1. technology and computing

Astec’s International Logistics department
serves a global market
Earthwork contractor expands operations
with high-tech asphalt plant
Latin American paving company utilizes
Roadtec’s MTV for better roads
Portable Astec plant benefits one of the
largest highways in France
YOUR DEPENDABLE SOURCE FOR NEWS ABOUT HMA TECHNOLOGY
PUBLISHED BY ASTEC INDUSTRIES, INC.
VOLUME 19 NUMBER 2 - 2014
ASTEC
USED
EQUIPMENT
14
26
VOLUME 19 NUMBER 2
Copyright © 2014
Hot-Mix Magazine is published by
the family of companies known
as Astec Industries, Inc.
Our mission is to provide members
of the HMA industry with up-to-date
news about HMA and WMA
technology and the recent advances
in the industry.
30
36
Editorial Staff
Editor:
Donna Campbell
Staff Writer:
J. Campbell
Staff Photographers:
Paul Shelton (Astec)
Brandon Meredith (Astec)
Scott Lee (Roadtec)
Sam Anselmi (Astec)
Subscription Services:
Diane Hunt
Directors of Advertising:
Paul Shelton (Astec)
Frank Eley (Heatec)
Eric Baker (Roadtec)
Editorial Board:
Malcolm Swanson
Steve Claude
Tom Baugh
Raji ElMawla
Andy Guth
Contact Information
If you would like to be added
to our free subscription list,
just call, fax, or write:
Hot-Mix Magazine
c/o Astec
P.O. Box 72787
Chattanooga, TN 37407
Phone: 423.867.4210
Fax: 423.867.3570
Website: www.astecinc.com
www.hotmixmag.com
5 Point of View
26 Century Asphalt Terminal
6 The Greenest Plant in Maine
28 Learning by Experience
Heatec’s design delivers loadout structures and automation
Malcom Swanson, president of Astec, Inc.
Earthwork contractor expands operations with high-tech plant
Asphalt producer explains the challenges of shingles
10 From Ship to Shore and Right Next Door 30 The Colors of Asphalt
Astec’s International Logistics department serves a global market
Paving company uses Roadtec’s MTV and infrared camera
Asphalt shingle recycler expands business with Peterson grinders
Swanson concludes his comments on WMA
12 Exceeding the RAS Standard
14 Highway A63 Takes Shape
Portable Astec plant benefits one of the largest highways in France
16 Astec Schools Preview
Registration opens October 1 for January 2015 classes
32 Clearing the WMA Smoke
36 Mega-Mountain Roadway Challenge
Colombian highway contractor tackles country’s first four-lane road
40 Tackling the M10 Reconstruction
Russian contractor uses Astec Portable Double Barrel® plant
18 RPM: Ratio Percentage Manager
41 Trade Show Spotlight
20 Paver Performance Delivers
43 Hot-Mix News
Astec Industries’ new data management tool
Roadtec RP-190e helps contractor achieve maximum smoothness
22 Built to Burn
Astec burners offer the latest in technology
Astec Industries exhibits at ConExpo to record attendance
What’s happening at Astec Industries
46 On the Front Lines
Astec’s Greg Painter wears many hats while assisting customers
ON THE FRONT COVER
Located in Gorham, Maine, Shaw Brothers operates a 400 TPH (362 MTPH) 8 ft x 40 ft (2.44
m x 12.19 m) Astec Double Barrel® plant, one of the largest asphalt plants in New England.
The plant features Astec’s patented warm mix system to take advantage of recycled asphalt
pavement (RAP) and includes the V-Pack™ Stack Temperature Control System.
Subscribe to Hot-Mix Magazine absolutely free!
To have your name added to our mailing list at no charge, just call 423.867.4210
and ask for Diane Hunt, or you can email your request to [email protected].
HOT-MIX MAGAZINE
3 VOLUME 19 NUMBER 2
Innovative Solutions
Peterson offers full service solutions
to your Asphalt Shingle Grinding operations-- from high volume horizontal
grinders, to screens and stacking conveyors.
Terra Select T6 Trommel Screen; Exclusively distributed
by Peterson
Get the right sized product, sort it out,
and stack it higher with Peterson!
Visit us a www.petersoncorp.com today
and see why Peterson is the industry
leader for disc and drum chippers, horizontal grinders, blower trucks, screens
and stacking conveyors.
Peterson GT3660 Tracked
Stacking Conveyor
800-269-6520 • www.petersoncorp.com
PO BOX 40490 • Eugene, OR 97404
Let us know how we can help you
grow your business!
POINT OF VIEW
Clearing the smoke on wma
Words from Malcolm Swanson, P.E.
President, Astec, Inc.
Warm-mix asphalt (WMA) is one of the most
beneficial improvements among paving
technologies in the last several decades. It is
often thought of as a recent innovation, because
its widespread application in the United States
has occurred since year 2000. However, it was
being used in Europe and had seen certain
applications in North America at earlier dates.
At this point, there is a considerable volume of
experience with WMA.
temperatures are sometimes used for other
reasons, such as with certain special mix
types, but are rarely necessary to accomplish
proper drying. High drying temperatures can
be used to overcome dryer deficiencies, but
good dryers in proper condition can do an
excellent job of drying almost any aggregate at
temperatures substantially below 300 degrees F
(149 degrees C).
Residual moisture is always internal (inside
individual aggregate stones) and is typically
My purpose in this writing is to offer some
Malcolm Swanson, P.E.
only found with porous aggregates. But most
clarification concerning erroneous information
President, Astec, Inc.
dryers today are capable of effectively removing
presented in the Portland Cement Association
internal moisture at temperatures in the range
(PCA) report “PCA Marketing Intelligence Report
of 250 degrees F (121 degrees C) and even lower in many
Concerning Warm-Mix Asphalt Potential.” I will address only that
cases. It is more a matter of how the stone is handled in the
about which I possess applicable information, some of which
dryer than of final temperature. Internal lifters (flights) should
may be later or more detailed than that used for the PCA report.
lift all the aggregate material
These topics will include
and provide good exposure
incomplete drying, moisture
of aggregate to hot burner
sensitivity, the need to add
gases inside the rotary dryer.
RAP to provide necessary
Worn or incorrectly designed
stiffness to the mix, and the
flights can cause incomplete
cost benefits of WMA.
drying by failing to sufficiently
Warm-mix technology does
expose all of the aggregate.
not result in incomplete
But then I would question
drying of aggregate.
whether a worn or incorrectly designed concrete plant makes
An important point of the referenced PCA report is that the
the same quality of concrete, as does one in proper operating
making of WMA causes incomplete drying of the aggregate,
status. It is basic to all industry to operate good equipment that
which results in pavement quality problems. The author of
is in proper condition.
the PCA report further states that hot-mix asphalt (HMA) is
I have seen lime and other additives used to address moisture
normally made upward of 340 degrees F (171 degrees C) to
sensitivity concerns, but the truth is that certain aggregate types
assure complete drying of the aggregate. The author correctly
and certain climatic conditions impact that decision. Those
states that additives, such as hydrated lime, may be required to
states where such conditions are common already require
enable good bonding of the asphalt to the stone when moisture
additives as a basic part of their DOT specifications even with
susceptibility is a problem.
HMA. So, that cost is not associated with whether the mix is
I have been in the industry since 1989, long before WMA use
HMA or WMA. There are few cases where an additive is required
became widespread. For several years, I was in a handsjust because of a change to warm mix. So, it is not correct to
on position working frequently at HMA plants in the field
indiscriminately decrease the anticipated savings associated
all over the country and world, as well as designing them. I
with WMA based on an assumption that an additive will be
have seen mix made at 340 degrees F (171 degrees C), but
required. Even in those cases where an anti-stripping additive
that is definitely not the norm. The typical HMA production
is used in WMA where it is not used in the corresponding HMA
temperature is 300 degrees F (149 degrees C). Unless a dryer
that does not change fuel consumption.
is experiencing some malfunction, that temperature is more
than sufficient to accomplish the necessary drying. Higher
…continued on page 32
“Warm mix asphalt (WMA) is one of
the most beneficial improvements
among paving technologies in the
last several decades.”
HOT-MIX MAGAZINE
5 VOLUME 19 NUMBER 2
The Greenest
Plant in Maine
Earthwork contractor expands operations
with state-of-the-art Astec asphalt plant
Shaw Brothers’ new and greener Astec
asphalt plant is located at its headquarters
on Route 237 in Gorham, Maine.
Thanks to Astec’s
latest technology, Shaw
Brothers has one of the
most eco-friendly asphalt
plants in New England.
I
n 1977, two brothers envisioned owning a company. With two employees, one backhoe, and
a handshake, Shaw Brothers Construction was
formed. The same founding principles of work hard,
satisfy the customer, and respect the people you work
with still guide the company today. Since its humble
beginning, Shaw Brothers Construction has grown into
one of Southern Maine’s largest earthwork contractors
for site development, heavy/highway, and utility projects. Shaw Brothers also provides the area with quality aggregates from its various gravel pit and quarry
locations. With the addition of Astec’s asphalt plant
featuring the newest technology, the company is now
operating the greenest plant in Maine. At the helm,
brothers Jon and Dan Shaw continue to manage the
day-to-day operations, now providing their customers
with a variety of asphalt mixes.
Shaw Brothers utilizes ½-in (1.27 cm) RAP (reclaimed asphalt pavement) in its mixes.
ASTEC PLANT RUNS ON NATURAL GAS
After 18 months of research, design, purchase, and
installation, Shaw Brothers launched its new Astec
400 TPH (362 MTPH) stationary asphalt plant in May
2014. The plant, installed at Shaw Brothers’ headquarters in Gorham, Maine, runs on natural gas and
processes aggregate from the company’s Brickyard
Quarry, also located on site.
“By locating the new plant by one of our quarries, we
lower trucking emissions,” said Jon Shaw, co-owner
of Shaw Brothers Construction. “Running the plant on
natural gas also minimizes emissions and reduces
cost, making the plant eco-friendly.”
For customers wanting a custom mix, Shaw Brothers has fine RAP stockpiled on location.
Co-owner Dan Shaw continued: “It was important to
us to have an asphalt plant with the latest technology, not only for the production of quality mix, but to
minimize our impact on the community with respect
to emissions and noise. We wanted to be able to
maximize the amount of recycle in our mixes to be a
good environmental steward of our resources. Astec’s
innovative approach to being ‘green’ met our expectations.”
ADVANCES IN GREEN TECHNOLOGY
Shaw Brothers’ new asphalt plant features the latest Astec technology, including the V-Pack™ Stack
Temperature Control System and the Double Barrel®
drum mixer with patented warm mix system.
The V-Pack™ Stack Temperature Control System
consists of V-flights, patent-pending flights with a
deep V-shape. V-flights produce a uniform veil of vir-
The Astec 400 TPH (362 MTPH) stationary asphalt plant has an eight-bin cold feed system.
HOT-MIX MAGAZINE
7 VOLUME 19 NUMBER 2
An upsized 80,000 CFM three mod reverse pulse baghouse was added to the configuration to reduce dust.
gin aggregate across the drum no
matter how much material is in the
drum, or what the production rate
is, or how much RAP (reclaimed
asphalt pavement) is used in the
mix. Because the V-flights shower
material uniformly, they never leave
a hole in the veil. More revolutions
per minute place more aggregate
in the air.
•Three recycle feed bins; two
for RAP (reclaimed asphalt
pavement) and one for RAS
(recycled asphalt shingles)
Astec’s patent-pending V-Pack
Stack Temperature Control System
monitors the exhaust gas temperatures at the baghouse inlet as the
primary reference for control. As the
exhaust gas temperature rises, the
Control System checks it against
a set point. When the temperature
exceeds the set point, the Control
System speeds up the drum’s rotational speed and controls temperature to the set point. This thickens
the veil, which reduces the stack
gas temperature. The drum speed
can be varied from a minimum
of about 7 RPM to a maximum of
about 12 RPM. (The normal speed
for Astec drums without the system
is 8 RPM.)
•Three Heatec 30,000 gal
(113,562 l) liquid asphalt tanks
HOT-MIX MAGAZINE
•Four 200-ton (181 tonne) insulated storage silos
•80,000 CFM three mod reverse
pulse baghouse
•Whisper Jet® burner
Shaw Brothers included the the Astec Double Barrel® drum mixer and warm mix
system in the plant setup.
For Shaw Brothers, the V-Pack system improves production of virgin
and high-RAP mixes by maintaining
temperature while running at higher
speeds.
The Astec Double Barrel® drum
mixer with the warm mix system
enables Shaw Brothers to utilize as
much RAP as possible. The drum is
8 VOLUME 19 NUMBER 2
known for keeping operating costs
per ton of mix low while meeting
stringent environmental codes.
The Astec warm mix system saves
energy and reduces smoke and
emissions.
Other plant features include:
•10 ft x 14 ft (3.05 m x 4.27 m)
eight-bin cold feed system
“By using the latest technology,
we have diminished the noise
and smell often associated with
asphalt plants,” noted Dan Shaw.
“We now have one of the most
environmentally friendly plants in
New England … the neighbors
and town may even forget we’re
here.”

FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
From Ship to Shore and
Right Next Door
Serving a global market, Astec
relies on International Logistics
to export quality customer care
A
quick review of the Astec website reveals that every country
in the world has an assigned
Astec sales representative, and
managing the logistics of sending
equipment to literally every corner
of the globe falls to the International
Logistics department. International
Logistics is a very specialized
endeavor. Based in Chattanooga,
Tennessee, they are charged with
handling much of the company’s
freight forwarding needs. Serving
as the “travel agents” for Astec’s
exports, they find the best routes and
best prices for each shipment.
HOT-MIX MAGAZINE
PART OF THE TEAM
In the simplest terms, Astec
Logistics is an extension of every
International Sales and Traffic
department of Astec Industries,
specializing in the exporting area of
international documentation, banking, and transportation.
“We are a very cooperative team in
the international freight movement,”
said Johnnie VanGelderen, director
of international logistics at Astec,
Inc. “I can’t say that International
Logistics does it all, because we are
part of a team. We would be nothing
without the support of those people
10 VOLUME 19 NUMBER 2
Cargo being loaded on a ship going to
Saint Petersburg, Russia. Astec ships
equipment all over the world in large
car carrier vessels—commonly referred
to as roll-on roll-off cargo ships—that
provide protection to valuable cargo on
its long voyage.
we assist in sales and, of course, the works with the sales department
people out loading the cargo.”
from the very beginning of a sale.
Logistics works closely with all
of Astec Industries’ companies,
complementing each individual company’s international sales coordinators and the people in traffic, who
are the actual facilitators of bringing
in the trucks to load the cargo.
VITAL TO SALES
International Logistics has a long
history and, with its myriad duties
and destinations, a long learning
curve. The department is associated
mostly with sales and traffic, and
VanGelderen noted that coordinating
information from shipping to sales is
important not just for the company,
but for the customer: “When a sales
representative comes in and has
a sales quotation that he or she is
making overseas, we provide the
freight rates that are included in
the initial quotation to the customer.
When Astec customers see the quotation, they know right away what
their landed cost is going to be for
that piece of equipment.”
Freight is not the only responsibility for International Logistics.
VanGelderen added, “We handle
the shipment, but our other focus
is ensuring payment from our
international customers and that all
documentation is provided so that
when the shipment arrives it does
not become hung up in red tape to
clear it from customs. Many times
we are paid by letters of credit, and
we prepare all the documentation for
the letters of credit and work with
the banks to ensure a smooth payment process for both ourselves and
our customers.”
VITAL TO THE CUSTOMER
International Logistics goes above
and beyond every day in trying to
obtain economy in shipping volume
with the steamship lines, combining
all of Astec’s companies in this effort An Astec Double Barrel® unit is blocked and set in place inside the ship alongside other miscellaneous units that are a part of a
complete asphalt plant.
by consolidating shipping requirements. Through consolidation, Astec
can command better shipping rates,
passing those savings on to the
customer.
“One of the challenges that we
have,” continued VanGelderen, “is
that with volume Astec Industries
can become important to the steamship lines as a customer and that
allows us to obtain not only good
shipping rates, but also the best
service for our company and our
product. And that allows us to give
our customer value as well.”
SAFE TRAVELS
It’s not uncommon that a typical
plant going out of Astec Inc. can be
from 3,000 cubic meters upwards
to 6,000 cubic meters of cargo. This
presents the International Logistics
department with the challenge of
ensuring safe passage for this enormous cargo.
“Most of our cargo is project cargo
here at Astec, Inc. We’re shipping
what they call ‘high, wide, and
heavy’ cargo in the trade,” explained
VanGelderen. “This includes plant
equipment, the drum, the control
centers—essentially an entire plant.
The ships of choice for us are ‘car
carriers’ where you drive the cargo
onto the ship, rather than a crane
lifting the equipment off the dock
and loading it to the cargo ship. The
same ships that carry our cargo are
Here, a tank from Heatec is going up the ramp into the ship, which is the size of a large building. Once the ship arrives at its
destination port, the equipment can be driven out to continue its journey.
the same ones carrying Cadillacs
and BMWs—right there, side by
side.”
These vessels, that are akin to large
buildings, allow Astec to know that
its equipment is fully protected
under-deck. Then, equipment is
ready to move off the ship and has
been protected all through its travel
toward its destination, wherever on
the globe that may be.
SERVING A GLOBAL MARKET
Astec Industries is developing new
business in more and more global
territories. Wherever there is oil
being discovered, equipment for
roads and infrastructure needs are
being brought in. The companies
exploring new areas for natural
resources and their partners need
roads to support their efforts, but
they aren’t always suitable in more
remote parts of the world. Astec’s
HOT-MIX MAGAZINE
ability to provide plants to a global
marketplace is helping make the
world a smaller place.

FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
11 VOLUME 19 NUMBER 2
R
ecycling is more than
a buzz word for Jason
McCullar, owner of JML
Energy Resources LLC based in
Brentwood, Tennessee. When it
comes to recycling asphalt shingles, McCullar believes he’s in the
right business.
“The company was founded in
2012, and is a combination of
two separate entities. Our name,
JML Energy Resources, reflects
the diversity of our business,”
said McCullar. “We do more than
just grind asphalt shingles for the
asphalt paving community, but
HOT-MIX MAGAZINE
The business of grinding asphalt
shingles is a profitable enterprise
when the right equipment and
entrepreneurial spirit combine.
“At the time of the company formation, we had the largest private
stockpile of asphalt shingles in
North America with just a little over
2 million tons (1.8 million tonnes)
and growing every day,” stated
McCullar.
In addition to the Tennessee location, JML Energy Resources curthat’s our niche, and we strive to
equipment and entrepreneurial
rently has four yards across the
provide the highest quality recycled spirit combine. Upon seeing a dem- U.S. for the collection of asphalt
asphalt shingles (RAS).”
onstration of a grinder making RAS, shingles from contractors: Charlotte,
the decision to have such a facility North Carolina; St. Louis, Missouri;
According to McCullar, the business
followed, and the Tennessee loca- Oklahoma City, Oklahoma; and
of grinding asphalt shingles is a
tion took shape.
Phoenix, Arizona. The company is
profitable enterprise when the right
expanding into Texas and adding
12 VOLUME 19 NUMBER 2
JML Energy Resources LLC
in Brentwood, Tennessee,
utilizes the Peterson 4700B
Horizontal Grinder for daily
production of recycled
asphalt shingles (RAS).
machine has a 60 in x 37½ in (152
cm x 95 cm) feed opening and a
hopper capacity of 9 yd3 (6.88m3).
The conveyor speed on the discharge system is 450 ft/min (137.2
m/min). The 4700B has a threestage grinding process with an upturning rotor and large grate area.
According to McCullar, the Peterson
grinder with a drum rotor is specifically designed to grind asphalt
shingles versus a wood grinder
modified to handle shingles.
“The Peterson machine grinds on
the upstroke instead of the downstroke, which makes for better
quality material,” noted McCullar.
“Some of the other components we
“
AC, and 28 percent AC content,
JML can create a material that is a
higher percentage than that.” How
much higher, McCullar won’t say.
“The asphalt industry has never
seen this before; and we are willing to guarantee the quality of the
material—also an industry first.”
LOOKING AHEAD
JML is committed to reusing
“green” products and hopes to
remove asphalt shingles from the
landfill waste stream.
“With the Peterson 4700B
Horizontal Grinder, we see ourselves
as a forward-thinking asphalt
shingle grinding company,” said
JML Energy Resources’ ability
to provide RAS material with a
higher AC content is an industry
game changer.
a location in Missouri, plus looking
to open a facility in Raleigh, North
Carolina.
material. While at the trade show,
McCullar explored the grinding
technology options available for the
What’s the catalyst for McCullar and company’s planned expansion.
his company expansion? Look no
“After reviewing equipment comfurther than the technology brought parisons, we chose the Peterson
to the asphalt grinding industry
4700B Horizontal Grinder; it was
from Peterson, an Astec Industries
simply the best choice for our
company located in Eugene,
asphalt shingle grinding operaOregon.
tions,” shared McCullar.
SURVEYING THE OPTIONS
JML Energy Resources was an
exhibitor at the 2014 CONEXPOCON/AGG exposition in Las Vegas,
Nevada, showcasing its RAS
THE PETERSON GRINDER
Powered by a Caterpillar C18 diesel engine with 765 horsepower
(570 kW), the Peterson grinder is
highly efficient and productive. The
”
are enjoying include the built-in air
compressor, the telemetry feature
that allows us to remotely monitor
the status of the equipment, and
an innovative airbag feature that
expels any scrap metal from the
shingles before entering the grinding drum.”
McCullar. “We depend on the reliable performance of the Peterson
grinder to continue gaining a
nationwide foothold for the production of RAS. Recycling asphalt shingles is just the tip of the iceberg for
us; we expect great things as we
continue to expand.”
McCullar continued: “Peterson has
an unmatched commitment to the
customer in the asphalt grinding
industry; they have exceeded our
expectations for service and have
gone the extra mile; it feels like we
have partner in our business versus
just a supplier.”
Since inception, JML has sold more
than 131,000 tons (117,934 tonnes)
of RAS material and that number
continues to grow. A normal day of
grinding yields between 700 and
900 tons (635 and 816 tonnes).
NOT YOUR TYPICAL RAS
What is the standard for RAS?
Normal asphalt roof shingles processed through a normal or average grinder will contain between
18 to 20 percent asphalt cement
(AC). JML can produce this typical
3/8-inch-minus (9.525 mm) material
on request, but is also delivering an
“industry first” product.
“We can deliver negative-asbestos
RAS material with a 28 percent AC
content,” said McCullar. “In addition to the normal 18 to 20 percent
HOT-MIX MAGAZINE
When asked about the future of
JML and the addition of Peterson
grinders, McCullar shared:
“By the end of year, we will have
doubled in size with at least two
Peterson grinders; in three years
we’ll likely have four Peterson
grinders and be six times bigger
than we are today.”

