What’s New in Asphalt Production?
BY Sandy Lender
AsphaltPro sets the standard for equipment and service information by focusing on what’s new in the industry. There are manufacturers and service providers in the asphalt industry with R&D departments that have crafted remarkable components for aggregate and asphalt production that stand the test of time. Over the years, those components require mere tweaking here and there to bring them up to date with some new code or concept from EPA. As those modifications are introduced, AsphaltPro is honored to share the information with readers, keeping everyone abreast of changes in our industry.
This product gallery focuses specifically on the branch of our industry that influences your bottom line when it comes to the production of aggregates, asphalts and mixes. This month, we asked OEMs and others to provide information related to mix production for equipment and services they launched this year. You’ve seen the old stuff. In alphabetical order, let’s take a look at what’s new in the asphalt production market place to enhance your bottom line.
From Atlas Copco Secoroc
Powerbit is the all-new range of top hammer bits for surface drilling from Atlas Copco Mining and Rock Excavation LLC, Commerce City, Colo. The series is designed for increased performance in hard to soft, abrasive to non-abrasive rock with the patented Enduro Extra surface treatment to give the bit more strength. Engineers have combined all aspects of drill-bit technology for long service life. The range features an entirely new bit shape with a harder, stronger steel bit body. Previously incorporated semi-ballistic buttons have been replaced with Atlas Copco Secoroc’s unique, trapezoid-shaped buttons—Trubbnos.
Results of 20 test series conducted at 13 sites globally, drilling more than 164,000 feet, in a variety of rock conditions, demonstrated increases in service of 20 percent or more than the market’s leading competitor bits with penetration rate increases of up to 10 percent. Product Manager of Atlas Copco Top Hammer Rock Drilling Tools Ross Gjerde said: “Our power bit testing domestically and abroad has consistently demonstrated substantial improvements in bit life when compared to our old assortment, and competitive product.”
- Use this in the quarry.
- For more information, contact Sofie Gielen at (720) 235-2325 or firstname.lastname@example.org
From CEI Enterprises
In addition to its well-known and established line of jacketed firebox hot oil heaters, CEI of Albuquerque, New Mexico, now also offers a new line of helical coil heaters. Standard helical coil modules feature two-pass design in outputs ranging from 1.2 million to 4 million BTU/hour. Larger sizes, as well as three-pass designs and vertical models are also available.
The helical coils are designed and built to ASME code. They are designed to provide a large heat transfer surface area, low flux rates, and an idea fluid velocity of 7 to 11 feet per second. ASME stamp is available as an option.
Both lines of CEI hot oil heaters feature UL-rated, NEMA 4 control panels as standard equipment. These panels provide watertight protection against splashing water, hose-directed water, rain, sleet, snow, ice, dirt and windblown dust. Panels that meet CSA specifications, and other NEMA standard enclosures are available optionally.
An extensive number of options for enhanced fuel efficiency and multiple thermal oil circuits are available for both lines of CEI hot oil heaters.
- Use this at the tank farm.
- For additional information, contact CEI at (800) 545-4034.
From CWMF Corp
The Portable Longneck Recycle System from CWMF Corp originally rolled out in 2009, but it’s been updated in 2016 with a custom, two-bin set-up headed to a client in June. The portable longneck recycle system directly feeds RAP into the recycle collar of the drum. It is available in single-bin set-up or a tandem bin set-up. A standard system would include a scalping screen and scale conveyor. It consolidates the typical recycle bin and scale conveyor set-up into one chassis. In addition, CWMF is able to incorporate a hammer mill system that will grind the oversized product coming off the screen. Quicker plant tear-down, quick set-up and less transportable loads are part of the design.
- Use this for RAP mixes.
- For more information, contact Travis Mick at (320) 267-3805 or email@example.com.
From D&H Equipment
D&H Equipment, Blanco, Texas, released its Heat Guardian tank and heater monitoring solution to the marketplace at the end of June. It was designed for owners, managers and operators to remotely monitor their hot oil heating systems and tanks. It provides real-time data to the user by text, web-based monitoring, as well as the full color touchscreen panel display, and includes the capability to send configurable text alerts based on user input variables.
Each Heat Guardian monitors events including power loss, a hot oil heater’s flame fault and oil temperature, and up to three tanks’ temperatures and levels. Receiving an alarm or getting the current system status is as easy as sending a text, according to the manufacturer. A built-in battery backup will allow the unit to alarm you even in the event of total power loss at the plant.
