Thursday, December 13, 2007

Asphalt plant


An asphalt plant is a plant used for the manufacture of asphalt, macadam and other forms of coated roadstone, sometimes collectively known as blacktop.

The manufacture of coated roadstone demands the combination of a number of aggregates, sand and a filler (such as stone dust), in the correct proportions, heated, and finally coated with a binder, usually bitumen based or, in some cases, tar. The temperature of the finished product must be sufficient to be workable after transport to the final destination. A temperature in the range of 100 - 200 degrees Celsius is normal.

Increasingly, recycled asphalt pavement (RAP) is used as part of the mix. The binder used is flammable, and the heaters are large liquid or gas fired burners. RAP is introduced after the heating process and must be accounted for in the overall mix temperature calcualtions.

There are three main classes of plant: batch heater, semi-continuous (or "asphalt plant"), and continuous (or "drum mix"). The batch heater has the lowest throughput, the continuous plant the highest at up to around 500 Tonnes per hour.

Supply of roadstone for large contracts is generally by tender with considerable pressure on price. A faulty batch of roadstone must be planed up and relaid, often with additional lane rental charges, at a cost which may be orders of magnitude higher than the original price, so sophisticated control systems are a necessity.


Sand

One key ingredient of most roadstones is sand. Sand generally has a high water content. Boiling off this water is a large part of the energy cost of heating the aggregate, in turn a significant part of the overall cost of operation. The water content of sand also varies considerably, especially when stored outdoors, being typically of the order of some tens of percent of the overall mass of wet sand. Since sand takes the form of small grains, with a high surface area per unit volume, and binder attaches to the surface of the aggregates, the amount of dry sand in the mix is particularly critical to the overall blend; the moisture content must be measured and the equivalent dry weight calculated.

Binder

Binder comes in different grades known as "penetration" or "pen" grades, with values varying between around 30 and 300. The pen value is an expression of the depth to which a standard needle will penetrate the surface of the binder at a specified temperature (the higher the value, the softer the binder). This has an effect on the workability of hot asphalt and the stiffness of the asphalt when cooled. Lower pen values give harder wearing. Asphalt wearing courses are typically 35-50 pen, base courses will be higher, typically 200 or 300 pen. The coating plant may combine binder of different grades to achieve a grade between those held on site.

Filler

Filler, as the name implies, fills the voids between aggregate grains and improves the wearing capabilities of the overall mix. It is stored and fed dry into the mix, during or after addition of binder. A common source of filler is fines from the heating process recovered by bag filters or wet filtration ponds from the exhaust of the heating drum.

Types of plant

Batch heater

A batch heater plant weighs the raw aggregates into a heater drum, where the batch is then heated up to temperature. The hot aggregate is discharged into a mixing drum where (dry) filler and binder are added. The blend is mixed and discharged either directly into the delivery vehicles or into a small weighing and collecting hopper. To increase throughput, the heater can be heating the next batch while the previous is being mixed. Capacity is usually of the order of tens of tonnes per hour.

Batch heater plant is used where short production runs are common (a different recipe can be used on each mix) or where total volume is low. Mobile batch heaters are available.

Semi-continuous

The term "asphalt plant" strictly refers to a semi-continuous plant. Aggregates and sand are brought up from ground hoppers by continuous conveyor belt in approximate proportions, heated in a drum to dry them and bring them up to temperature, screened back into their respective sizes by diameter (e.g. sand, <10mm,>

Level sensors in the hoppers may be used to inform the aggregate feed rates to ensure that the level of each hot aggregate remains reasonably consistent.

Batch weighing and mixing allows for rapid changes of mix, but the time delay in heating and screening means that the overall balance of aggregates needs to be matched to the ovewrall feed, so this type of plant is less suitable for very short runs. Capacity is typically of the order of a few hundreds of tonnes per hour.

Continuous

In the continuous plant, raw aggregate is brought up from ground hoppers at a precisely controlled rate and fed into a heater drum similar to that used in the asphalt plant. Once heated it is immediately coated in the same drum (with the binder spraybars situated behind the burner) or in a smaller drum situated immediately behind it. Finished product is almost invariably discharged into a hot store rather than directly into delivery vehicles.

Changing mix is achieved by varying the feed rates of the aggregate, filler and binder feeders, with time delays so that the change of blend occurs at the same point in the coating drum. Sand tends to move more slowly through the heating drum, so the blend proportions will not necessarily change at the same point on the feed conveyor. It is common to divert a small amount of material to a waste chute when the transition point reaches the hot elevator.

Drum mix plants are not really suitable for short production runs; although with sophisticated controls the change of mix can be accurate to within some seconds, production rates of hundreds of tonnes per hour may equate to a tonne every ten seconds or so.

Hot storage

Finished roadstone must be kept heated to avoid setting. It is commonly stored in large electrically heated insulated stainless steel silos, from which it is weighed into delivery vehicles. This may be achieved by intermediate weigh hoppers (which may shuttle between hoppers) or by mounting the hoppers directly on load cells. Control of loadout by this method involves accurately predicting the material "in flight" between the discharge door and the vehicle.

Types of dump trucks

Dump trucks come in a variety of configurations each specified to accomplish a specific task in the construction material supply chain.