FOR INFORMATION
Contact Michael Spreadbury
541.607-7911
[email protected]
13 VOLUME 19 NUMBER 2
Highway A63
Takes Shape
Colas SOUTH WEST uses portable
Astec plant for one of the largest
highway projects in France
Colas SOUTH WEST set up the Astec Portable Six Pack® facility to provide hot-mix asphalt for a 104-km (65 mi) portion of Highway A63 in France.
I
n 2010, a consortium including
Colas secured the 40-year concession contract for a 104-km
(65 mi) portion of Highway A63 in
the Landes region of southwestern
France. The contract included the
design, financing, construction,
maintenance, and operation of the
motorway until 2051.
COLAS SOUTH WEST
Founded in 1984, Colas SOUTH
WEST is a subsidiary of Colas
Group. Colas SOUTH WEST has a
network of 65 agencies totaling
3,600 employees, 31 quarries
spread over 18 departments of
southwestern France, with 25
stationary asphalt plants and two
mobile plants for the production of
hot-mix asphalt (HMA).
HOT-MIX MAGAZINE
Colas SOUTH WEST invested in
Astec’s Portable Six Pack® facility
with the Double Barrel® drum mixer
for RAP on the move.
THE A63 PROJECT
ing the Iberian Peninsula to the
The construction of A63, entrusted rest of Europe, it is traveled daily
to the consortium Atlandes, includ- by 30,000 vehicles, of which 30
percent are heavy vehicles. The
ed project leader Colas SOUTH
project, mobilizing 800 to 1,200
WEST charged with upgrading
people, began in September 2011
Former Route RN10 to current
with delivery by June 2014. They
motorway and environmental
planned the installation of 1.2 milstandards. This meant widening
lion tons (1.4 million tonnes) of
the 6-lane roadway to improve
bituminous mixes (produced out
user safety and service. Located
of three asphalt plants), containing
on a major European axis link-
14 VOLUME 19 NUMBER 2
up to 30-percent recycled aggregate products. The challenge was
to do the work, while keeping the
road open for traffic flow.
ASTEC SIX PACK® FACILITY
According to Colas SOUTH
WEST equipment manager Alan
Thouvenot, the magnitude of the
infrastructure project required a
portable and durable asphalt plant.
“We contacted Astec and reviewed
their asphalt plants. We made
the decision in September 2010
to purchase the Astec Six Pack®
HMA facility with a portable 7 ft x
35 ft (2.13 m x 10.67 m) Double
Barrel® drum mixer with a capacity of 300 TPH (272 MTPH) with
aggregates at 3 percent moisture.”
The production of asphalt continued day and night as Highway A63 was widened to six lanes while maintaining traffic flow.
The Astec Portable Six Pack® facility with the Double Barrel® drum mixer provided the ability to use high rates of recycle.
The plant was inspected at the
• Portable Self-Erecting 90-ton
Astec workshop in Chattanooga,
(82 tonne) Surge Bin
Tennessee, by Alain Thouvenot
• 350 BBL (40 m3) dry additive
and Colas SOUTH WEST equipsystem
ment manager Jean-Claude Arolfo
in December 2010. The plant was
• Portable recycle feed (RAP)
designed to meet the second catesystem with lump breaker and
gory of road transport limitations in
self-erecting conveyor
France, especially the self-erectable
The Bitumen tanks were supplied
90-ton (82 tonne) bin.
by a local manufacturer. Electricity
The plant components included:
and plant controls were entrusted
to Astec’s agent Mix Process in
• Portable 10 ft x 12 ft
France.
(3.05 m x 3.65 m) four-bin cold
feed system
PORTABLE PLANT IN ACTION
On its arrival in France, the plant
• Portable 30 in x 60 ft (76 cm
was first set up as a test in a Colas
x 18.29 m) inclined conveyor
SOUTH WEST depot. The plant
• Portable 7 ft (2.13 m) Double
was then moved to two different
®
Barrel drum mixer
sites for two small jobs consisting of 10,000 tons (9,071 tonnes)
• Whisper Jet® 75 MBTU/hr
and 14,000 tons (12,700 tonnes)
oil/gas burner
before being moved in September
• Portable 52,264 CFM Express
2011 to a site in Pissos for the
Baghouse with inertial dust
construction of A63.
separator
Kevin Riviere, plant manager,
handled the plant’s relocation to
the different sites. “The plant is
very easy to set up; it comes apart
and is back up very quickly,” said
Riviere.
the mixing zone through the door.
The possibility of heating up the
baghouse in the morning before
the start was also a plus.
Alain Thouvenot, equipment manager, added: “The concept of the
Astec Double Barrel® is new for
Colas in France. It allows high
rates of recycling and the flame
is not in contact with reclaimed
asphalt or bitumen. With the
introduction of reclaimed asphalt
and bitumen outside the drying of
materials, the drum provides low
VOC emissions.”
After two years of production for
A63, the Astec Colas SOUTH WEST
plant produced a total of 534,620
tons (485,000 tonnes) of asphalt,
including 468,482 tons (425,000
tonnes) with 30 percent RAP
(reclaimed asphalt pavement) for
undercoats and wear coats.
“It’s easy to recycle with the Astec
plant, up to 50 percent RAP with
no problem, and when the materials are not too wet, it can produce
330 TPH (300 MTPH) with 30 percent RAP,” noted Riviere.
The A63 project was completed seven months ahead of
schedule.

Riviere especially liked the Astec
Double Barrel® drum mixer and the
cleanliness in the area of drying
materials, the access to the burner,
and the ease of maintenance of
HOT-MIX MAGAZINE
FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
15 VOLUME 19 NUMBER 2
A stec S chools P review
Experience the best in training from industry experts and seasoned professionals
W
ith the changing of the seasons from summer to fall, it’s
time again to make plans to
attend the Astec Advanced Customer
Schools located at the Astec, Inc. training facilities in Chattanooga, Tennessee.
Registration opens October 1 for classes
held in January and February. The school
sessions will be offered four different
times, and each session is expected to
sell out.
2015 SCHOOL DATES:
“
• January 5–8
• January 12–15
• January 26–29
• February 2–5
WHAT’S NEW
Astec training
promotes best
practices in asphalt
plant operations.
Astec engineers discuss the variations in flighting for highRAP mix production.
Hands-on burner instruction provides practical knowledge for setting burner limits.
”
The Astec Advanced Customer Schools
will have a new class format. Longer, indepth classes will allow for more instructor interaction. There will also be ample
time for hands-on learning with the
various equipment components. In addition to gaining insight and training from
the Astec staff, attendees also have an
opportunity to network with each other.
CLASS TOPICS
What does it take to run an asphalt
plant? How do you maximize production
and uptime? The classes offered during
the school session include instruction on
drums, drag and silos, trunnions, weigh
bridges, conveyers and belts, controls
and controls trouble shooting, baghouses, and burners. Astec engineers are
available to field questions and the Astec
Service Department will offer advice
about how to handle wear and tear.
Attendees will have plenty of opportunity
to take advantage of the hands-on time
with models and simulators.

“We’ve had a lot of fresh faces in the class sessions these past three
years,” said Troy Norris, Astec service support coordinator. “We have
attendees from around the globe and we strive to present detailed,
educational, and easy-to-understand material for plant operations and
trouble shooting. We want everyone that attends the Astec Advanced
Customer Schools to come away with the information they need to
advance their operations and business. It’s time well spent.”
HOT-MIX MAGAZINE
16 VOLUME 19 NUMBER 2
Shattering Boundaries in Paving Technology
Carlson Paving – leading the industry with innovative new products
Front Mount EZV Screed
LED Blade Light
High Density Bolt-on
CP75 Comercial Paver
Safety Edge Endgate
EZR2 Rear Mount Screed
RPM
Ratio Percentage
Manager
Astec’s new data management tool provides an independent mix design entry point
RPM gives plant
operators a chance to
write their own history.
T
he simplest way to
describe RPM, or
Ratio Percentage
Manager, is that it is
a data management
tool—a new interface
that allows customers
to design their mixes
and input material data
and ingredient channel
data. Currently, it’s available exclusively with
the new PM3 system.
In the future, it will be
backwards compatible
with the PMII and TCII
systems.
However, when compared to Astec’s previous
methods of inputting mix
design, this program is
independent of the main
control systems. As long
as users—whether at the
plant or in the office—
have access to the
system’s Data Dictionary,
they can input mix design
data right where they are,
and the plant can access
that data.
popular WM2000 truck
management system
looks at and that the
plant’s main control
systems log data to.
However, RPM doesn’t
need to be run from
within the main control
system, whereas previous mix design systems
did. Offering an independent mix design entry
point, RPM is primarily
for hot mix, but there is
potential for expansion. If
a client is running a concrete plant, for example,
RPM can be used for that
as well.
“If an Astec customer has
an existing mix design
and wants to update it,
it’s really simple to do
in RPM,” said Marlene
Williams, lead engineer
for RPM. “There’s one
tab, dedicated to specifically designing the customer’s mix.”
RPM is a more adaptable,
user-friendly, and streamlined interface, giving the
FLEXIBLE AND
operators greater flexSTREAMLINED
ibility in how they access
The Data Dictionary is
the same one that Astec’s the data they need.
HOT-MIX MAGAZINE
The RPM Mix Design tab, with mix.
The Material tab as seen in RPM. In RPM, if a user makes a change to a material name, RPM can apply
that change universally throughout the system so it stays consistent.
18 VOLUME 19 NUMBER 2
EASY TO USE
In RPM, each tab
offers a View-asReport option, with
the ability to export
data as a PDF or
spreadsheet.
This simplicity in design gives
RPM an inherent advantage over
other data management systems
in the field. By being focused
around ease-of-use, RPM offers
more options in how plant personnel view, edit, and record their
designs.
“So let’s say plant operators
choose to remove an ingredient,”
added Williams. “They would just
select the mix design they want to
look at, click on whichever ingredient they wish to remove or edit,
and now they are just one click or
a couple of keystrokes away from
removing or updating a data field
for that ingredient.”
Furthermore, after all the changes
are made in RPM, the user can
now save those changes and
know that they are accessible
from the main control system as
well. Once the data is saved using
RPM, if other users access the
main control system or if the user
needs to access it at a later date,
the data can be re-selected and
all of the previous changes will
be there.
The RPM Calibration
Data tab. One
improvement RPM
offers over other
systems is its
ability to access
a historical log of
calibration points.
LEARNING FROM HISTORY
Before RPM, with previous mix
design systems—especially as it
related to material data and calibration data—users could go into
data records, make a change or
delete a record, but there was no
going back. RPM instead provides
the user with a more reliable way
to update data. The user is guided
as to what type of data can be
input and can also back out of
changes before they are applied.
Tools are also available to help
maintain data integrity.
a change to that material name
universally throughout the system
so it all stays consistent.”
“In the past, with regard to
material data, one concern we
heard from our customers was
a common occurrence in many
plants,” reported Williams. “One
user might establish a name for a
particular material, yet other users
could make a change that could
potentially lose any data associated with that name—the ‘where
is my data?’ problem. But in RPM,
if someone makes a change to
a material name, RPM can make
In previous mix design systems,
calibrations were actually done
from within the system. Now, calibrations are done independently
of the mix design system. From
RPM, users simply look at and
edit calibration data as needed.
Any data updated from RPM is
flagged as such, so it’s easy to
distinguish between automatic
calibration points and manually
updated points. RPM will save to
the previous point in addition to
any edits that a user makes to the
calibration point. Now, a plant will
have a comprehensive history of
all calibration points ever created.
each of the available tabs there
is a View-as-Report button.
Whatever data a user is looking
at on that particular screen can
be exported into a print-friendly,
VIEW AS REPORT
easy-to-use, and easy-to-share
In addition to making data easy to report that can be printed or
use and easy to record, another
saved as a spreadsheet or a PDF
advantage of RPM is that it makes file.”
mix design data easy to share—
either at the plant or around the
world.
FOR INFORMATION
“Some customers didn’t think
Contact Diane Hunt
there was an adequate way to
423.867.4210
see reports of their plants’ data,”
[email protected]
Williams added. “But in RPM, in

