the notch is reduced during compaction. Second, the width of the taper may be reduced during rolling since the rolldown of the mix may move the mix over the taper section. The outer edge of the tapered section normally remains intact and does not move out during rolling. One of the primary purposes of constructing a tapered edge on an asphalt mat is to increase the safety of a vehicle crossing over an open mat edge. It is generally desirable to reduce any vertical drop along an edge to approximately one inch. The Wedge Joint Maker by TransTech is designed to give the user the ability to adjust the shape of the

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open mat edge to achieve reduction of a deep vertical mat edge to a contoured shape with no single vertical drop exceeding one inch. Using the example above, here is how we might set up the Wedge Joint Maker initially to achieve the desired shape of the tapered edge after compaction. A total rolldown of .75 inch is expected. This rolldown will be seen at the notch. If it is desired to end up with a one inch notch after rolling, then the Notch Section must be adjusted into position so that the depth of the uncompacted notch is at least 1.75 inches deep. Use the Notch Section Depth Indicator and the Notch Section Depth Adjustment Rod to adjust to these settings. In an asphalt mat of this depth, it is typical that the largest stone size might be .75 inch (maybe as large as 1.0 inch). In setting the position of the Wedge Section, it is critical that the vertical drop at the outer edge of the taper be slightly higher than the size of the largest stone size. It would be safe to set the angle of the Wedge Section in this example so that the vertical drop at the outer edge is approximately 1.0 inch high. Use the Wedge Angle Adjustment Rod to adjust to this setting. In our example, the dimensions of the uncompacted mat are as follows: the full mat depth is 3.0 inches, the depth of the notch from the top of the mat to the start of the taper is 1.75 inches, the taper reduces the mat height by only .25 inches, and the height of the vertical drop at the outer edge of the taper is 1.0 inch. After compaction, the dimensions of the mat edge will be as follows: the full mat depth will be 2.25 inches, the height of the notch will be 1.0 inches, the taper will reduce the mat height by .25 inches, and the vertical drop at the outer edge of the taper will be 1.0 inch. The width of the taper might be reduced from 12 inches wide to 10 inches wide. 7.0 Guidance on Using the Wedge Joint Maker 7.1 Calculating Mat Widths It is important to know that the Wedge Joint Maker increases the width of the mat being laid by approximately 4”. This extra width needs to be included when deciding on paving width of each paving pass. 7.2 Settings at Initial “Takeoff” of the Paver Under most paving conditions, the initial “takeoff” of the paver is done at full mat depth off of blocks or prior paving. Under paving conditions where “takeoff” is from a “zero” mat height and the screed is then raised to full mat depth, special precautions must be taken when using the Wedge Joint Maker. Failure to make proper adjustments could result in damage to the Wedge Joint Maker and interruptions in paving. When adjusted to produce a notched, tapered edge, the Notch Section and Wedge Section of the Wedge Joint Maker are set lower than the bottom of the screed plate. When paving

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begins at “zero” mat height, these two sections need to be raised above the bottom of the screed plate then lowered into position once the full mat depth is reached. Before paving begins, setup the Wedge Joint Maker as desired. Note the position of the Notch Section Depth Indicator. Then, rotate the Notch Section Depth Adjustment Rod clockwise so until the Notch Section Depth Indicator indicates the bottom of the Notch Section is even with the bottom of the Joint Maker Section. Check visually to be sure that both the Notch Section and the Wedge Section are above the bottom of the screed plate. Once full mat depth is achieved, rotate the Wedge Section Adjustment Rod to create the taper and then the Notch Adjustment Rod to start creating the notch or step.