Standard dump truck

Another kind of 8x4 dump truck: three rear (two powered) axles
Another kind of 8x4 dump truck: three rear (two powered) axles

A standard dump truck is a full truck chassis with a dump body mounted to the frame. The dump body is raised by a hydraulic ram mounted forward of the front bulkhead, between the truck cab (traction unit) and the dump body (semi-trailer). The tailgate can be configured to swing on hinges or it can be configured in the "High Lift Tailgate" format wherein pneumatic rams lift the gate open and up above the dump body.

A standard dump truck has one front axle, and one or more rear axles which typically have dual wheels on each side. Common configurations for a standard dump truck include the six wheeler which has one rear axle, the ten wheeler with two rear axles, and the tri-axle with three rear axles. These are mainly found in inner cities and in the deep south.

The short wheelbase of a standard dump truck makes it more maneuverable than the higher capacity semi-trailer dump trucks.

Articulated dump truck

Articulated dump truck or dumper
Articulated dump truck or dumper

An articulated dump truck has a hinge between the cab and the dump box, but is distinct from semi trailer trucks in that the cab is a permanent fixture, not a separable vehicle. Steering is accomplished via hydraulic rams that pivot the entire cab, rather than rack and pinion steering on the front axle. This vehicle is highly adaptable to rough terrain. In line with its use in rough terrain longer distances and overly flat surfaces tend to cause driveline troubles, and failures. Articulated trucks are often referred to as the modern scraper, in the sense that they carry a much higher maintenance burden than most trucks. See the first mass produced articulated dump truck (articulated hauler):

Transfer dump truck

Example of a transfer truck and trailer
Example of a transfer truck and trailer

A transfer dump (colloquially referred to as a "Slam-Bang!" because of the noise made when transferring) is a standard dump truck which pulls a separate trailer which can also be loaded with aggregate (gravel, sand, asphalt, klinker, snow, wood chips, triple mix, etc.)

The second aggregate container, (B box) on the trailer which is powered by either an electric, pneumatic motor or hydraulic line from a PTO (power take off) mounted on the transmission of the tractor, rides on small wheels and rolls on rails off of the trailer frame and into the empty main dump (A) box. The key advantage of this configuration is to maximize payload capacity without sacrificing the maneuverability of the short and nimble standard dump truck. Transfer dumps are typically seen in the western United States because of the peculiar weight restrictions on western highways.

Another configuration seen is called a Triple Transfer Train, which consists of a B and C box. These are common on Nevada and Utah Highways but not in California. Depending on the axle arrangement, a Triple Transfer can haul up to 129,000 with a special permit in certain US states. The Triple Transfer usually costs a contactor about $105 an hour while a A/B config usually runs about $85 per hour (2007 stats).

Truck and pup

A truck and pup is very similar to a transfer dump. It consists of a standard dump truck pulling a dump trailer. The pup trailer, unlike the transfer, has its own hydraulic ram and is capable of self-unloading.

Example of a Pup trailer
Example of a Pup trailer

Superdump truck

A Superdump is a straight dump truck equipped with a Strong Arm trailing axle, a liftable, load-bearing axle rated as high as 13,000 pounds. Trailing 11 to 13 feet behind the rear tandem, the Strong Arm axle stretches the outer "bridge" measurement—the distance between the first and last axles—to the maximum overall length allowed. This increases the gross weight allowed under the federal bridge formula, which sets standards for truck size and weight. Depending on the vehicle length and axle configuration, Superdumps can be rated as high as 80,000 pounds GVW and carry 26 tons of payload or more. When the truck is empty or ready to offload, the Strong Arm toggles up off the road surface on two hydraulic arms to clear the rear of the vehicle. Strong Arm axles are built by Strong Industries Inc., of Houston, Texas. Truck owners call their Strong Arm-equipped trucks Superdumps because they far exceed the payload, productivity, and return on investment of a conventional dump truck.

The superdump with the Strong arm is said to be safer with the fact that every axle has brakes. They have recently added a new secondary lateral suspension system that has added much more stability to the truck also. They have also added an out of level system if you get a flat tire that will release the pressure on the axle to help with handling even if the tire is low on air it will release the pressure.

Semi trailer end dump truck

End dump trailer.
End dump trailer.

A semi end dump is a tractor-trailer combination wherein the trailer itself contains the hydraulic hoist. A typical semi end dump has a 3-axle tractor pulling a 2-axle semi-trailer. The key advantage of a semi end dump is rapid unloading. A key disadvantage is that they are very unstable when raised in the dumping position limiting their use in many applications where the dumping location is uneven or off level.

Semi trailer bottom dump truck

Bottom dump trailer.
Bottom dump trailer.

A semi bottom dump (or "belly dump") is a 3-axle tractor pulling a 2-axle trailer with a clam shell type dump gate in the belly of the trailer. The key advantage of a semi bottom dump is its ability to lay material in a wind row (a linear heap). In addition, a semi bottom dump is maneuverable in reverse, unlike the double and triple trailer configurations described below. These trailers may be found either of the windrow type shown in the photo, or may be of the 'cross spread' type with the gates opening front to rear instead of left and right. The cross spread gates will actually spread gravel fairly evenly the width of the trailer. by comparison, the windrow gates leave a pile in the middle. The cross spreads jam and do not work well with larger materials. Likewise they are not suitable for use where spreading is not desired such as when hot asphalt paving material is being dumped in front of a paving machine.