HOT-MIX MAGAZINE
19 VOLUME 19 NUMBER 2
Paver Performance Delivers
New asphalt paver
helps contractor
achieve maximum
smoothness bonus
The Roadtec RP-190e provides consistent
lay down of the asphalt pad, and with its
newer technology, the machine automatics
are designed to ensure exacting results
without regular adjustments.
M
achine demonstrations or
demos provide the opportunity for a contractor to
learn about a machine and test it. A
contractor gets the chance to see if
the equipment matches his needs,
fits comfortably into the fleet, and
passes the critical evaluation of the
crew, before spending a dime.
Chester Bross Construction Company used the Roadtec RP-190e
paver for a superpave job on I-55 in Scott County, Missouri, and
made the decision to purchase based on the paver’s performance.
ride numbers they were achieving
were substantially better than what
there were getting with an older
piece of existing equipment. The
numbers continued to hit maximum
bonus on the project for the next
two days of the demo.”
Mike Bross, owner and vice president of operations for Chester Bross
For Chester Bross Construction
Construction Company, said that
Company, headquartered in
together with his father, Chester
Hannibal, Missouri, a bit of a loveBross, they made the decision to
at-first-sight product demo has
purchase strictly on the perforturned into a permanent, solid rela- mance they were experiencing with
tionship. Chester Bross has more
the Roadtec RP-190e paver during
than 40 years of general paving and the demo trial period.
construction experience ranging
“Like everyone in the industry, we
from, as they phrase it, “driveways
were having a challenging busito highways.” The company’s startness year,” stated Mike Bross. “We
to-finish services include excavawere not intending to make any
tion, asphalt paving, concrete pavlarge capital investments, but if we
ing, curb and gutters, cold-milling,
can increase productivity and get
diamond grinding, profiling, culresults achieving or approximating
verts, bridges, structures, surveying,
100 percent bonus then the purand site rehabilitation.
chase of a new machine becomes a
no-brainer.”
ON-SITE DEMO
“We brought our new, latest techDESIGN OFFERS MORE
nology Roadtec RP-190e rubberCONTROL
tired asphalt paver to a Chester
Bross road project and let them run According to the manufacturer, the
the machine on a current project,” 10-ft (3.05 m) Roadtec RP-190e
highway class asphalt pavers have
stated Austin Miller, regional sales
received a major redesign, including
manager with Roadtec, Inc. “The
The Roadtec RP-190e paver features a 10-ft (3.05 m) main screed with a 5-ft (1.52 m) extension wing on the right and a 4-ft (1.22 m) extension wing on the left, which
accommodated the 12-ft (3.66 m) wide highway.
the addition of Tier 4i, Cummins®
QSB 6.7 engines rated at 230 hp
(172 kW) at 1,800 RPM, and heavyduty offset type conveyor chains,
chromium carbide floor plates
that can drop in without bolts, and
updated dual operator stations that
feature hydraulic-pivot consoles
and selectable seat positions.
Additionally, the paver’s augers can
be operated independently of the
conveyors, which are designed to
provide the operator with complete
control over the material.
The SMA is stickier, which is
designed to adhere better to the
base layer. A total of 120,000 tons
(108,862 tonnes) of asphalt was
used on this project—50,000 tons
(45,359 tonnes) for the finish lift,
70,000 tons (63,503 tonnes) for
the base.
INCREASED PRODUCTIVITY
The $7 million Missouri Department
of Transportation (MoDOT) project
was delayed because of the rainy
weather in the spring. Chester
Bross commenced work in late
One of Chester Bross’ first jobs run- September 2013 and needed to be
ning the new paver was a 14-mi
completed by the second week in
(22.53 km), four-lane stretch of I-55 November, before winter weather
in Scott County, Missouri, near the
might start.
city of Sikeston. Interstate highway
I-55 runs through the middle of the “This less than two-month timeU.S. stretching north from LaPlace, table was a bit of a production
Louisiana, about 30 mi (48.28 km) crunch for our eight-member
crew,” Dowell said. “We worked
west of New Orleans, to Chicago.
16- to 18-hour days and we were
“This was a superpave job, mean- happy to have the new RP-190e
ing we placed two lifts of asphalt
paver. The machine’s anti-segregaover the old, worn-out concrete
tion design, electric flow gates, and
highway surface,” stated Phillip
18-in (45.72 cm) hydraulic tunnel
Dowell, site superintendent for
extensions provided the control of
Chester Bross. “The first course
the material flow from the hopper
was a deeper 2-in (5.08 cm) lift to to the screed that we needed.”
smooth out the uneven surface. The
In addition to the consistent lay
finish lift was 1¾-in (4.44 cm) of
stone-mastic asphalt (SMA) to pro- down of the asphalt pad, Dowell
vide longer wear life on this stretch liked that the paver could be set
up quickly in the morning and with
of heavy traffic highway.”
its newer technology, the machine
automatics are designed to ensure
exacting results without regular
adjustments. The Roadtec RP-190e
paver features a 10-ft (3.05 m)
main screed with a 5-ft (1.52 m)
extension wing on the right and a
4-ft (1.22 m) extension wing on the
left, which accommodated the 12-ft
(3.66 m) wide highway.
“Compared to our old paver, we
are able to run the RP-190e much
faster without sacrificing quality,”
Dowell stated. “I’m not sure we
would have met the project deadline without the efficiencies of the
new paver. We literally saved at
least two days of production.”
SMOOTH OPERATIONS
The MoDOT I-55 project had
a pavement surface smoothness requirement with monetary
bonuses for achieving better than
the minimum requirement of an
International Roughness Index
(IRI) of 80 or better. Chester Bross
Construction Company achieved
IRI scores of less than 30 on most
of the completed roadwork, which
earned them a five percent bonus.
The remaining sections were
between 30 and 70 on the IRI
scale, netting them a three percent
bonus.
HOT-MIX MAGAZINE
“Clearly, we wouldn’t have
achieved those high Profilograph
measures without the new
Roadtec RP-190e paver,” said
Dowell. “The screed is easy to
use, the controls are easy to
understand, and the machine
requires little adjusting to get the
results we got.”
MoDOT inspectors were pleased
with the finished smoothness of
the road and the fact that the work
was completed ahead of schedule.
The smoothness of the completed
I-55 section falls within MoDOT’s
initiative to “smooth out much
of the state’s pavement,” which
is projected to improve annual
fuel economy in the state by 2.4
percent.
As Dowell succinctly summarized:
“We made the road really smooth;
got it done really fast; and made
my company some money …
couldn’t ask for more.”

FOR INFORMATION
Contact Roadtec Sales
800.272.7100
[email protected]
21 VOLUME 19 NUMBER 2
Astec burners offer the latest in reliable burner technology
combined with complete one-source responsibility.
A
t the core of every Astec asphalt plant is a burner, operating with efficiency and
reliability. With five burner options available, you’ll be able to find the perfect fit for
your plant’s configuration. Let’s take a closer look at Astec’s burners:
PHOENIX® TALON BURNER
PHOENIX® FURY BURNER
The Phoenix Talon burner delivers very low emissions
combined with energy efficiency, all due to using the
latest burner technology. An optional silencing package
makes it possible to have a phone conversation on the
burner platform while it is firing.
The Phoenix Fury Burner is the most simple with
its robust build, making it a cost-effective choice.
It is an open-fire design able to achieve better
emissions and fuel efficiency by putting 50 percent
more combustion air through the burner than competitive designs. For noise concerns, the burner has
an optional silencer.
Advanced Emission Reduction. The Phoenix Talon
uses precise, high-quality mixing of air and gaseous
fuel to achieve reduced emissions. This is accomplished by turbulent tube mixers thoroughly mixing the
air and gaseous fuels for low CO and NOX emissions.
The advanced compressed air, oil nozzle, and air swirler
design achieves self-circulation and very rapid burning
creating some of the lowest oil firing emissions available today.
Electric Power Efficiency. The variable speed main
combustion blower uses significantly less electrical
energy and helps provide precise firing rate control.
This eliminates the need for an air damper and for drive
motor adjustments and maintenance.
Firing Efficiency. The most compact flame available
with a small combustion zone is created by the high
quality mixing of air and fuel. This ensures that all of
the fuel is combusted for peak efficiency without diminishing dryer heating capacity.
The Phoenix Talon burner is the second most common burner manufactured by Astec. The burner fits in
almost any drum. It is a preferred gas burner, but does
a good job on oils. A plant owner ordering a standard
plant could chose the Phoenix Talon. This burner is
emissions friendly, quieter, and uses less power consumption. Its versatility allows it to run on a variety
of fuels. Models range from 50 million to 150 million
BTU per hour.
HOT-MIX MAGAZINE
22 VOLUME 19 NUMBER 2
Simple and Efficient. The rugged design keeps
maintenance costs to a minimum. Efficient combustion is achieved with fast swirling, high-energy
air. The swirling air and flame are created by the
fixed internal spin vanes, high-pressure blower, and
the high velocity nose.
Compact Flame Shape. The Phoenix Fury burner
burns natural gas and fuel oil cleanly. Its compact
flame makes the burner compatible with almost all
drum designs; no complicated adjustments needed.
No Compressed Air. The Astec designed pre-filming fuel nozzle uses the combustion air from the
high-pressure blower to atomize fuel. This eliminates the need for compressed air at the burner,
and helps increase the life of the nozzle.
Reliability. For the most reliable oil light-off, the
Phoenix Fury burner comes equipped with Astec’s
exclusive heat tracing and insulation system on
heavy oil burners. This system makes light-off
dependable, even in cold and harsh conditions.
The Phoenix Fury burner is the solution for the
plant owner wanting a solid, reliable burner for
low-cost plants or for low-cost retrofits. The models of the Fury range from 25 million to 100 million
BTU per hour.
PHOENIX® BIOMASS BURNER
WHISPER JET® BURNER
PHOENIX® PHANTOM BURNER
The Phoenix Biomass burner is
designed to burn wood dust. Its combustion system uses a wood preparation skid that reduces the size of the
incoming wood fuel and delivers it to
the burner. The burner uses a refractory
combustion chamber to help support
the combustion.
The Whisper Jet was the first burner
developed by Astec. The burner burns
oil or gas cleanly and efficiently. Its
compact flame makes it compatible
with virtually all drum designs without
complicated adjustments.
The Phoenix Phantom burner is the
only burner in the hot-mix asphalt
industry using the latest technology
to achieve lean burn premix. This
is the precise and complete mixing of air and gaseous fuel for low
NOx and CO. The Phoenix Phantom
burner’s multiple parallel turbulent
tube mixer mixes fuel and air almost
perfectly.
Multiple Fuel Options. The Phoenix
Biomass burner can use natural gas,
#2 oil, recycled fuel oil, or heavy oil as
a support fuel for continuous ignition of
the biomass fuel. In the upper part of
the firing range, the support fuel can be
turned off, allowing the burner to run on
100 percent biomass fuel. In the event
that the biomass supply is not available,
the support fuel can fire at 100 percent
of rated capacity.
Compact Flame. A compact flame
is produced as a result of the burner
design and its combustion system,
which is easily adapted to modern
aggregate dryer designs.
No Visible Stack Emissions.
Comparable to emissions produced
when burning waste oil, the Phoenix
Biomass burner emits virtually no
smoke. Stack emissions are at zero
percent opacity.
Trouble-free Maintenance and
Operation. The careful design of the
Whisper Jet burner virtually eliminates
maintenance and downtime. The burner is comprised of the highest quality,
field-proven components. Astec’s
exclusive heat tracing and insulation
system is supplied on heavy oil burners for reliable light-off.
Low Combustion and Noise
Emissions. The Whisper Jet burner
uses unique, patented technology to burn clean and efficiently.
Synonymous with its name, the burner
is designed to reduce burner noise
over other burners.*
Efficient Combustion. Rapidly swirling high energy is the key to the
Whisper Jet burner’s efficient combustion. The swirling air and flame
are created by the fixed internal spin
vanes and the patented castellated
nose, ring, and nozzle design.
The Whisper Jet burner is the typical workhorse burner and does not
require a sophisticated control system.
Reliable and Efficient Firing.
Variable speed blower controls provide damper-less air flow control.
For the most accurate and reliable
burner control, combustion air and
fuel flow meters can be combined
with Astec PLC/computer burner
controls.
Compact Flame. The compact
flame contributes to the burner’s
efficiency by ensuring that all of the
fuel is combusted without losing
dryer heating capacity.
The Phoenix Phantom burner is the
solution in areas where Ultra-Low
NOx emission limits are a concern.
The Phoenix Phantom burner is not
supplied with an optional oil nozzle
because its premium Ultra-Low
emissions technology applies to
gaseous fuels only.
With retrofit capabilities, Astec is able to offer everything from a simple burner replacement to a complete installed system. Prior to shipment, each burner is tested on one of Astec’s two, quad-fuel (oil,
gas, and coal) test stands to ensure fast and easy start-up at installation.