Features of the Heat Guardian include:
- Instant text notification to two numbers for power loss, heater flame failure or faults, high and low level alarms for tanks, and high and low temperature alarms for heater and tanks;
- Operations monitoring via text, web browser or Heat Guardian’s touchscreen panel;
- Interfaces with existing RTDs, thermocouples and analog inputs without having to replace installed sensors;
- Adjustable alarm setpoints for levels and temperatures; and
- Ability to reset burner via text.
- Use this to monitor your tank farm.
- For more information, contact Jason Cox at (830) 833-5366 or firstname.lastname@example.org.
From Eagle Crusher Company
UltraTraxx™, Eagle Crusher Company’s latest product innovation, came on the market May 2016. This portable impactor track unit, equipped with the company’s UltraMax® UM-15 impactor, is designed for ultra-mobile crushing on the job site.
To keep producers up and crushing, UltraTraxx has fuel capacity for more than 10 hours of operation. The UM-15 impactor provides the industry’s only lifetime rotor warranty (North America only) on its solid-steel, three-bar, sculptured rotor for minimum downtown. The load-sensing hydraulics improve fuel efficiency and reduce component wear for lower operating costs and minimum downtime as well, according to the manufacturer.
Helping producers achieve their highest production rates, the UltraTraxx all-hydraulic, hydrostatic-drive system allows independent operation of the conveyors, feeders and impactor. Material processing efficiency is maximized by the UltraTraxx smart feeder drive system by monitoring engine load for more efficient production and product consistency.
Further enhancing production rates, the UltraTraxx dual-motor, under-crusher pan feeder, with discharge clearance of more than 20 inches, provides greater material flow and maximizes uptime by virtually eliminating clogging, according to the manufacturer.
UltraTraxx high torque drives ensure superior tramming and gradability, enabling the unit to track while crushing, so operators can continue stockpiling and also maximize production. Uptime is maximized with the UltraTraxx on board hydraulic cooling fan that reverses to minimize heat exchanger clogs.
Thoughtfully designed maintenance features also help provide maximum uptime and include the easily removable discharge conveyor for quick access to the under-crusher area for inspection, maintenance, and cleaning. With the discharge conveyor removed, operators can also quickly inspect and maintain the conveyor. The discharge conveyor is fitted with one of the plant’s easy-access grease banks for lubricating the head and tail pulley bearings, and the conveyor folds for transport or to remain out of the way for more compact storage when not in use.
To help ensure the highest quality spec product, UltraTraxx is equipped with a permanent, cross-belt magnet to remove steel contaminants from crushed material. The magnet is reversible to allow steel to discharge from either side of the unit, and the magnet does not need to be removed for transport.
The UltraTraxx heavy-duty hopper is sized for feeding with a loader or excavator, and the unit has a discharge conveyor height of 12 feet 5 inches for feeding directly into an optional screener.
The UltraTraxx includes a wireless remote control to operate and monitor plant functions including filter status, hydraulic oil temperature, engine load and charge pump pressure. The control can be tethered to the unit for operation if the remote battery loses its charge. Typically, a charge will last 8 to 10 hours, or operators may change the battery when filling the fuel tank. Remote monitoring of crusher production performance, engine loading, temperature, and location is also available. These may be monitored via wireless service to a smart phone or computer.
- Use this to crush material.
- For more information, contact Eagle at (800) 253-2453 or email@example.com.
From Fairbanks Scales
Fairbanks Scales Inc., Kansas City, Mo., now offers its Talon series highway vehicle scales with Intalogix® technology. The Talon is offered in two capacities to meet unique application requirements. The Talon HV design is dependable for most applications, according to the manufacturer. The Talon HVX is designed to withstand duty-cycles of extreme volume weighing applications.
The Talon is offered with either a steel deck or field-poured concrete—built to federal bridge standards. Talon scales have a solid deck design to resist deflection and metal fatigue. The open bottom design creates a natural ventilation system. Armored stainless steel load cell cabling is provided for durability. The Talon also has hermetically sealed load cells for protection from moisture as well as encapsulated circuit boards.
Fairbanks’ innovative Intalogix digital load cell technology is a standard feature of all Talon scales now. Intalogix works by converting a weak analog load cell signal to a stronger digital interface. Intalogix technology is designed to ensure consistent performance.