Double and triple trailer bottom dump truck

Double and triple bottom dumps consist of a 2-axle tractor pulling one single-axle semi-trailer and an additional full trailer (or two full trailers in the case of triples). These dump trucks allow the driver to lay material in wind rows without ever leaving the cab or even stopping the truck. The main disadvantage is the difficulty in backing double and triple units in reverse.

The specific type of dump truck used in any specific country is likely to be closely keyed to the weight and axle limitations of that jurisdiction. Rock, dirt and other types of materials commonly hauled in trucks of this type are quite heavy, and almost any style of truck can be easily overloaded. Because of this, this type of truck is frequently configured to take advantage of local weight limitations so as to maximize the allowed weight. For example, within the United States, a maximum weight limit of 40 tons is mandated throughout the country except for specific bridges that may not be safe with that weight, however, individual states in some instances are allowed to authorize trucks up to 52.5 tons, however, most states that do so, require that the trucks be very long so as to spread the weight out over more distance. It is in this context that you see the double and triple bottoms within the United States.

Side dump truck

A side dump truck consists of a 3-axle tractor pulling a 2-axle semi-trailer. It has hydraulic rams which tilt the dump body onto its side, spilling the material to either the left or right side of the trailer. The key advantages of the side dump are that it allows rapid unloading and can carry more weight in western United States. In addition, it is almost immune to upset (tipping over) while dumping unlike the semi end dumps which are very prone to tipping over. It is, however, highly likely that a side dump trailer will tip over if dumping is stopped prematurely. A disadvantage occurs when dumping lose materials or cobble sized stone, the side dump will often get stuck in its own pile.

Off-road dump truck

Liebherr T 282B mining truck.
Liebherr T 282B mining truck.
Hitachi mining truck.
Hitachi mining truck.

Off-road dump trucks more closely resemble heavy construction equipment or engineering vehicles than they do highway dump trucks. They are used strictly off-road for mining and heavy dirt hauling jobs.

The term ‘Dump’ Truck is not generally used by the mining industry, or by the manufacturers that build these machines. The more appropriate US term for this strictly off road vehicle is, ‘Haul’ truck. The classification bottom and side for example, describes how the loaded material is discharged once loaded. In the case of the Haul truck illustrated, a Liebherr T 282B the load is discharged to the rear, designating this particular vehicle as an end dump. Bottom dump normally describes a trailer that discharges its load by opening two clam shell doors under the load space, in some examples several trailers (road train) are pulled by one truck mainly these are on road machines. The only remaining example of what is described as a unitized bottom dump coal hauler is manufactured by Kress Corporation. This large capacity truck is used for the transportation of coal from a loading device (shovel) directly to a power station or bulk storage area.

Winter service vehicles

Many winter service vehicle units are based on dump trucks, to allow the placement of ballast to weigh the truck down or to hold salt for spreading on the road.

Dangers

Potentially flying goods must be covered (i.e. using a canvas, straps or a rope) to prevent loose material from flying outside the bed when the truck is moving, and to keep the goods from damaging other vehicles. Also heavier items loaded over the edge of the truck must be secured to prevent them from dropping off the truck in turns, on bad roads or when braking the vehicle.

Trucks are normally built for some amount of off road driving or construction site driving, which means that bumpers are either placed high or not even there because the chassis and height of the drivers seat protects the driver fairly. The disadvantage is that in a collision with a family car, the entire motor section or luggage compartment goes under the truck bumper and only the roof and window section makes mentionable contact to the truck. This means that passengers in the car could be cut off at chest height instead of having minor damage in the lower leg region which would be the part the car is protecting through its design. Several countries have made rules that new trucks should have bumpers approximately 40 cm above ground in order to protect other drivers better. There are also rules about how long the load or construction of the truck can go beyond the rear bumper to prevent cars that rear-end the truck from being cut off. Several pictures on the internet show one such case, a Corvette sticking out 50 cm from the edge of a semi trailer

Farm tractor

A modern John Deere 8110 Farm Tractor plowing a field using a chisel plow.
A modern John Deere 8110 Farm Tractor plowing a field using a chisel plow.

The most common use of the term is for the vehicles used on farms. The farm tractor is used for pulling or pushing agricultural machinery or trailers, for plowing, tilling, disking, harrowing, planting, and similar tasks. Charles City, Iowa is the birthplace of the farm tractor in the early 1900's by the Hart-Parr Company,[citation needed] Later sold to White Tractor.

History

The first powered farm implements in the early 1800s were portable engines – steam engines on wheels that could be used to drive mechanical farm machinery by way of a flexible belt. Around 1850, the first traction engines were developed from these, and were widely adopted for agricultural use. Where soil conditions permitted, like the US, steam tractors were used to direct-haul ploughs, but in the UK, ploughing engines were used for cable-hauled ploughing instead. Steam-powered agricultural engines remained in use well into the 20th century, until reliable internal combustion engines had been developed.

In 1892, John Froelich built the first practical gasoline-powered tractor in Clayton County, Iowa. Only two were sold, and it was not until 1911, when the Twin City Traction Engine Company developed the design, that it became successful.