* The Phoenix Phantom, Phoenix Biomass, and Phoenix Talon emit lower noise levels than the Whisper Jet.
HOT-MIX MAGAZINE
FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
23 VOLUME 19 NUMBER 2
where do you fit?
%
%
0 -100
RAP becomes more important to your operation
every day. Whether you run a little or a lot,
chances are you plan to run even more in the
future. ASTEC leads the way with a drum line-up
built around helping you utilize RAP.
ASTEC HAS
SEVEN
DRUMS
COVERING
Only Astec has the patented Double Barrel Green® System.
THE
RAP
SPECTRUM
FROM
0%
to
100%
RAP
USAGE
Century
Asphalt
Terminal
Heatec’s design
delivers loadout
structures and
automation
Century Asphalt Materials expanded with the addition of a terminal located in Baytown, Texas, to provide storage of liquid asphalt.
Y
ou’ve heard it takes a village, but for Century Asphalt
Materials, it takes a terminal.
cost of liquid asphalt is lowest, said
Lee. “The price of liquid asphalt can
fluctuate and having adequate storage reduces our material cost and
allows us to make lower bids and
win more jobs.”
Century Asphalt Materials provides
Southeast Texas with hot-mix
asphalt (HMA) and warm-mix
asphalt (WMA) products, four sealcoat products, and eight construction aggregate products. To meet
the need of base materials, Century
Asphalt Materials operates 13 HMA
plants and a concrete crushing plant
located throughout Houston and the
Hill Country of Texas. A second concrete crushing plant is being added
in the Greater Houston area. And
since 2011, the company operates
THE TERMINAL PROJECT
a terminal for bulk storage of liquid Century Asphalt Materials turned
asphalt to stay cost-competitive.
to Heatec, based in Chattanooga,
According to Bill Lee, terminal man- Tennessee, for the expertise and
equipment to make the terminal a
ager for Century Asphalt Terminal,
reality.
the hub allows for the purchase of
liquid asphalt when it’s at its lowest “Heatec personnel did the engineercost point.
ing and programming,” said Lee.
“We got the whole package from
“With more than 300,000 barrels
Heatec instead of having to go out
(35,772,141 l) of storage, we’re
and subcontract.”
able to make purchases when the
“
According to Heatec, the project
Century Asphalt Terminal to a dock
on the Cedar Bayou Waterway. It
was developed from scratch; no
existing structures were used or
consists of the following:
refurbished. The site includes six
• Approximately 1,800 ft (548 m)
54,000-barrel (9,072 tons/2,268,000
of 10-in (25.4 cm) asphalt piping
gal/6,438,985 l) inventory tanks,
from the dock to the plant site,
plus another 1,200 ft (365 m) of
piping to the last tank.
Century Asphalt has gained
distinct advantages with its
terminal, whether due to price,
supply, or unforseen opportunities.
HOT-MIX MAGAZINE
26 VOLUME 19 NUMBER 2
”
two 5,000-barrel (840 tons/210,000
gal/596,202 l) day tanks, and two
10,000-barrel (1,680 tons/420,000
gal/1,589,873 l) day tanks, as well
as the piping and heaters to bring in,
heat, store, transfer, load out material, and more.
BY BARGE
The barge unloading system from
Heatec provides asphalt piping from
• The piping has 11 expansion
loops and three bridges, which
also serve as expansion loops.
• All of the asphalt piping is heated with oil tracing exept for the
dock line piping; once it leaves
Century’s property, it is heated
with electric tracing.
• Unloading rate is 1,600 GPM
(6,055 l/min).
• The dock has a 20 ft x 30 ft
(6.09 m x 9.14 m) steel platform
and a hose crane.
“At the dock, we would bring in a
barge holding up to 20,000 barrels
(2,384,809 l) of asphalt,” Lee said.
The pump for moving the liquid
Heatec designed pipe, pipe racks, and routings.
Truck loading station with Astec programming for the automated system.
Heatec designed the rail unloading station with piping to heat the
railcars for unloading asphalt.
Heatec steam generator to provide steam for railcar unloading.
material is aboard the barge, but
a Century Asphalt crew member
hooks up the hose from the dock.
“We have about 3,000 ft (914 m)
of electrically traced piping going
back to the terminal,” Lee continued.
“Typically it takes about 8 to 12
hours to unload each barge.”
Dock with platform to unload barges.
The pipe rack holds all the piping
necessary for moving materials
between the tanks and for unloading material from the rail cars. It
also carries the hot oil through the
system for heating the tanks, as well
as the piping.
the wheels of the truck [as a safety
protocol—this practice alerts personnel if there’s any movement of
the truck]. They go upstairs and lock
down a safety bridge. They go inside
to answer a series of questions.
They use their loading number to
unlock the system. Then one final
BY TRUCK
safety stop—they have a pedal they
BY RAIL
The automated truck loading system have to step on to be able to load
Liquid material is delivered by rail
is run with Astec programming for
the truck. The entire process takes
from the north. Approximately 80 to ease of use, allowing the truck driv- about 25 to 30 minutes from start
120 rail cars a month are brought
ers to load with a series of steps.
to finish, which means we can load
in, each one of those carrying about The process can be done without
somewhere around 80 to 90 trucks
500 barrels (59,620 l) of asphalt.
terminal personnel at any time.
per day, depending on arrival times
Century Asphalt Materials invested
of the trucks.”
“The automated truck loading
in loadout structures and automation
rack at the terminal has two active
WHAT’S NEXT?
from Heatec to make the system as
scales,” Lee said. “Trucks pull onto
user-friendly as possible.
According to Lee, three expansion
one of the scales. The driver chocks
HOT-MIX MAGAZINE
projects with Heatec are slotted to
be done over the winter: adding
20 additional rail slots; adding rail
loading capabilities; and adding
polymer-modification equipment.
“We see this terminal as an evolving process. As we get used to the
processes that we already have
capabilities for, we’re adding new
capabilities and expanding the terminal.”

FOR INFORMATION
Contact Tom Wilkey
423.821.5200
[email protected]
27 VOLUME 19 NUMBER 2
LEARNING
BY EXPERIENCE
Asphalt producer explains the challenges
of recycling asphalt roofing shingles
Ideker’s plant near the southern city limit of Kansas City, Missouri, is equipped
to run recycled asphalt roofing shingles.
A
s more and more asphalt
producers gain experience
with running shingles, they
are learning what it takes to do so
effectively. While shingles offer a
less expensive source of asphalt
cement, they involve certain challenges.
One challenge is to accomplish the
correct blend of virgin AC with your
shingles and reclaimed asphalt
pavement, if RAP is also in the mix.
While some states may allow as
much as 5 percent recycled asphalt
shingles (RAS) in a mix, that percentage may not work the best.
much like sticking a frozen pie in
the oven versus a tater tot.”
Last year, Ideker fitted up one plant
with a special RAS bin not built by
Astec, and did run the finer grind of
shingles for a time. “With the fine
grind, we could run up to probably
6 percent shingles and you don’t
even know it’s there,” said Neel. But
the bin failed, and that company
is currently working on supplying
Ideker with another RAS bin.
This year, Ideker is working with
Astec to supply another RAS bin
for the second plant, new control
software, and an effective way to
transfer the RAS to the mixing drum
A FINER GRIND
Most producers who run RAS use a of the dual-drum plant. Both Astec
traditional cold-feed bin and weigh- and the other company are supplying Ideker with weigh-depletion
belt system to enter the shingles
RAS bins, which have load cells in
into the mix. And a typical state
them.
specification will call for the RAS
to be ground to 3/8-in (9.525 mm)
As the RAS is fed out to the plant,
minus. But Ideker Construction Co., it gets weighed by the load cells.
based in St. Joseph, Missouri, has a “Weigh depletion is a much more
different idea. The company located accurate way to know exactly
and bought a shingle grinder that
what’s going into the mix than the
will produce RAS ground to 1/10-in
traditional weigh-belt,” said Neel.
(0.254 mm) minus. The fine grind
Earlier this year, Astec was writwill produce more effective liquid
ing software to enable Ideker’s
AC to coat the aggregates, said
Jack Neel, asphalt division manager controls to call the RAS the primary
source of liquid AC in the mix. “By
at Ideker.
using these weigh depletion bins,
“Chances are that 3/8-in (9.525 mm) we actually meter the amount of
chip is not getting melted down
shingles or oil going into the mix,”
to be 100-percent effective oil,”
said Neel. The virgin AC pumps do
said Neel. “The PG grade of those
their job, but that AC enters as a
shingles is extremely high. It takes secondary source of asphalt.
a lot of heat to melt them down. It’s
HOT-MIX MAGAZINE
28 VOLUME 19 NUMBER 2
Ideker’s Astec RAS (recycled asphalt shingles) bin for finely ground shingles is set up
on load cells.
Recycled shingles don’t flow in
like normal aggregates. They can
form bridges, and not feed into a
weigh-belt system. So with Ideker’s
new weigh depletion system, if a
blockage somehow occurs, the
new software automatically knows
that it’s feeding less RAS in, and
the software will speed up the AC
pump to enter more virgin asphalt.
“So that way we always keep our
AC binder as close to accurate as
possible,” said Neel. “The other nice
thing about the fine grind shingles is
that you get a more homogeneous
mix.”
Ideker will enter the finely-ground
RAS into a chute between the drying drum and the mixing drum.
“That way, your oil products are not
exposed to any burner, but since
they’re ground up fine enough, the
heat of the virgin aggregates helps
melt that fine shingle, and they get
mixed in the mixing drum,” said
Neel.
This system has its challenges.
“It’s in transferring the material to
the mixing drum where the biggest
challenge is,” said Neel. “We’re still
trying to get over that hump. So
hopefully we can get the bin to do
what we need it to do. We’re talking
about stuff that nobody has done
yet. Everybody is in kind of a race
to do this. Because it only makes
sense, that the finer you can grind
the shingle, the more effective oil
you will get out of it.”