The Talon product line is available for application in permanent above-ground foundations or shallow pit applications.
- Use this at loadout.
- For more information, contact Fairbanks at (800) 451-4107 or visit fairbanks.com.
Heatec says that managers of asphalt facilities in the United States and Canada are showing a remarkable response to the Recon™ monitor system that the company introduced in late 2015. Recon units are now in operation at 23 facilities and being installed at 9 others. Heatec is working through a significant backlog of orders for additional units at press time.
The Recon system enables plant personnel to remotely monitor the live status of asphalt heaters and asphalt storage tanks at their HMA plants. Operators use this information to avoid unwanted shutdowns due to heating problems. And they keep close watch on asphalt use and inventories to better plan tank refills.
The Recon monitor shows heater alarm status, hot oil temperatures, asphalt tank temperatures, tank liquid levels and tank mixer on-off state. Operators can use a smartphone, tablet or PC to access the system.
Chris Cook, Plant Superintendent at King Asphalt, Pacolet, South Carolina, says he really likes the remote access that his Recon system provides. He uses his iPhone to keep close watch on tank levels and temperatures at their facility. And he looks forward to finding ways to use the historical data that the system records.
- Use this at the tank farm.
- For more information, contact Heatec at (423) 821-5200.
From Larson Electronics
Larson Electronics, an industrial lighting company, has experienced expansion into the film entertainment industry with their latest debut in USA Network’s television series “Falling Water.” Larson Electronics’ line of industrial grade, explosion proof lights and heavy duty spotlights continue to be a popular choice in cinematic productions with appearances in several big screen movies including Total Recall, Max Payne, Robocop and The Incredible Hulk. In the process of filming the season premiere of USA Network’s new series “Falling Water,” producers have chosen the EPL-48-2L to be featured in the new dreamscape thriller.
The EPL-48-2L is an explosion proof fluorescent light fixture that is Class 1 Division 1 approved, carries a T6 temperature rating, and ideal for locations where flammable chemical or petrochemicals exist. The lamps in this unit are protected by heat and impact resistant Pyrex tubes and the fixture is constructed of copper free aluminum alloy. The lamp reflectors are corrosion resistant heavy gauge aluminum and coated with a high gloss reflective finish. This fixture is surface mounted with two adjustable brackets and can be pendant mounted as well. This fixture is multi-voltage capable and can operate on any voltage ranging from 120 to 277 volts AC.
- Use this in your work area.
- For more information, contact Larson at (800) 369-6671 or larsonelectronics.com.
From Meeker Equipment
Meeker Equipment announced it recently shipped a 500 TPH drag conveyor to Virginia. The conveyor features a 50-inch deep cambered main frame, 1-inch thick Ni-Hard floor and wall liners solidly cast. The reject chute opens 100 percent, allowing for complete drop out of rejected material. All sprockets on the conveyor, including idler sprockets, are segmented for easy maintenance. As standard, the conveyor comes with chain tensioning indicator to notify operators that it is time to tighten chain. All chain adjustments are done on the top side of the conveyor with hydraulic pump. Chain adjustments on the bottom allow the point of entry of the asphalt to the drag conveyor to change causing wear. Meeker conveyors feature 6-inch pitch chain with ¾- x 8-inch tall slats. Conveyors are available in hot oil heat (all the way to the top) and electric heat.
- Use this for asphalt production.
- For more information, contact Jeff Meeker at (717) 667-6000.
To help customers capitalize on growing opportunities in recycling markets, Rotochopper has launched a new line of industrial slow-speed shredders. The track-mounted diesel TS-2 made its debut at Expo Richmond in Richmond, Virginia. The TS-2 is an aggressive dual-shaft shredder designed to pre-process stumps, commingled C&D, railroad ties, and other forms of mixed or contaminated waste.
Boasting simplified operation, streamlined maintenance and rugged reliability, the TS-2 features an open shredding table, allowing dirt, stones and other abrasives to pass. Paired with easily accessible routine maintenance areas, the TS-2 avoids the complicated upkeep often associated with slow speed shredders.
In addition, Rotochopper and Key Knife have launched the Key Knife Chipper knife package, which allows horizontal grinder owners to chip and grind with a single machine. The chipper knife package is a bolt-in option that works with the same patented replaceable mount rotor for the Rotochopper B-66 and B-66 E. This chipper knife system makes it simple to diversify into chipping applications without a complex conversion kit or a second machine.