In Britain, the first recorded tractor sale was the oil-burning Hornsby-Ackroyd Patent Safety Oil Traction engine, in 1897. However, the first commercially successful design was Dan Albone's three-wheel Ivel tractor of 1902. In 1908, Saundersons of Bedford introduced a four-wheel design, and went on to become the largest tractor manufacturer outside the USA.

While unpopular at first, these gasoline-powered machines began to catch on in the 1910s when they became smaller and more affordable. Henry Ford introduced the Fordson, the first mass-produced tractor in 1917. They were built in the U.S., Ireland, England and Russia and by 1923, Fordson had 77% of the U.S. market. The Fordson dispensed with a frame, using the strength of the engine block to hold the machine together. By the 1920s, tractors with a gasoline-powered internal combustion engine had become the norm.

The classic farm tractor is a simple open vehicle, with two very large driving wheels on an axle below and slightly behind a single seat (the seat and steering wheel consequently are in the center), and the engine in front of the driver, with two steerable wheels below the engine compartment. This basic design has remained unchanged for a number of years, but enclosed cabs are fitted on almost all modern models, for reasons of operator safety and comfort.

Originally, plows and other equipment were connected via a draw-bar, or a proprietary connecting system; prior to Harry Ferguson patenting the three-point hitch. Recently, Bobcat's patent on its front loader connection has expired; and compact tractors are now being outfitted with quick-connect attachments for their front-end loaders.

There are also lawn tractors. Cub Cadet, Husqvarna, John Deere, Massey Ferguson and Toro are some of the better-known brands.

Operation

A small red tractor towing a cargo cart
A small red tractor towing a cargo cart

Modern farm tractors usually have five foot-pedals for the operator on the floor of the tractor. The pedal on the left is the clutch. The operator presses on this pedal to disengage the transmission for either shifting gears or stopping the tractor. Two of the pedals on the right are the brakes. The left brake pedal stops the left rear wheel and the right brake pedal does the same with the right side. This independent left and right wheel braking augments the steering of the tractor when only the two rear wheels are driven. This is usually done when it is necessary to make a tight turn. The split brake pedal is also used in mud or soft dirt to control a tire that spins due to loss of traction. The operator presses both pedals together to stop the tractor. For tractors with additional front-wheel drive, this operation often engages the 4-wheel locking differential to help stop the tractor when travelling at road speeds.

A fifth pedal just in front of the seat operates the rear differential lock (diff lock) which prevents wheelslip. The differential allows the outside wheel to travel faster than the inside one during a turn. However, in traction conditions on a soft surface the same mechanism could allow one wheel to slip, thus preventing traction to the other wheel. The diff lock overrides this, causing both wheels to supply equal traction. Care must be taken to unlock the differential, usually by hitting the pedal a second time, before turning, since the tractor cannot perform a turn with the diff lock engaged.

The pedal furthest to the right is the foot throttle. Unlike in automobiles, it can also be controlled from a hand-operated lever ("hand throttle"). This helps provide a constant speed in field work. It also helps provide continuous power for stationary tractors that are operating an implement by shaft or belt. The foot throttle gives the operator more automobile-like control over the speed of the tractor for road work. This is a feature of more recent tractors; older tractors often did not have this feature. In the UK it is mandatory to use the foot pedal to control engine speed while travelling on the road. Some tractors, especially those designed for row-crop work, have a 'de-accelerator' pedal, which operates in the reverse fashion to an automobile throttle, in that the pedal is pushed down to slow the engine. This is to allow fine control over the speed of the tractor when maneuvering at the end of crop rows in fields- the operating speed of the engine is set using the hand throttle, and if the operator wishes to slow the tractor to turn, he simply has to press the pedal, turn and release it once the turn is completed, rather than having to alter the setting of the hand throttle twice during the maneuver.

Power and transmission

Modern farm tractors employ large diesel engines, which range in power output from 18 to 575 horsepower (15 to 480 kW). Tractors can be generally classified as two-wheel drive, two-wheel drive with front wheel assist, four-wheel drive (often with articulated steering), or track tractors (with either two or four powered rubber tracks). Variations of the classic style include the diminutive lawn tractors and their more capable and ruggedly constructed cousins, garden tractors, that range from about 10 to 25 horsepower (7.5-18.6 kW) and are used for smaller farm tasks and mowing grass and landscaping. Their size—especially with modern tractors—and the slower speeds are reasons motorists are urged to use caution when encountering a tractor on the roads.

A PTO shaft connected to a tractor.
A PTO shaft connected to a tractor.

Most tractors have a means to transfer power to another machine such as a baler, slasher or mower. Early tractors used belts wrapped around a flywheel to power stationary equipment. Modern tractors use a power take-off (PTO) shaft to provide rotary power to machinery that may be stationary or pulled. Almost all modern tractors can also provide external hydraulic fluid and electrical power.

Most farm tractors use a manual transmission. They have several sets of gear ratios divided into speeds. In order to change the ratio, it is usually necessary to stop the tractor. Between them they provide a range of speeds from less than one mile per hour suitable for working the land, up to about 25 miles per hour (40 km/h) for road use. Furthermore it is usually not necessary to change gear in order to reverse, one simply selects a lever. Older tractors usually require that the operator depress the clutch in order to shift between gears (a limitation of straight-cut gears in the gearbox), but many modern tractors have eliminated this requirement with the introduction of technologies such as power shifting in the 1960s and more modern continuously variable transmissions. This allows the operator more and easier control over working speed than the throttle alone could provide.