FOR INFORMATION
Contact Diane Hunt
432.867.4210
[email protected]
Every
thing
you
want
for asphalt storage:
Complete systems. Vertical tanks.
Horizontal. Portable. High efficiency.
Low emissions. Hot oil. Direct-fired.
Electric. 5,000 – 40,000 gallons.
Worldwide parts & service support.
800.545.4034. ceienterprises.com.
CEI ENTERPRISES,INC.
an Astec Industries Company
245 WOODWARD RD, SE • ALBUQUERQUE, NM 87102 USA • 800.545.4034 • FAX 505.243.1422 • ceienterprises.com
The Colors of Asphalt
Paving company in Latin America uses Roadtec’s
MTV and infrared camera for better roads
Coflan uses the infrared camera as a tool to coordinate the compaction process.
I
nversiones Coflan C.A. was
founded in 1999 to participate
in civil engineering works in
Venezuela. In 2003, the company
decided to specialize in the design,
construction, and maintenance of
asphalt pavements. In 2009, during
a visit to Roadtec’s used equipment
division in Chattanooga, Tennessee,
to buy a milling machine, Coflan
acquired its first material transfer
vehicle (MTV), the Shuttle Buggy®
SB-2500, as a technological contribution to the asphalt industry in
Venezuela.
BETTER COMPACTION
PROCESS
The Roadtec Shuttle Buggy MTV’s
advantages convinced the Coflan
directors. The MTV can store and
transfer hot-mix asphalt from a
truck to the paver for continuous
paving for smoother roads. The
triple-pitch mixing auger at the
HOT-MIX MAGAZINE
The asphalt has to be seen in
colors; the use of the infrared
camera is essential to control and
register temperature during the
laying of hot-mix asphalt.
bottom of the 25-ton (22.7 tonne)
bin eliminates the aggregate and
temperature segregation. Coflan
acquired an infrared camera to initially prove and register the laying
temperature of the hot-mix asphalt
(HMA), and as a tool to identify in
real time the thermic differentials
produced by wrong paving practices, as well as other processes
during transport. Currently, Coflan
is using the infrared camera as a
tool to coordinate the compaction
process.
30 VOLUME 19 NUMBER 2
Eduardo Martínez, Coflan’s vice
president, said, “The asphalt has
to be seen in colors; the use of the
infrared camera is essential to control and register temperature during
the laying of hot-mix asphalt.”
Roadtec’s Material Transfer Vehicle
homogenizes the gradation and
temperature of the HMA in order
to obtain uniform densities after
compaction, which is an elementary property in the construction of
durable pavements. It is of utmost
importance to eliminate HMA cold
spots produced by the cooling of
the mix in the dump truck. The cold
spots will be more difficult to compact and will have more vacuum,
which can cause the loss of more
than 50 percent of the estimated
useful life, producing an increase
on the road maintenance costs and
insecurity.
THE COFLAN ROADTEC FLEET
Inversiones Coflan C.A. has the
biggest fleet of Material Transfer
Vehicles in Latin America, owning three Shuttle Buggy SB-2500s
and renting one. Currently, this
equipment works in the Autopista
Regional del Centro, the main road
with more traffic in Venezuela which
connects the cities of Caracas, La
Victoria, Maracay, Guacara, and
Valencia, as well as other minor
cities. Valencia is known as the
industrial capital of Venezuela. It
belongs to the Eje Vial Nacional
Comparison of the HMA Temperature Before Compaction
Troncal 1—more than 100,000
cars per day travel this road.
Inversiones Coflan C.A. has been
recognized by the Public Works
Ministry of Venezuela for its
excellent pavement finishing and
work quality, specifically for the
smooth, safe, and durable surfaces. Coflan C.A. was also chosen
in 2013 as International Member
of the National Asphalt Pavement
Association (NAPA).
Without Shuttle Buggy SB-2500
With Shuttle Buggy SB-2500
Currently, a second generation of
members of the Martínez family
is completing their engineering
studies in order to continue with
the high-standard of quality on the
daily paving process with the same
passion as the founders.
HIGH-QUALITY PAVING
Ricardo Martínez, Coflan’s director, mentioned, “I don´t conceive
the idea of paving without the use
of the Material Transfer Vehicle
Shuttle Buggy in these times, with
the current tools, like the infrared
camera, the portable density testing devices, and the surface profilers to measure the smoothness
daily, which demonstrate the difference in quality like uniform density and smoothness of the paving
jobs performed with and without
the use of the Shuttle Buggy.”
Paul Lavaud, Roadtec director
of international sales for Latin
America said, “Each time I hear
the Inversiones Coflan directors and meet them at asphalt
shows talking about how proud
they are about their paving jobs, I
feel more than thankful that they
use our Material Transfer Vehicle
Shuttle Buggy SB-2500 as one
of their most important pieces of
equipment to improve their daily
process and quality. They are
very professional in each step
of the paving process. I am sure
that more paving companies will
follow their philosophy of high
quality.”
Coflan paving job Autopista Regional del Centro in Venezuela.

FOR INFORMATION
l to r: Coflan’s directors: Eduardo Martínez, Ricardo Martínez, Paul Lavaud with Roadtec, Rafael Martínez, and Walter Fajardo at
World of Asphalt 2013.
HOT-MIX MAGAZINE
Contact Roadtec Sales
800.272.7100
[email protected]
31 VOLUME 19 NUMBER 2
…continued from page 5
WMA produced by the water
foaming method does not
increase stripping.
Concerning WMA made by the
water foaming method, the PCA
document claims that application of
this WMA production method entails
elevated risk of moisture sensitivity
(stripping), which is manifested as
a loss of bond between the liquid
asphalt and the stone aggregate.
This concern is related to the
misunderstanding that water is
introduced into the asphalt mix.
Actually, the water is not injected
into the mix. It is injected into the
liquid asphalt, which causes the
asphalt to foam and greatly expand
in volume, improving the coating
of the aggregate and the lubricity
of the mixture. Even though a very
small amount of water is injected,
approximately 2 lbs or 1 kg (about
a quart or a liter) for each ton of
mix, even that does not remain.
The injected water is immediately
HOT-MIX MAGAZINE
turned to steam by the heat in the
liquid asphalt. Most of the steam
escapes to the exhaust system at
that point.
mixes of the same types. If there
is a stripping problem because
of porous aggregate, or for other
fundamental reasons, warm mix (by
foaming method or any other) will
The final residual water retained in
not fix it, but it is certainly not the
a ton of mix by the time it becomes
cause.
“RAP and WMA are good partners...
this combination may provide better
performing and lower-cost pavements
than previously available”
pavement on the road is typically
about ½ ounce per ton of mix
or about 0.0012 percent. Most
state DOT specifications allow 0.1
percent residual water or about 83
times the amount that the water
injection method contributes to
the pavement. Further evidence
is that stripping associated with
the water foaming method is not
seen in actual construction practice
with any greater frequency than
any other method or than HMA
32 VOLUME 19 NUMBER 2
RAP is not needed to provide
stiffness.
The author of the PCA document
also comments that RAP is needed
to provide the requisite stiffness
in the pavement. The addition of
RAP to HMA or WMA does in fact
tend to stiffen the mix. However,
the basic means of controlling the
pavement strength is the selection
of aggregates and virgin binder as
well as additives, such as polymers
and fiber. The addition of RAP has
not typically been used to remedy
any problems with hot mix or warm
mix. However, the addition of RAP
to any mix saves money. There is
a substantial indication that WMA
actually facilitates the inclusion of
RAP with an outcome of superior
pavements. Recent studies at
the National Center for Asphalt
Pavement Technology (NCAT)
have shown superior performance
in resistance to cracking in
50-percent RAP WMA pavement as
compared with the corresponding
50-percent RAP HMA and the
test control mix, which was a
100-percent virgin material. The
exceptional performance of the
high RAP WMA mixes has been
attributed to the greater beam
strength of the pavement. So, yes,
RAP and WMA are good partners,
not because the WMA needs help
from the RAP, but because that
combination may very well provide
better performing and lowercost pavements than previously
available.
Cost benefits of WMA extend
beyond fuel savings.
The referenced PCA report
correctly acknowledges that
substantial fuel savings result
from the making of WMA in
place of HMA. However, it seems
that it has been incorrectly
assumed that fuel savings are
the only savings associated with
that change. In fact, there is a
fundamental difference in the way
WMA behaves in production and
placement, it is usually more easily
compacted. This results in a better
road surface (more compacted)
with less effort. The lower required
effort sometimes reduces the
size of crew and amount of
equipment needed at the paving
site. Another unmentioned cost
advantage is that paving jobs can
proceed faster with WMA. Most
asphalt plants are limited in their
production capacity by exhaust
system limitations. Making mix
at a lower temperature requires
less fuel burn and produces less
exhaust, thereby relieving the
exhaust system and allowing
the plant to run faster. Faster
production reduces days on a
project. Certain fixed costs at the
plant and at the road, as well as in
trucking, are avoided in proportion
to the number of days by which
the duration of the project is
reduced. The increased use of RAP
is another major savings. Also,
more durable roads may very well
result and resurfacing will become
less frequent.
Another important benefit of WMA
is that the lower temperatures
avoid much of the oxidation that
is detrimental to the liquid asphalt
in the mix. It also avoids most
of the evaporation of the lighter
fractions of the asphalt. The
lower evaporation rate keeps all
of the components of the liquid
in the mixture where it belongs.
Obviously, the better the quality of
the liquid asphalt, the better the
performance of the mix, resulting
in increased pavement life and
reduced resurfacing costs.