To switch from grinding to chipping, the operator does not need to swap the whole rotor drum or assemble a complex overlay onto the grinding rotor. Instead, he swaps the grinder tooth mounts with chipper knife mounts.
This system uses patented Key Knife® technology to minimize knife replacement costs. Key Knife shipping inserts are indexable (reversible). By loosening the knife clamp bolts, the operator can flip the knife to use a second chipping edge.
- Use this for recycling.
- For more information, contact Monte Hight at (320) 548-3586.
From Stansteel/Hotmix Parts
Hotmix Parts & Service®/Stansteel® introduces the Accu-Add™ precise pump and metering systems. Designed, built and installed for use with over 18 different types of liquids including rejuvenators, anti-strips, Evotherm™, polymers, latexes and more. The applications include delivery of the liquid, proper metering, interlocking and calibrating, for achieving the goal of better and more cost-effective mixes. The Accu-Add is designed for use with any RAP or RAS process.
- Use this for blending mixes.
- For more information, contact Rick Rees at (502) 245-1977.
From Stockpile Reports
Stockpile Reports, an inventory management system companies use to measure volume and tonnage of materials via drone, plane and iPhone-based measurement tools, released its new Verified Measurements feature June 13, 2016.
Stockpile Reports’ Verified Measurement feature gives a confidence score to each one of the stockpile measurements at construction and aggregate producer sites. When stockpiles are measured, there can be all kinds of measurement risks. Vegetation growing on the pile, standing water, equipment obstructions and more, all can cause big errors in a company’s inventory numbers. The Stockpile Reports system automatically highlights those risks, so companies can always have the insights they need to know whether to have crews do some pile cleanup and re-measure. Companies can almost eliminate write-offs and costly budget overruns.
- Use this for product management.
- For more information, contact Maury Margol at (425) 285-4303 or firstname.lastname@example.org.
From Systems Equipment
SYSTEMS Equipment has announced the release of the 1292 Material Temperature Capture at Time of Load, the newest companion product to the company’s Windows-based loadout system, the WIN-LC3000. Product conception was spurred by feedback from both producers and end-users in the asphalt industry with a common objective—to have an efficient way of measuring and documenting the temperature quality of hot mix being used for any given job.
The 1292 assembly consists of a PLC and two modules to be mounted in the control center (with an optional enclosure), as well as a probe and housing assembly that is mounted to each loadout silo (or drum, if used with the blend system).
Asphalt plants employing this technology have the unique position of being able to measure and document asphalt temperatures at time of load, as well as adjust temperatures with better precision for ongoing production based on feedback from pavers applying the product. This quality assurance discipline provides accountability throughout the asphalt “chain” for any given job. Some state- and federally-funded projects also require this temperature measurement to ensure that the asphalt mix meets code-specific requirements.
The 1292 includes a single infrared probe protected by an enclosure measuring approximately 4.5 inches high by 3 inches wide by 3 inches deep. One probe per silo is required. When used in tandem with the loadout system, the active end of the probe is mounted to the loadout silo frame and directed toward the truck bed. A small air valve incorporated into the enclosure prevents debris from attaching itself to the end of the probe and skewing the reading. As loading proceeds, the probe measures the temperature of the newly loaded asphalt mix. The temperature reading is both stored in the loadout database and printed on the driver’s loadout ticket.
The 1292 assembly can also work cooperatively with the blend system, capturing material temperature as the asphalt mix exits the drum. Due to the thick metal housing on traditional temperature measurement units, getting an accurate reading takes time as the heat must work its way through the housing and to the probe. “With the 1292 assembly, the reading is almost instantaneous,” Fred Axmear, software engineer at SYSTEMS Equipment Corporation, said. “This is particularly helpful with small batches, and also improves reaction time when temperatures need to be adjusted because feedback is both quick and accurate.”
He added, “By installing the 1292, operators now have a much greater level of control over the quality of their hot mix. Having the ability to document mix temperatures at time of load also gives them an added level of assurance and documentation for jobs with higher requirement levels, such as federal highway projects. Their bases are covered.”
- Use this at loadout.
- For more information, contact Systems Equipment at (563) 568-6387 or email email@example.com.