Slow, controllable speeds are necessary for most operations that are performed with a tractor. They help give the farmer a larger degree of control in certain situations, such as field work. However, when travelling on public roads, the slow operating speeds can cause problems, such as long queues or tailbacks, which can delay or aggravate other road users. To alleviate conditions, some countries (for example the Netherlands) employ a road sign on some roads that means "no farm tractors". Some modern tractors, such as the JCB Fastrac, are now capable of much more tolerable road speeds of around 50 mph (80 km/h).

Safety

The classic Row Crop tractor (an Allis-Chalmers WD). Note the absence of any rollover protection system.
The classic Row Crop tractor (an Allis-Chalmers WD). Note the absence of any rollover protection system.

Agriculture in the United States is one of the most hazardous industries, only surpassed by mining and construction. No other farm machine is so identified with the hazards of production agriculture as the tractor. Tractor related injuries account for approximately 32% of the fatalities and 6% of the non-fatal injuries in agriculture. Over 50% is attributed to tractor overturns.

The roll over protection structure(ROPS) and seat belt, when worn, are the two most important safety devices to protect operators from death during tractor overturns.

Modern tractors have rollover protection systems (ROPS) to prevent an operator from being crushed if the tractor overturns. It is important to remember that the ROPS does not prevent tractor overturns. Rather, it prevents the operator from being crushed during an overturn. This is especially important in open-air tractors, where the ROPS is a steel beam that extends above the operator's seat. For tractors with operator cabs, the ROPS is part of the frame of the cab. A ROPS with enclosed cab further reduces the likelihood of serious injury because the operator is protected by the sides and windows of the cab.

ROPS were first required by legislation in New Zealand in the 1960s (in Sweden, summer of 1959). Before ROPS were required, some farmers died when their tractors rolled on top of them. Row-crop tractors, before ROPS, were particularly dangerous because of their 'tricycle' design with the two front wheels spaced close together and angled inward toward the ground. Some farmers were killed by rollovers while operating tractors along steep slopes. Others have been killed while attempting to tow or pull an excessive load from above axle height, or when cold weather caused the tires to freeze down, in both cases causing the tractor to pivot around the rear axle.

For the ROPS to work as designed, the operator must stay within the protective frame of the ROPS. This means the operator must wear the seat belt. Not wearing the seat belt may defeat the primary purpose of the ROPS.

Farm tractor rear turnover
Farm tractor rear turnover

Applications

An unusual application - road roller powered by a tractor-drive
An unusual application - road roller powered by a tractor-drive

Farm implements can be attached to the rear of the tractor by either a drawbar or a three-point hitch. The three-point hitch was invented by Harry Ferguson and has been standard since the 1960s. Equipment attached to the three-point hitch can be raised or lowered hydraulically with a control lever. The equipment attached to the three-point hitch is usually completely supported by the tractor. Another way to attach an implement is via a Quick Hitch, which is attached to the three-point hitch. This enables a single person to attach an implement quicker and put the person in less danger when attaching the implement.

Some farm-type tractors are found elsewhere than on farms: with large universities' gardening departments, in public parks or for highway workman use with blowtorch cylinders strapped to its sides and a pneumatic drill air compressor permanently fastened over its power take-off. These are often fitted with grass (turf) tyres which are less damaging to soft surfaces than agricultural tyres.

Supposedly, I4 (industrial bar tires) are less damaging to lawns and soft surfaces than agricultural tires, but provide similar traction, and have the benefit of being self-cleaning. Often, these can be seen on road construction backhoes.

Precision agriculture

Space technology has found its way down to agriculture in the form of GPS devices, and robust on-board computers installed as optional features on farm tractors. These technologies are used in modern, precision farming techniques. The spin-offs from the space race have actually facilitated automation in plowing and the use of autosteer systems drone on tractors that are manned but only steered at the end of a row, the idea being to neither overlap and use more fuel nor leave streaks when performing jobs such as cultivating.

Compact Utility Tractor

Kubota and New Holland Compact Tractors equipped with Front End Loaders
Kubota and New Holland Compact Tractors equipped with Front End Loaders
In the middle is a 24 hp (18 kW) diesel CUT illustrating the size difference between a small farm tractor and a garden tractor
In the middle is a 24 hp (18 kW) diesel CUT illustrating the size difference between a small farm tractor and a garden tractor

A Compact Utility Tractor, also called a CUT is a smaller version of an agricultural tractor but designed primarily for landscaping and estate management type tasks rather than for planting and harvesting on a commercial scale. Typical CUTs range in from 20 to 50 horsepower (15-37 kW) with available power take off (PTO) horsepower ranging from 15 to 45 hp (11-34 kW). CUTs are often equipped with both a mid-mounted PTO and a standard rear PTO, especially those below 40 horsepower (30 kW). The mid-mount PTO shaft typically rotates at/near 2000 rpms and is typically used to power such implements as mid-mount finish mower, a front mounted snow blower or front mounted rotary broom. The rear PTO is standardized at 540 rpms for the North American markets, but in some parts of the world a dual 540/1000 rpm PTO is standard and implements are available for either standard in those markets.