When the
WMA Smoke
Clears
Many of the benefits of WMA as mentioned have obvious
cost benefits, but those returns have not yet been fully
determined because that will take some time; but it is
abundantly clear that a little fuel savings is just the “tip of
the iceberg.” Any dollar-estimate of the benefits in terms
of fuel savings alone is likely to be conservative to the
extreme.
While we at the Astec Industries, Inc. family of companies
make both asphalt plants and concrete plants, I do not
think it is our best interest or that of the public for one
material to be used in preference over another based on
erroneous information.
“ ”
My wish is to let the real facts
speak for themselves.
Dillman builds tough equipment.
Equipment that performs reliably
for years. Equipment you can
count on to produce high quality
asphalt mix. Full plants. Single
components. Individual parts.
Dillman gets the job done
HOT-MIX MAGAZINE
33 VOLUME 19 NUMBER 2
It’s the little
things...
2014 SOLD OUT in record time. There were 454 total students
from 119 companies, 38 American states, seven Canadian
provinces, and three countries. 80% were attending for the first time.
Register early. Space is limited. Registration opens October 1st.
PH 423.867.3754 | FAX 423.867.9761
| E-MAIL [email protected]
WK 1 — MonDay - thursDay, January 05 - 08
WK 2 — MonDay - thursDay, January 12 - 15
WK 3 — MonDay - thursDay, January 26 - 29
WK 4 — MonDay - thursDay, february 02 - 05
that make a
big difference
ASTEC Advanced Customer School attendees delve into the
subject matter to master the how, when, where, and what to
do that makes a big difference in a plant’s potential ROI.
Reserve rooms at least 30 days in advance for discount rate.
Call 423.756.5150 and mention the session discount code.
Discount DeaDline Dec. 05 for Jan. 05 coDe: aZ1
Discount DeaDline Dec. 12
for
Jan. 12 coDe: at2
Discount DeaDline Dec. 26 for Jan. 26 coDe: at3
Discount DeaDline Jan. 02
for
feb. 02 coDe: at4
The DoubleTree by hilTonTM
$
92. 00 USD per night + tax is the Astec Advanced Customer Schools
discounted room rate for a standard king or standard two-bed room.
Mega-Mountain
Roadway Challenge
Colombian highway contractor tackles country’s first
four-lane road through mountainous terrain
HOT-MIX MAGAZINE
36 VOLUME 19 NUMBER 2
Mario Huertas Corporation is
using an Astec Double Barrel®
plant with warm mix system for
the new highway, slated to be
complete in 2015, that will link
Colombia to Venezuela.
S
ince the 1920s, Mario
Huertas Corporation has
been a key player in the
development of infrastructure in
Colombia. Today, the Bogota-based
company ranks as one of the top
five Colombian highway contractors and has landed a number of
high-profile projects and awards,
including a $400 million, five-year
highway contract in Bucaramanga,
Colombia.
Mario Huertas Corporation’s (MHC)
roots trace back to 1920, when the
company was founded by owner
Mario Huertas’ great-uncle. At the
time, it worked exclusively in the
ports on the Magdalena River, the
principal river of Colombia that
flows north through the western
half of the country. Years later,
Huertas’ father started his own
company, expanding the family
business into other construction
and infrastructure-related activities
including roads, bridges, viaducts,
and residential building at the district, state, and national level.
Making the selection of quality
equipment prior to the start of
the job is one of the most crucial
steps in the process.
With more than 900 employees and
$600 million in contracts, MHC is
well-established as a progressive
pioneer in the industry accustomed to conquering massive civil
engineering projects in challenging conditions. The company has
earned recognition with the prestigious National Engineering Prize for
its work on the Sesquile Dam, and
currently has two contracts with
INVIAS (National Highway Institute).
“Mario Huertas Corporation is not
just a large company in Colombia,
but it is truly an engineering company,” said Hugo Diaz, sales representative for Rodríguez y Loñdono,
a KPI-JCI and Astec Mobile Screens
authorized dealer in Colombia. “It is
Now, for the past 39 years, Huertas recognized for its quality and innohas been leading the company and vation. Mario Huertas is a person
works with his son, 28-year-old
who is always thinking about the
Esteban, who represents the fourth technology and equipment, on how
generation in the family business.
to improve processes by automat-
ums, clay, sandstones, and also
parts with veins of limestone,”
Huertas said. “This combination
requires that the work is thoroughly
planned, not only in order to use
the aggregates but also for the stability of the slopes.”
The new highway, slated to
be complete in 2015, will be a
much-needed channel that links
ing them, and is always updated
with what is going on in the world Colombia to Venezuela. The project’s difficulty lies not only in
in order to apply it to Colombia.”
finding usable material in a close
“He is absolutely a pioneer in this
proximity to build the road, but
industry,” Diaz added.
also in overcoming the country’s
demanding topography. The curROCKY TERRAIN
rent road between Bucaramanga
Developing infrastructure in a
and Cúcuta is narrow and steep,
country riddled with mountains
with altitudes ranging from 900 m
and jungles is no easy feat. When
(2,952 ft, 9 5/64 in) above sea level
Huertas won the bid over 22 other up to 3,600 m (11,811 ft). The new
contractors to construct an 87-mi
highway’s design levels out the
(140.01 km), four-lane highway
road to a maximum 7.5 percent
across the Andes Mountains
incline—down from a high of 18
between Bucaramanga and Cúcuta, percent. Once complete, vehicles
the company was tasked with the
will be able to go as fast as 50
mammoth challenge of designmph (80.46 kph), reducing travel
ing and building the country’s first time from Bucaramanga to Cúcuta
four-lane road—as well as all of
from 6 hours to 2.5 hours.
the bridges and tunnels—located
All of this had to be accomplished
in a mountain range.
without interrupting the flow of
“It is a very difficult task given
traffic of vehicles traveling from
its components, such as colluviBucaramanga to Cúcuta, and, at
Opposite Page: The Andes Mountains in South America has a challenging terrain with colluviums, clay, sandstones, and veins of limestone. With careful planning to use the
aggregates on-site and maintain the stability of the slope, Mario Huertas Corporation is building Colombia’s first four-lane road through the mountain.
HOT-MIX MAGAZINE
37 VOLUME 19 NUMBER 2
the same time, maintaining the
integrity of the natural landscape.
“Our work has been exemplary
both from an environmental point
of view and regarding the handling
of the resources of a public works
project,” Huertas said. “The entire
responsibility falls to us to take
care of the fauna and flora of these
mountains, and we must recover
many areas with native species.
Therefore, it is a much more
comprehensive construction than
older projects or other projects in
Colombia.”
The end result is a country that
will have an updated infrastructure
capable of meeting Colombia’s
growing needs for travel and trade,
according to Dave McCracken,
international sales director for Latin
America and the Caribbean for KPIJCI and Astec Mobile Screens.
“The construction of modern,
multi-lane highways in Colombia’s
HOT-MIX MAGAZINE
With track-mounted equipment,
we were able to rapidly transport
these machines during aggregate
processing, saving time and money.
mountainous and rugged terrain
is making travel safer and faster
for its citizens,” McCracken said.
“On the commercial side, industrial
goods for export will be done more
efficiently and at a reduced cost as
they move to Colombian ports.”
was seeking a relationship with a
manufacturer and local dealer that
would listen to his specific needs
and provide a solution.
“Throughout this process, we
expected to be guided and advised
by the dealer and the manufacturer
in terms of making improvements
FORGING FORWARD
or adapting the machinery to our
The complexity of the project
environment, which is different
required MHC to invest in highquality mobile equipment that could in each country, given the operation, geography, and site location,”
classify aggregate without the
Huertas said. “KPI-JCI and Astec
use of water—which is limited in
Mobile Screens, as well as Astec,
the region—as well as provide a
Inc., provided me with research
high production rate, according to
and the opportunity to observe
Huertas. But most importantly, he
38 VOLUME 19 NUMBER 2
the equipment working in other
countries, so as to unify criteria and
optimize resources.”
“What led us to purchase the
equipment is the personalized
relationship between the dealer, the
factory, and all of the engineers that
act on a product,” he continued.
“The quality of equipment is also
crucial. According to our experience, it is not a good practice to
try to sell a product only for the
sake of the sale. It is important for
the product not only to be able to
produce aggregates, but also to
allow the owner to have additional
capacity in the future. It is critical
that there is a long-term connection
between the manufacturer, dealer,
and the producer.”
Through KPI-JCI and Astec
Mobile Screens authorized dealer
Rodríguez y Loñdono and Fernando
Marroquin, international regional
manager for Astec Aggregate and
Mining Group, Huertas purchased
Mario Huertas Corporation purchased three GT165DF screen plants, as well as
two FT4240CC impact crushers, a 2500 vertical shaft impactor, and a PTSC 2618
high frequency screen from Rodríguez y Loñdono, a KPI-JCI and Astec Mobile
Screens authorized dealer in Colombia.
three GT165DF screen plants to
clean the raw material, as well as
two FT4240CC impact crushers,
a 2500 vertical shaft impactor,
and a PTSC 2618 high frequency
screen to make asphalt aggregate.
MHC also invested in a new Astec
Double Barrel® plant with warm mix
system.
wearing out parts or components of This reality makes the customerthe machines used.”
dealer partnership a vital aspect of
the purchasing process.
Another key factor in partnering
with KPI-JCI and Astec Mobile
“We cannot afford equipment with
Screens was the mobility of
lower-than-expected performance
the track-mounted equipment.
or quality of the products,” he said.
According to Huertas, the equip“It was very important to us that we
ment’s portability provided versatil- could visit the factories, and have a
ity and efficiency to the project.
dealer who was constantly available
One of the major challenges of
According to Huertas, the sucwhenever there was a problem.
“Because the equipment is
the project was obtaining the land
cess of the asphalt plant is directly
Rodríguez y Loñdono’s methodolmounted on tracks, we were able
to house the asphalt plant and
linked to the success of the crushogy is to solve the problem, find an
to rapidly transport these machines
aggregate processing equipment,
ing and screening of the aggregate,
immediate solution for it, and then
during the processing of aggreHuertas said. The company ultimaking the selection of quality
start thinking about the causes. I
gates,” he said. “We could bring the
mately selected a limestone quarry equipment prior to the start of the
think this methodology has tightmachines directly to the aggregate
at Surata near Bucaramanga, which job one of the most crucial steps in
ened bonds and made KPI-JCI and
deposits where the raw materials
reduced travel and allowed all of
the process.
Astec Mobile Screens’ products
are being obtained so we could
the crushing and screening equipmore and more popular within the
“The GT165DF track-mounted
classify them, which saved us time
ment to be located in the same
Colombian market.”
screens make it possible to classify and money.”
place. Unlike many other quarries,
the raw aggregates and remove the
every piece of material is used,
fines, which can affect the crushing NO ROOM FOR ERROR
eliminating waste from the comGiven the highly-competitive conof the aggregates,” Huertas said.
FOR INFORMATION
pany’s operation.
“This feature has greatly helped us struction market in Colombia and
Contact Melinda Schweitzer
the tight margins for profit, Huertas
“We use any raw material that
be more effective and arrive at a
605.668.2524
much more real crushing tonnage, said there is no room for error when
comes out of this quarry,” Huertas
[email protected]
it
comes
to
investing
in
equipment.
thus preventing the fines from
said. “Our materials are being
completely used; the materials are
clean, combined, or reused, but
there is no waste, because we have
always believed that any material
that is obtained or crushed must
be placed in the place where it is
required, either for making concrete, fillers, pavement structures,
subbases, or bases.”