7.3 Recommended Initial Rolling Patterns Rolling of the mat edges and of the longitudinal joint when paving the closing pass is critical to achieving the best tapered mat edge and the highest density longitudinal joint. It is recommended that the first rolling pass on the freshly laid mat be made with the roller drum overlapping the air at the tapered edge by about 3-5 inches. The roller should be driven straight up to the back of the paver and back without turning the roller. If possible, this should be done in vibratory mode. This process “sets” the higher density edge and reduces deformation of the notch during the balance of rolling. If the notch is losing its height in this process, it may help to do this first rolling pass in static mode, then the remainder in vibratory. When closing the longitudinal joint, it is recommended that the first rolling pass be made with 3-6 inches of the roller drum overlapping the edge of the first mat ie, with most of the roller drum over the hot mat. Another key point about the closing paving pass: it is critical that the second mat be laid down over the taper section with enough material to accommodate rolldown. If the uncompacted mat is laid “flush” with the edge of the first, or “cold”, mat the roller will bridge on the edge of the cold mat and density in the joint section will be greatly reduced. It is critical that the longitudinal joint area be rolled at least as many times as the center area of the asphalt mat in order to achieve the highest possible density. These suggestions are a general guide. If maximizing density in the longitudinal joints is a key objective, cores in the joints should be taken on a regular basis and adjustments in the Wedge Joint Maker and in rolling patterns be executed to increase density results. TransTech customer service personnel are available to assist customers in analyzing results and developing alternatives.

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7.4 Adjusting Edge Shape During Paving Under most paving conditions, the shape of the tapered edge can be adjusted during paving. The height of the notch can be increased or decreased by rotating the Notch Section Adjustment Rod. The angle of the Wedge Section and the height of the vertical drop at the outer edge of the taper can be adjusted by rotating the Wedge Section Adjustment Rod. Only minor adjustments should be necessary during paving; the most common is adjustment of the Notch Depth. 7.5 Warning!: During paving, parts of the Wedge Joint Maker are positioned below the bottom of the screed plate. If the mat thickness is reduced during paving, the Wedge Joint Maker could be severely damaged. This is particularly true at the point of takeoff or at the end of a paving run. There are several shear pins at critical points in the Wedge Joint Maker which may add some protection, but the user will bear the expense of repair if damage is sustained under these circumstances.

Warning!: During paving, the Wedge Joint Maker could be exposed to contact with the crossfeed auger and auger shaft if the hydraulic screed extension is drawn in too close to the main screed. Severe damage could occur to both the crossfeed auger and the Wedge Joint Maker if they come in contact. 7.6 Keeping Paver End Gate in Proper Position In order for the Wedge Joint Maker to work properly, the paver end gate ski must be kept riding directly on the surface being paved. Most end gates have a tension rod, or compression spring, mechanism which can be adjusted to keep enough downward pressure on the ski so that it does not lift up during paving. If the end gate lifts off the pavement for any reason, asphalt may flow out the side of the paver and not provide enough asphalt to the Wedge Joint Maker to achieve proper precompaction in order to construct a high quality notched tapered edge. 8.0 Closing the Longitudinal Joint over a Tapered Edge The Wedge Joint Maker is designed to be used in a pair, with one unit for the left side and one unit for the right side of the paving machine. When closing a longitudinal joint, the Wedge Joint Maker can be adjusted to achieve increased density when covering a tapered edge. This adjustment of the Wedge Joint Maker can also be made to achieve a precompacted vertical open edge when paving a vertical “butt” joint. •

Ensure that the Joint Maker Section is one inch above the bottom of the screed plate.

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Rotate the Notch Depth Adjustment Rod so that the Notch Section is level with the bottom of the Joint Maker Section.

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Rotate the Wedge Angle Adjustment Rod so that the Wedge Section is level with the bottom of the Notch Section and parallel to the bottom of the screed plate.

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With these settings, bottom edges of all three sections of the Wedge Joint Maker should be in a straight line one inch above the bottom of the screed plate. The Wedge Joint Maker will precompact asphalt in the outer 12-16 inches of the mat.

For assistance during installation and usage of the Wedge Joint Maker, call TransTech at 1-800-724-6306 for Customer Support.

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