Howse brand modular Subsoiler mounted to a tractor
Howse brand modular Subsoiler mounted to a tractor
Broadcast seeder mounted to a Kubota Compact Utility Tractor
Broadcast seeder mounted to a Kubota Compact Utility Tractor

One of the most common attachment for a Compact Utility Tractor is the front end loader or FEL. Like the larger agricultural tractors, a CUT will have an adjustable three-point hitch that is hydraulically controlled. Typically a CUT will have four wheel drive, or more correctly 4 wheel assist. Modern Compact Utility Tractors often feature a Hydrostatic transmission, but many variants of gear drive transmissions are also offered from low priced simple gear transmissions to synchronized transmissions to advanced glide-shift transmissions. All modern CUTs feature a government mandated roll over protection structure (ROPS) just like agricultural tractors. The most well known brands in North America include Kubota, John Deere Tractor, New Holland Ag, Case-Farmall and Massey-Ferguson. Although less common, compact backhoes are often attached to compact utility tractors.

JD 71 Flexi Planter for tractors 20 to 35 horsepower
JD 71 Flexi Planter for tractors 20 to 35 horsepower

Compact Utility Tractors require special smaller implements than full size agricultural tractors. Very common implements include the box blade, the grader blade, the landscape rake, the post hole digger (or post hole auger), the rotary cutter (also called a slasher or a brush hog), a mid or rear mount finish mower, broadcast seeder, subsoiler and the rototiller (also rotary tiller). In northern climates, a rear mounted snow blower is very common, on smaller CUTs some models are available with front mounted snow blowers that are powered by a mid-PTO shaft. There are many more implement brands than there are tractor brands offering CUT owners a wide selection of choice.

For small scale farming or large scale gardening, there are some plating and harvesting implements sized for CUTs. One and two row planting units are commonly available as are cultivators, sprayers and different types of seeders (slit, rotary and drop).

Backhoe loader

A common backhoe-loader. The backhoe is on the left, the bucket/blade on the right.
A common backhoe-loader. The backhoe is on the left, the bucket/blade on the right.

The most common variation of the classic farm tractor is the hoe, also called a hoe-loader. As the name implies, it has a loader assembly on the front and a backhoe on the back. Backhoes attach to a 3 point hitch on farm or industrial tractors. Industrial tractors are often heavier in construction particularly with regards to the use of steel grill for protection from rocks and the use of construction tires. When the backhoe is permanently attached, the machine usually has a seat that can swivel to the rear to face the hoe controls. Removable backhoe attachments almost always have a separate seat on the attachment.

Backhoe-loaders are very common and can be used for a wide variety of tasks: construction, small demolitions, light transportation of building materials, powering building equipment, digging holes,loading trucks, breaking asphalt and paving roads. Some buckets have a retractable bottom, enabling them to empty their load more quickly and efficiently. Buckets with retractable bottoms are also often used for grading and scratching off sand. The front assembly may be a removable attachment or permanently mounted. Often the bucket can be replaced with other devices or tools.

Their relatively small frame and precise control make backhoe-loaders very useful and common in urban engineering projects such as construction and repairs in areas too small for larger equipment. Their versatility and compact size makes them one of the most popular urban construction vehicles.

In the UK, the word "JCB" is sometimes used colloquially as a genericized trademark for any such type of engineering vehicle, JCB now appears in the Oxford English Dictionary, although it is still treated as a trademark.

Engineering tractors

A tractor factory in Chelyabinsk in the Soviet Union circa 1930.
A tractor factory in Chelyabinsk in the Soviet Union circa 1930.

The durability and engine power of tractors made them very suitable for engineering tasks. Tractors can be fitted with engineering tools such as dozer blade, bucket, hoe, ripper, and so on. The most common attachments for the front of a tractor are dozer blade or a bucket. When attached with engineering tools the tractor is called an engineering vehicle.

A bulldozer is a track-type tractor attached with blade in the front and a rope-winch behind. Bulldozers are very powerful tractors and have excellent ground-hold, as their main tasks are to push or drag things.

Bulldozers have been further modified over time to evolve into new machines which are capable of working in ways that the original bulldozer can not. One example is that loader tractors were created by removing the blade and substituting a large volume bucket and hydraulic arms which can raise and lower the bucket, thus making it useful for scooping up earth, rock and similar loose material to load it into trucks.

A front-loader or loader is a tractor with an engineering tool which consists of two hydraulic powered arms on either side of the front engine compartment and a tilting implement. This is usually a wide open box called a bucket but other common attachments are a pallet fork and a bale grappler.

Other modifications to the original bulldozer include making the machine smaller to let it operate in small work areas where movement is limited. There are also tiny wheeled loaders, officially called Skid-steer loaders but nicknamed "Bobcat" after the original manufacturer, which are particularly suited for small excavation projects in confined areas.

