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Asphalt Batch Mix Plant At Best Price In India

What is Asphalt mixing?

It would be interesting to observe the response when you approach a lay-person who has nothing to do with the technology we discuss here and ask if he/she knows what the word ‘asphalt’ means. This is because, actually he/she already knows it; just that they know it by their other name. Asphalt, also known as ‘Bitumen’ in the engineers’ and builders’ circles, iscommonlyalso known as ‘Tar’ or ‘Damar’ in colloquial language. Tell them this and you may receive a smile. Asphalt is the key ingredient, along with construction aggregates for preparing a mixture that is used to lay out, repair, and even resurface roads, parking lots, land-fills, race-tracks, etc. It is prepared by adding it, at standard temperature and in an accurate proportion, to a heated mixture comprising construction aggregates, sand, and stone dust, each of which have to be present in an appropriate proportion too. Asphalt has to be fresh and hot while laying it on the road. The ambient and the pavement surface temperature at the site are also taken into consideration by the contractors working on this. Therefore, asphalts are prepared on sites in ‘mixing’ plants. The final material is also referred to as Hot Mix Asphalt (HMA).

Types of Asphalt Mix Plant

There are two primary types of Asphalt Mix Plants– the Asphalt Batch Mix Plants and the Asphalt Drum Mix Plants. The choice between the two would be made by the construction company depending on the specific requirement of the site they are working on or upon the construction management plan they adopt.

While Batch Mix plants are used when it is desired to finish the work in different parts or batches and allowing to work in small components, the Asphalt Drum Mix plants are used where the pavement construction is desired to be finished in a continuous process. In fact, Asphalt Batch Mix plants are also preferred by construction companies who work with different recipes of asphalt on the site and these Batch Mix plants can flexibly switch from one recipe to another and even back to the first one on the same site.

Asphalt Batch Mix Plants – The Technical Components

It surely helps knowing the machinery you are working with in and out. Here, we tell give you a basic understandingof the typical Asphalt Batch Mix plant in terms of its components and the primary functional processes that are undertaken through each of these components.

A typical Batch Mix Plant comprises of the following components for processing the asphalt before pouring it at the construction site:

  • Feeder Bins, through which construction aggregates are fed into the plant
  • Conveyor, to transfer the cold aggregates from the Feeder Bin to the Dryer Drum
  • The Drying Drum with a burner, where the aggregates are heated
  • Elevator, for feeding the hot aggregates to the vibrating screen after drying
  • Vibrating screens, to separate the hot aggregates into different compartment as per the sizes
  • Hot bins to hold the hot aggregates before weighing
  • Filler storage and weighing system
  • Bitumen storage and weighing system
  • Aggregate weighing system
  • Pug mill mixing unit, where the materials are mixed in the plastic state
  • Dry dust collector, to remove off the dry particles from the asphalt paste
  • Bag filter, also sometimes called ‘bag houses’ that collect away the dust particles exhausted from the batch-mix plant
  • Control system, by which various processes are controlled

Asphalt Batch Mix Plant – its processing

Whatever the choice of the plant is, the primary processes that go into preparation of asphalt for your construction site will include: drying and heating the aggregates; getting the specific proportions of the aggregates, asphalt and binding material for the mixture right, and mixing them; and finally pouring the readied hot-mixed asphalt at the site.

Let us see this process in detail and from technical perspective. The first step includes introducing the aggregates into the plants through the feeder bins. Aggregates of different sizes such as 10mm, 20mm and 40mm sizes are introduced into the plant through separate feeder bins. It is highly recommended that these feeder bins are kept filled at all times since yourAsphalt Batch Mix plant will require an uninterrupted flow for a smooth operation. At this stage the aggregates are often referred to as ‘cold’ aggregates; also because they might be wet from wash.

Conveyor belts transport these aggregates from each of the feeder bins at controlled speeds thereby controlling the amounts of each of these aggregates introduced in the plant for a later mixing. Since the speeds of these conveyor belts for each of the bins of different aggregate-sizes vary, you will observe that your feeder-bins start getting empty at different speeds and time. These conveyor belts send the aggregatesto drying drums where the aggregates are heated to a specifically desired temperature thereby removing any moisture content present in them. Heating is done by a burner to which a desired fuel source (diesel, coal, natural gas, etc.) are provided. At this stage, it is important for the plant operator to check for the moisture content and also temperature control. The drying drum keeps in a rotating motion during the heating process, due to which the aggregates of different sizes that we introduced in the plantget all mixed up.

To separate the aggregates once again for measuring (i.e. weighing) they are sent to vibrating screens through the elevators. The primary function of the vibrating screens is to separate the aggregates according to their differing sizes, which is achieved through screens / meshes of different sieve sizes placed on top of each other, with the smallest sieve being for sand particles. It is highly recommended that the sieves are maintained well and not torn out. The separated aggregates are sent into different storage compartmentscalled hot binsfor different sizes, after which they are weighed in the aggregate weighing system before being sent to the pug mill mixing unit. The latter is where all the constituent materials for preparing HMA are mixed.

Before asphalt is mixed in the mixing unit section, it is introduced in the Asphalt Batch Mix plant in separate cylinders/tanks, is heated, and weighed to ensure a specific quantity of heated asphalt is introduced in the mixing unit. Similarly, the binding filler material is introduced into the Asphalt Batch Mix plant through separate tanks and into the mixing unit in accurate quantity. The aggregates, asphalt, and the binding material are all mixed in the mixing unit for specific time duration to achieve the right consistency of the HMA, and once this is done, it is ready to be lain on the surface for pavement.

You need a plant of standard quality

In the construction business, getting work accomplished on time determines your profitability and your brand image and that, as we all know, ultimately boils down to the quality of the machinery you work with. FABHIND can provide you the Asphalt Batch Mix plant you are looking for.

FABHIND is India’s leading road construction machinery manufacturer and supplier since 1991. We have been producing high quality asphalt plants for our customers in India as well as internationally. We have an expertise that is built on an extensive experience in the sector over these years and through continuous striving at providing our customers high quality products and focus on our costumers’ needs. All our machinery is designed, engineered and manufactured with the latest technology for a top-notch performance, trouble-free and smooth functioning, enhanced fuel efficiency for an improved productivity for the customer.

Our FAB series plants provide an outstanding guarantee that there will be: huge power savings, highest fuel-efficiency that we achieve by providing an auto-modulating burner, reliable and field-proven performance with an efficient counter-flow drier drum, technology for 3-D mixing, pollution control system complying with international standards, lower maintenance costs, a user-friendly SCADA system, fully-computerized automatic process controls and much more. Additionally, with any of our products we provide our customers an unmatchable and unbeatable after-sales customer service and spares support wherever you are anywhere across the globe.

FABHIND supplies Asphalt Batch Mix plants in different sizes and configurations from its FAB series that comprises plants with rated capacities ranging from 80-200 tonnes per hour (TPH).