World news: Half warm mix asphalt plant with emulsion

 FABREMASA society has to be at the forefront of new technologies with the launch of a world premiere: the assembly of hardened asphalt.

aBased on its extensive experience in the industry, Antonio Alvarez society established in 1990 FABREMASA, S. L, dedicated to the manufacture of construction machinery, mining and civil works. The Madrid company’s offering covers the study, design, manufacture, installation, commissioning and after sales teams that incorporate advanced technologies. Account for this, with an excellent team, a technology developed by investing heavily in R + D + i and personalized attention for each project. With these assumptions, FABREMASA now has a wide range of products, which has just joined a revolutionary tempered particle board plant, developed from a floor installation of cold cement and plywood, which is coupled a group Ammann. As a result we have obtained a product that respects the environment (70% less CO2 emissions in heating aggregates and reuse 100% of the milled material), which provides significant energy savings (consumption reduction fuel up to 75%) and is characterized by its mobility and easy installation (only needed one and a half for full installation). When produced in the work itself or nearest quarry also reduce transport costs, while ensuring less lost in the mix temperature during transport. With its flexible pavements are obtained using high-performance and durability that enhance the mixing cold and hot.

Highly specialized equipment

bFor the development of this innovative concept has been taken into account three aspects: respect for the environment, investment in R + D + i, and energy consumption. With them has gone to work a team of government and universities, Repsol, Research Center Elpidio Sanchez Marcos (CIESM), Elsamex International, under the tutelage of Fabremasa. The results of this study are described in the following article.

Types of asphalt

Asphalt mixtures are composed of aggregates of different sizes, which is given cohesion by using a hydrocarbon binder, usually bitumen, for hot mix, or an emulsion in water, cold mixes. Sometimes by other components, such as fibers, rubbers, polymers, etc.. The origin of these components, their characteristics and the extent to which we will define mix different types of mixtures to be used, as shown in Table I.

Table I. end-product

Cold mix

Hot mix

Temperate mixed

Design Method

Cántabro

Marshall/Cántabro

Marshall/Cántabro

Vehicle to get the polish adhere to the aggregates and put them into work

Water

Temperature

Water/Temperature

Fabrication

Aggregates
Emulsion
Room temperature

Aggregates
Bitumen
Heating
at 180 ºC

Aggregates
Emulsion
Temperature
65 ºC – 130 ºC

Commissioning Work

Pavers
Tandem compactor
Pneumatic compactor

Pavers
Tandem compactor
Pneumatic compactor

Pavers
Tandem compactor
Pneumatic compactor

Producto final

Aggregate + bitumen

Aggregate + bitumen

Aggregate + bitumen

Methods of making asphalt

Table II shows the different methods for the manufacture of asphalt, whether cold, warm or hot, depending on whether the plant is of continuous type, batch or production control.

Table II. Methods of making asphalt
Cold Mix Hot Mix Temperate Mixed
Discontinuous X X (*) X
Continuous X (*) X (*) X
Controlled manufacturing X X X (*)
(*) Below are the most common stages of manufacture of mixtures.

To analyze the behavior of asphalt mixtures have been studied temperate volumetric parameters (density and empty) and the mechanical parameters (stiffness and permanent deformation-wheel tracking and cyclic compression test).

In search of environmental benefits

cTAll production activities must contribute to environmental protection. Particularly, the road is a priority focus, because they have to optimize the energy consumption of their products. In Spain, producing more than 45 million tons of asphalt at high temperature. So far the paving systems have been governed primarily by two criteria, economic and technical, and from now on the environment will be the third factor to be considered to make the right decision. The hot bituminous mixtures heat materials need between 150 and 180 ° C, which implies strong fuel consumption. Of the gases emitted by the dryer aggregates, corresponding to 7% CO2. Making a MAT to reduce these emissions by up to 70%. The purpose of the warm mix asphalt is to get an improvement over the conventional HMA, in terms of the reduction of energy consumption in manufacturing and harmful emissions into the atmosphere during the manufacturing and commissioning work.