Garden Tractors

Garden Tractors (also called Mini Tractors) are small, light and simple tractors designed for use in domestic gardens. Garden Tractors are usually designed primarily for cutting grass, being fitted with horizontal rotary cutting decks. The distinction between a garden tractor and a ride-on lawnmower is often hard to make- generally Garden Tractors are more sturdily built, with stronger frames, axles and transmissions. Garden Tractors are generally capable of mounting other implements such as harrows, cultivators/rotavators, sweepers, rollers and dozer-blades. Like ride-on mowers, Garden Tractors generally have a horizontally-mounted engine with a belt-drive to a transaxle-type transmission (usually of 4- or 5-speeds, although some my also have two-speed reduction gearboxes or hydraulic gearboxes). However, Wheel Horse (now part of Toro) garden tractors have vertically-mounted engines with belt-drive, whilst Allen/Gutbrod tractors had an automotive-type clutch and gearbox. The engines are generally 1- or 2-cylinder petrol (gasoline) engine, although diesel engine models are also available, especially in Europe.

In the U.S., the term riding lawn mower today refers to mid or rear engined machines. Front-engined tractor layout machines designed primarily for cutting grass and light towing are called lawn tractors, and heavy duty lawn tractors, often shaft driven, are garden tractors. The primary difference between a lawn tractor and a garden tractor are the frame weight, the rear wheels (garden tractors almost always have multiple mounting bolts, while most lawn tractors have a single bolt or clip on the hub.), and the ability to use ground engaging equipment such as plows or disk-harrows. Craftsman, MTD, Snapper and other major mowing equipment manufacturers use these terms.

As well as dedicated manufacturers, many makers of agricultural tractors have made (or continue to make) ranges of garden tractors, such as Case, Massey-Ferguson, International Harvester and John Deere.

EPA tractor

A Ford rebuilt to an EPA tractor.
A Ford rebuilt to an EPA tractor.
A Volvo Duett rebuilt to an EPA tractor. Obviously the intended use is no longer as a farm vehicle.
A Volvo Duett rebuilt to an EPA tractor. Obviously the intended use is no longer as a farm vehicle.
An "A tractor" based on Volvo 760. Notice the slow vehicle triangle and the longer boot.
An "A tractor" based on Volvo 760. Notice the slow vehicle triangle and the longer boot.

During World War II there was a shortage of tractors in Sweden and this led to the invention of a new type of tractor called the EPA tractor (EPA was a chain of discount stores and it was often used to signify something lacking in quality). An EPA tractor was simply an automobile, truck or lorry, with the passenger space cut off behind the front seats, equipped with two gearboxes in a row. When done to an older car with a ladder frame, the result was not dissimilar to a tractor and could be used as one.

After the war it remained popular, now not as a farm vehicle, but as a way for young people without a driver's license to own something similar to a car. Since it was legally seen as a tractor it could be driven from 16 years of age and only required a tractor license. Eventually the legal loophole was closed and no new EPA tractors were allowed to be made, but the remaining were still legal, something that led to inflated prices and many protests from people that preferred EPA tractors to ordinary cars.

In March 31, 1975 a similar type of vehicle was introduced, the A tractor [from arbetstraktor (work tractor)]. The main difference is that an A tractor has a top speed of 30 km/h. This is usually done by fitting two gearboxes in a row and not using one of them. Volvo Duett was for a long time the primary choice for conversion to an EPA or A tractor, but, since supplies have dried up, other cars have been used, in most cases a Volvo.

Lifting mechanisms

There are several distinct types of aerial work platform, which all have specific features which make them more or less desirable for different applications. The key difference is in the drive mechanism which propels the working platform to the desired location. Most are powered by either hydraulics or possibly pneumatics. The different techniques also reflect in the pricing and availability of each type.

Articulated lift being demonstrated.
Articulated lift being demonstrated.

Articulated


Articulated lifts, also known as boom lifts or hydraulic platform are almost exclusively hydraulically powered, and are the closest in appearance to a crane. They consist of a number of jointed sections, which can be controlled to extend the lift in a number of different directions, which can often include 'up and over' applications.

'Spider' set up outside a building.
'Spider' set up outside a building.

This type of AWP is the most likely of the types to be known as a 'cherry picker', owing to its origins, where it was designed for use in orchards (though not just cherry orchards). It lets the picker standing in the transport basket pick fruit high in a tree with relative ease (with the jointed design ensuring minimum damage to the tree). The term 'cherry picker' has become generic, and is commonly used to describe articulated lifts (and more rarely all AWPs).

This type of AWP is now widely used for maintenance and construction of all types, including extensively in the power and telecommunications industries to service overhead lines, and in arboriculture to provide an independent work platform on difficult or dangerous trees. A specialist type of the articulated lift is the type of fire apparatus used by firefighters worldwide as a vehicle to provide high level or difficult access. These types of platforms often have additional features such as a piped water supply and water cannon to aid firefighters in their task.

Some articulated lifts are limited to only the distance accessible by the length of each boom arm, however, by the use of telescoping sections, the range can be vastly increased. Some large hydraulic platforms mounted on a lorry can reach heights of over 100 metres.

The majority of articulated lifts require a wide supportive base to operate safely, and most models have extending legs/struts to help accomplish this. These legs can be manual or hydraulic (usually depending on size and price of the machine). Some AWPS are classified as 'spiders' due to the appearance of these legs. Spiders are also available in especially compact form, to fit through doorways for use inside buildings.

