New Asphalt Plant

NEW ASPHALT MANUFACTURING PLANTS

Contact ANGDAL Asphalt Solutions to discuss your Asphalt Plant requirements

ANGDAL Asphalt Solutions

There are various types of asphalt production plants available, the difference being reliant on the process. The final products are the same and must comply with the rigorous specifications of regulatory organisations.

The main types of asphalt mixing plant can be categorised as follows:

  • Asphalt Batch Plants
  • Continuous Asphalt Plants

Asphalt Batch Plants

Asphalt batch plants are the most widely in use around the world due to their practicality, versatility, and the ability of producing asphalt for a variety of specifications with ease, and compliance with regulatory specifications. The production method is based on processing ingredients in proportion into one batch, which depending on the size of the asphalt batch plant can range from 1 tonne to 5 tonnes per batch, with total output capacities ranging from 100 tonnes to over 400 tonnes per hour.

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Continuous Asphalt Plants

Continuing development to improve efficiency has led to variations in the design and operation of continuous asphalt production processes, which depending on the size of the production plant can produce asphalt mix from 100tph to over 700tph. The main continuous asphalt production processes include: Parallel Flow Drum Mix Plants; Counter Flow Drum Mix Plants; Double Drum Counter Flow Mix Plants.

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Asphalt Production Plant Components

Asphalt production plants are made up of individual component units and synchronised into the production process.

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Process control & telematics

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Power generation

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Fuel tank storage

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Aggregate cold feed systems

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Aggregate handing equipment

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Bitumen storage tanks

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Heating and transfer systems

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Additive storage and feeding equipment

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Hot Mix storage systems

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Ancillary asphalt production plant

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Spare parts & after sales service

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Bitumen emulsion production equipment

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Cutback bitumen production equipment

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Bitumen drum decanting systems

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Asphalt haulage trucks

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Weighbridge & ticketing systems

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Asphalt Raw Materials

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Bitumen

Bitumen is added to bind the aggregate materials together and to make the asphalt mix sufficiently workable for paving and compaction, and can be supplied in bulk, bitucontainers, and drums. Bitumen is supplied in many grades and specifications, and the bitumen content of the asphalt mix varies according to the grade, but typically between 4.5% and 5.5% by weight of the total mix.

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Aggregates

Crushed rock aggregate materials are supplied from quarries in various sizes to comply with project specifications.

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Additives

Various additives can be added into the asphalt mix to enhance the project specifications.

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Mineral fillers

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Polymers

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Fibres

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Rubber

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Colour pigments

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Anti-Stripping Agents

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Environment

Exhaust emissions, noise, and smell are key issues to be considered especially in urban areas. The regulatory authorities exercise very strict regulations and policies to tackle pollution and have the powers to close down an asphalt plant operation that does not comply. There is an increasing demand for using waste materials in place of aggregates in the asphalt mixing process as a method of reducing costs. Waste products include: glass, rubber tyres, plastics, etc.

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Reclaimed Asphalt Pavement (RAP)

RAP is old road pavement, which when heated returns to its natural state and can be recycled and reprocessed through an asphalt mixing plant. Asphalt plant manufacturers continue development using the latest technology to incorporate up to 100% Reclaimed Asphalt Pavement (RAP) and other suitable recyclable waste products into the asphalt mix. Increasing use and incorporation of RAP into the asphalt mix solves environmental issues and waste disposal problems, and also reduces the requirement for bitumen and aggregates.

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Asphalt Mix Variations

Asphalt production plants also have the capacity to manufacture variations of the standard asphalt mixes for use on special projects.

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Warm Mix

Warm Mix uses bitumen that is modified to remain workable at lower temperatures. Is environmentally friendly by reducing fuel consumption and emissions.

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Asphalt Cold Mix

Asphalt Cold Mix uses emulsified bitumen and or other fluxing agents as a binder in the asphalt mix.

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Foam Mix Asphalt

Foam Mix Asphalt is where additives allow steam to be injected into the bitumen allowing it to foam and create foamed bitumen for use as a lower temperature binder in the asphalt mix.

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Hydraulic Asphalt

Hydraulic Asphalt is used for waterproofing dams, canals, reservoirs, sea and coastal defences.

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Coloured Asphalt

Coloured Asphalt uses pigments and polymers to provide asphalt in a variety of colours for traffic delineation, prestige works, school playgrounds, etc.

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Quality Control

It is important that a fully equipped asphalt quality control laboratory be set up at the asphalt mixing plant together with qualified and experienced laboratory technicians with the ability test representative samples of asphalt materials at prescribed intervals to ensure that the asphalt mix produced complies with required specifications.

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Technical Services

ANGDavis Associates, our sister company, is a highway engineering consultancy specialising in asphalt pavements and operating on a world-wide basis. ANGDavis Associates is able to provide a high level of expert services to owners of new and existing asphalt production plants.

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Asphalt production plant commissioning services

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Quality assurance services

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Commissioning of quality control laboratory facilities

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Procurement of laboratory equipment

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Training of quality control staff

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Compliance investigation of materials for asphalt, bitumen, aggregates, concrete, and also structural testing

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Asphalt mix design and testing services

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Refurbishment, retrofit and up-grading of existing asphalt plants

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Trouble Shooting

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