MAT + Project

dThe name comes from MAT stands for Temperate Asphalt Mix, involving the manufacturing of all components Fabremasa plant. The name Plus (+) gives it its versatility, since it also can be made cold mix asphalt, gravel emulsions; recycled cold floor emulsion cement gravel, soil cement and concrete. The plant designed by FABREMASA, S. L. is based on an adaptation of a manufacturing plant for cold mixes, drum-dryer interspersed between cold hoppers and mixer. The manufacturing system provides continuous monitoring of heavy, temperature and humidity in different parts of manufacturing, allowing comprehensive control of the mixture and the proportions of its components. It also incorporates a tape parallel to the drum-dryer to heat different fractions of aggregates.

Why MAT?
MAT Project has been operating in the performance of milling on the Atlantic Highway A-9, in the execution of the road to Porroy Morata de Jalon, by the Deputation of Zaragoza, and the performance of semi-closed mixed temperate in the province of Murcia, heating aggregates between 110 and 130 ° C. Once tested in the field can be said that among the competitive advantages they bring warm asphalt mixtures included the following:

  • Environmental technology: Reduces up to 75% CO2 emissions in the heating of aggregates
  • Simplicity, portability and economy of manufacture and commissioning work.
  • Some mixtures temperate allow storage.
  • Reuse of 100% milled plant.
  • It works at lower temperatures in a hot recycling.
  • Facing the cold recycling improves the control of the final mixture to be made ??central.
  • No mixing required a period of “maturation” thanks to the elimination of most of the water during the manufacturing process

For other mixtures are also reasons that make them preferable:

Advantages over conventional cold mixes:

  • Improvement of workability.
  • Open to traffic without topdressing.
  • Having faster curing of the water evaporated during heating.

Advantages compared to hot mix:

  • Reduced fuel consumption of around 75%.
  • No smoking in the work setting.
  • Mixtures of high quality flexible.
  • Very useful in bad road base.
  • Ability to gather in the summer.
  • Saving on transport to the work to be placed in the quarry closest to them.
  • Greater mobility. Assembly plant in one day.
  • Less heat loss in the mixtures during transport (lower thermal gradient, improves the homogeneity of the mixture).
  • Execution of microsurfacing flexible, without the disadvantage of rapid cooling.
  • Aspects of durability: Reduction transformation (stiffening) of the binder during the stages of processing, transportation and placement.

One drawback worth mentioning that the production of mixtures increases considerably temperate closed emulsion costs per ton of mix, but can be reduced with the advantages of reduced transport, depending on the situation of the work.

Commissioning

The system in place for the signature of General Studies and Projects, S. L. includes the following elements:

  • Screening
  • Filling and calibration cold hoppers
  • Adjusting the grading curve in cold
  • Weighing Control
  • Heating of aggregates from 65 to 130 ° C
  • Recovery of filler
  • Verification of temperature, humidity control and checking the weight after heating in the drum-dryer
  • Setting the grain size of the aggregates in temperate
  • Elevation of the aggregate to the mixer
  • A mixture of aggregate, emulsion and filler filler and / or recovery
  • Download

The great advantage of the plant is its high mobility, which can be mounted on a day which is made up of four mobile platforms, which houses the various elements of it.

Conclusions

eThe asphalt templadasconstituyen an evolution of the cold mix and hot mix. This mix of high quality, highly flexible and very friendly to the environment (70% less CO2 emissions during the manufacturing process and ability to reduce transports to start work). Additionally, the fact is emissions to almost zero the MAT occupational hazards during commissioning work. As a postscript, have greater durability, by annulling the oxidation of bitumen. Efforts in R + D + i allow the normalization of and their application in any road sign. But the work does not end here. The objects for working Fabremasa technical team, in collaboration with governments, universities and private companies spend to achieve the normalization of MAT, as well as becoming an international reference on its use. Today, the MAT are mixtures usable up to T2. There are semi-closed mixed experiences for T1 and hope to get to R & D at some applications of a T0. Also, looking for ways to achieve greater respect for the environment. Other lines of research on work already Fabremasa focus on the execution of gravel-emulsions Construction Solid Waste (CDW) and semi-closed mixed run for road, 100% recycled solid layers using techniques temperate mixtures steel execution temperate and execution of gravel-cement RCDS.

Acknowledgements

FABREMASA team is grateful for the trust placed by the Research Center Elpidio Sanchez Marcos (CIESM), for their valuable contribution to the Project and the General Company for Studies and Projects, as the first customer who has relied on this product and as importers Emsa the firm Ammann, a manufacturer of trommel dryer and filters. The manufacturing plant of warm asphalt mixes will be sold exclusively for the entire national territory by the firm EMSA.

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