Large scissor lift extended.
Large scissor lift extended.

Scissor

A scissor lift is a type of platform which can usually only move in the vertical plane. The mechanism to achieve this is the use of linked, folding supports in a criss-cross 'X' pattern. The upward motion is achieved by the application of pressure to the outside of the lowest set of supports, elongating the crossing pattern, and propelling the work platform vertically. The Platform may also have an extending 'bridge' to allow closer access to the work area (because of the inherent limits of vertical only movement).

The contraction of the scissor action can be hydraulic, pneumatic or mechanical (via a leadscrew or rack and pinion system). Depending on the power system employed on the lift, it may require no power to enter 'descent' mode, but rather a simple release of hydraulic or pneumatic pressure. This is the main reason that these methods of powering the lifts are preferred, as it allows a 'fail safe' option of returning the platform to the ground by release of a manual valve.

Mechanical

There are a number of smaller lifts which use mechanical devices such as rack and pinion or screw threads to extend. These often have juxtaposed sections which move past each other in order to create the movement, usually in a vertical direction only. This lifts usually have limited capability in terms of weight and extension, and are most often used for internal maintenance tasks such as changing lightbulbs.

Motive mechanisms

AWPs, by their nature, are designed for temporary works and therefore frequently require transportation between sites, or simply around a single site (often as part of the same job). For this reason, they are almost all designed for easy movement.

Unpowered

These usually smaller units have no motive drive and require external force to move them. Dependant on size and whether they are wheeled or otherwise supported, this may be possible by hand, or may require a vehicle for towing or transport. Small non-powered AWPs can be light enough to be transported in a pickup truck bed, and can usually be moved through a standard doorway.

Self propelled

These units are able to drive themselves (on wheels or tracks) around a site (they usually require to be transported to a site, for reasons of safety and economy). In some instances, these units will be able to move whilst the job is in progress, although this is not possible on units which require secure outriggers, and therefore most common on the scissor lift types. The power can be almost any form of standard mechanical drive system, including electric or gasoline powered, or in some cases, a hybrid (especially where it may be used both inside and outside).

Telescoping articulated platform mounted on firefighting appliance.
Telescoping articulated platform mounted on firefighting appliance.

Vehicle mounted

Some units are mounted on a vehicle, usually a truck, though other vehicles are possible, such as railway cars. This vehicle provides mobility, and may also help stabilize the unit - though outriggers are still typical, especially as vehicle-mounted AWPs are amongst the largest of their kind. The vehicle may also increase functionality by serving as mobile workshop or store.

Control

The power assisted drive (if fitted) and lift functions of an AWP are controlled by an operator, who can be situated either on the work platform itself, or at a control panel at the base of the unit. Some models are fitted with a panel at both locations or with a remote control, giving operator a choice of position. A control panel at the base can also function as a safety feature if for any reason the operator is at height and becomes unable to operate his controls. Even models not fitted with a control panel at the base are usually fitted with an emergency switch of some sort, which allows manual lowering of the lift (usually by the release of hydraulic or pneumatic pressure) in the event of an emergency or power failure.

Controls vary by model, but are frequently either buttons or a joystick. The type and complexity of these will depend on the functions the platform is able to perform. The controls can control features such as:

  • Vertical movement
  • Lateral movement
  • Rotational movement (cardinal direction)
  • Platform / basket movement – Normally, the system automatically levels the platform regardless of boom position, but some allow overrides, tilting up to 90 degrees for work in difficult locations.
  • Ground movement (in self propelled models)

Safety

Aerial work platforms in use.
Aerial work platforms in use.

The majority of manufacturers and operators have strict safety criteria for the operation of AWPs. In some countries, a licence and/or insurance may be required to operate some or all types of AWP. Most protocols advocate the giving of training to every operator, whether mandated or not. Before usage, most operators also prescribe a range of pre-usage checks on the unit itself, and manufacturers recommend regular maintenance schedules.

Most AWPs are fitted with safety or guard rails around the platform itself, in order to help contain operators and passengers. This is supplemented in most models by a restraining point, which designed to secure a harness or fall arrestor. Some work platforms may also have a lip around the floor of the platform itself to avoid tools or supplies being accidentally kicked off the platform. Some protocols require all equipment to be attached to the structure by its own lanyard.

AWPs often come equipped with a variety of tilt sensors. The most commonly activated sensor (especially with two people on a lift), will cause the machine to refuse to raise the platform beyond a certain height. Sensors within the machine detect that weight on the platform is off balance to such a point as to risk a possible tip-over if the platform is raised further. Another sensor will refuse to extend the platform if the machine is on a significant incline. Some models of AWPs may additionally feature counterweights, which extend in order to offset the danger of tipping the machine inherent in extending items like booms or bridges. Some lifts are also fitted with sensors which will prevent operation if the weight on the platform exceeds the safe working load.

As with most potentially dangerous mechanical devices, almost all AWPs are fitted with an emergency stop button or buttons for use in the event of a malfunction or potentially dangerous occurrence. Best practice indicates fitting of emergency stop buttons on the platform and at the base as a minimum. Other safety features include automatic self checking of the AWPs working parts, including a voltmeter, which detects if the lift may not have sufficient power to complete its tasks (which will result in it refusing to operate for safety).

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