HOT-MIX MAGAZINE
39 VOLUME 19 NUMBER 2
Tackling the M10 Reconstruction
R
ussian company
Technostroy is a local
contractor in the region of
Karelia, situated next to the border
of Finland in Northwestern Russia.
The company started operations
in 2000 with the acquisition of a
200 MTPH (220 TPH) Astec 6 ft
(1.83 m) Portable Double Barrel®
plant. Over the past 10 years, the
company has grown into one of
the largest paving contractors
in Russia, working mostly with
the Federal Highway administration across the territory of seven
regions with the combined population of 20 million.
In 2013, the company reached the
level of producing almost 1 million tons (907,184 tonnes) of HMA
(hot-mix asphalt) and embarked
on paving jobs in various regions
requiring high capacity, high
mobility of equipment, and use of
the most recent HMA technologies
available.
NEW PLANT COMMISSIONED
Facing the challenges, the company turned to its long-term
partner—Astec,Inc.—and commissioned the delivery of the latest
version of the Six Pack® Portable
Double Barrel® plant incorporating
the latest developments over the
last 10 years. Among the specific
features requested by Technostroy
were full compliance with Russian
and European regulations, high
portability and fast erection times,
plus documentation and the control system in Russian.
Russian contractor
uses Astec Portable
Double Barrel® plant
on highway project
Technostroy in Northwestern Russia invested in the Astec Portable 6 ft x 33 ft (1.83 m x 10.06 m) Double Barrel® plant for paving projects.
The portable Six Pack® plant with
Astec’s warm mix system provided the
latest technology for Technostroy.
many sections of M10 needed
repair. The reconstruction of M10
became the first project where the
Six Pack asphalt plant was used.
According to Rebikov, the Astec
Six Pack is ideal for large highways. “Portability and the compact
With WMA, we benefit in terms of
Currently, it runs on average 170
size of equipment are extremely
MTPH (187 TPH) using two to three quality by having very little temimportant for Technostroy, which
perature drop despite long hauling constructs and repairs roads in difmix designs per day.
stretches. The mix hauled to the
ferent parts of Northwestern Russia
ASTEC WARM MIX SYSTEM
site is consistent and of good qual- and has to move from site to site.
The Astec Six Pack is delivered
ity,” he said.
The transportation of the Six Pack
complete with Double Barrel® drum
is easy and convenient, and can
M10 PROJECT
mixer and the Astec warm mix
be set up close to the jobsite. It
The Six Pack asphalt plant was set
system, which can produce both
The new plant started operations
reduces transportation time and
up in Veliky Novgorod (Novgorod
conventional hot-mix asphalt and
in July 2013.
fuel consumption and provides
environmentally friendly warm-mix the Great)—one of the oldest
good quality of asphalt.”
“The machine does a very good
asphalt. The production of the plant Russian cities. Veliky Novgorod is
and accurate job,” says Dmitry
in 2013, after four months of oper- located on M10, a federal highway Rebikov continued: “High serviceRebrikov, Technostroy plant opera- ation, was approximately 250,000 in Russia connecting Moscow and ability is the best feature of the Six
tor, who’s been working with Astec m3 (326,987 yd3). The company
Saint Petersburg. The major federal Pack; it has no vertical members
HMA plants since 2003. “You just
highway is not the longest in the
typical of batch plants and requires
has been using the Astec Double
need to power it on in the morning Barrel® and warm mix system
country at 664 km (412.5 mi), but no working at height.”
and power it off in the evening. It
one of the most important ones. It
for producing warm-mix asphalt
took us as little as three days to
(WMA) for virtually for all highway runs through numerous cities and
have it up and running.”
settlements and is always in high
projects and all mix types.
FOR INFORMATION
demand. High traffic loads (approxThe maximum performance of
Smalkov Andrey, manager of
Contact Sergei Dymov
imately five times more than
the Six Pack asphalt plant is 200
Technostroy, believes WMA is a
011 7 921 967 3636
expected) caused severe damage
MTPH (220 TPH) with nominal
very efficient technology. “Autumn to the pavement, and by 2013,
[email protected]
capacity of 180 MTPH (198 TPH).
is a cold season here in Russia.

HOT-MIX MAGAZINE
40 VOLUME 19 NUMBER 2
Trade Show
Spotlight
Astec Industries exhibited at
ConExpo to record attendance
H
eld in March at the
Convention Center in Las
Vegas, Nevada, CONEXPOCON/AGG 2014 was crowned the
largest trade show in the United
States with nearly 130,000 attendees in four days, making this the
second highest attendance in its
history, according to Exhibit City
News. An estimated 2,400 exhibitors were spread across three main
indoor halls, as well as six outdoor
parking lots, which allowed manufactures to showcase and demonstrate equipment, products, and
services.
witnessed in quite a few years.
Not only were we able to visit
with many of our long-term and
key customers, but we were also
fortunate enough to meet with a
number of new customers, both
domestically and internationally.
We were encouraged to hear that
many of our contacts were evaluating and seriously considering either
upgrading their plant equipment or
purchasing a new plant.”
Claude continued: “We introduced
our ‘Zero to One Hundred Percent
RAP Plant lineup,’ combining existing and newly designed technoloIn Central Hall, exhibitor Astec
gies we now offer from either our
Industries Inc. and its family of
Astec, Inc. and Dillman facilities.
companies created a buzz for
The message we wanted to conRAP (reclaimed asphalt pavement) vey to our existing and prospecand showcased its equipment for
tive customers was that we offer
asphalt road building and aggregate the industry’s most complete and
processing.
comprehensive package when they
consider our unsurpassed lineup of
Steve Claude, executive vice presihot-mix asphalt plants, backed up
dent of Astec, Inc., commented on
by the industry’s strongest afterthe trade show: “Astec, Inc. was
sales support for technical service,
extremely pleased with the terrific
parts, and engineering expertise.”
attendance our booth received durAccording to Malcolm Swanson,
ing the entire show, and felt the
president of Astec, Inc., RAP usage
turnout was the strongest we had
continues to increase
as a way for producers to keep costs
down while utilizing stockpiles of
reclaimed asphalt
pavement. To
meet this need,
Astec, Inc. increased
the ability of its signature Double
Barrel® drum dryer/mixer to handle
up to 65 percent RAP. A 1/8-scale
model of the new
Astec Double Barrel
HR was on display
at ConExpo.
“The Double Barrel
HR (high RAP) is
a key product in
the Astec line. It
fulfills a need for
those producers
who already run
high percentages of
RAP and in whose
markets the trend
toward running more
recycle is expected
to increase,” said
Swanson.

HOT-MIX MAGAZINE
Staff from Astec Industries’ family
of companies ready to greet and
meet with booth visitors from
around the globe.
A 1/8-scale model of the new high
RAP Double Barrel® drum from Astec,
Inc. on display at ConExpo 2014.
41 VOLUME 19 NUMBER 2
U N M AT C H E D TH ER M A L EFFI C I EN CY
Most HMA plant people know that heaters with high
thermal efficiency use less fuel than those with low
efficiency. That’s why so many heater makers claim
their heaters have high thermal efficiency.
But what is high? Heaters by our competitors rarely
come close to the numbers our heaters achieve:
85% (90% with our Stackpack heat exchanger).
Even a 2% advantage provides worthwhile fuel savings. And we have found that our heaters usually
have even greater advantages in efficiency.
Actual thermal efficiencies of heaters are easy to
determine and compare. The exhaust gas heat,
which is wasted energy, provides a good indication
of thermal efficiency. The higher its temperature the
lower the thermal efficiency.
So if you want to compare the efficiency of two
heaters, just measure the temperatures of their
exhaust gases.
Be sure to insert the stem of your thermometer into
a port hole near the base of the exhaust stack to get
the true temperature of the exhaust gas.
An exhaust temperature of 665 degrees F indicates
a thermal efficiency of 83%. If your measured
temperature is equal or higher than that, it would be
worthwhile for you to contact us about a replacement heater.
Our thermal efficiency is unmatched.
Please call today for more
information.
HEATEC
H E AT E C , I N C .
®
an Astec Industries Company
5200 WILSON RD • CHATTANOOGA, TN 37410 USA 800.235.5200 • FAX 423.821.7673 • heatec.com
NEWS
KPI-JCI and Astec
Mobile Screens
Promote Egge
to Engineering
Manager
KPI-JCI and Astec Mobile
Screens promoted Alan
Egge to engineering manager of Kolberg-Pioneer,
Inc., the company’s
Yankton, South Dakotabased manufacturing
facility. Alan’s first name
was incorrect under his
photo in the last issue.
Congrats to Alan on his
new position.
Astec Promotes
Francisco to Director
of Service
Astec, Inc. announces the promotion of Daniel Francisco to the
position of director of service.
Astec executive vice president
Steve Claude said, “Daniel’s dedication, background, experience,
and understanding of the importance of serving our customers in
‘the Astec way’ will tremendously
benefit his efforts in leading our
service organization.”
Alan Egge

Daniel joined Astec, Inc. 22 years
ago and has held several positions,
his most recent as controls service
manager.
Daniel Francisco

Astec, Inc. Hosted I Make America
Astec, Inc. in Chattanooga, Tennessee,
hosted a stop on the nationwide I Make
America Harley Tour on July 9, 2014.
On behalf of the Association of Equipment
Manufacturers (AEM), I Make America and
its more than 30,000 supporters advocate
for pro-manufacturing policies to create
more jobs in the U.S. and keep the economy
competitive with other countries.
The purpose of the Harley Tour is to raise
awareness about I Make America and its
mission, as well as engage AEM member
companies and their employees to help
make a difference. Everyone who signs up
through October 3 has a chance to win the
2014 Harley-Davidson Road King, featuring a custom I Make America paint job that
was on display during the event. Anyone
can register to win the Harley by visiting
www.IMakeAmerica.com and becoming
an I Make America supporter.
During the event, Astec employees were
joined by employees from Roadtec and
Heatec for a motorcycle ride-in before
Astec president Malcolm Swanson, AEM
president Dennis Slater, and AEM chairman
Rick Patek (Astec Industries group president
for Aggregate and Mining) addressed the
crowd.

Astec, Inc. hosted a stop on the I Make America Harley Tour in July.
Astec, Roadtec, and Heatec employees participated in a motorcycle ride-in during the event.
HOT-MIX MAGAZINE
43 VOLUME 18 NUMBER 1
NEWS
New Regional Sales Managers Hit the Road for Astec
Astec, Inc. welcomes new regional
sales managers to the Astec family.
Jeff Baugh has been promoted
to regional sales manager for
Tennessee, Kentucky, West Virginia,
and Pennsylvania.
Kent Hood joined Astec as the sales
manager for Alaska, Colorado,
Idaho, Montana, Oregon, Utah,
Washington, Wyoming, and the
Canadian provinces of Alberta,
British Columbia, Manitoba, N.W.
Territory, Nunavut, Saskatchewan,
and Yukon.
Ken Mayo joined Astec as the
sales manager for Iowa, Ohio,
Michigan, Wisconsin, Minnesota,
North Dakota, South Dakota, and
Nebraska.
Jeff Baugh
Kent Hood
Ken Mayo

Astec Model on
Display in Italy
Astec, along with sister company Roadtec, exhibited at
the Asphaltica International
Asphalt Industry Exhibition
co-located with the Samoter
Earth Moving Equipment
Exhibition in Verona, Italy, May
8-11, 2014, in the booth of its
Italian dealer MS Tecnologie.
Astec exhibited a 1/8-scale
model of a relocatable plant,
as well as a large model of a
Double Barrel® drum dryer/
mixer featuring a cut-away
section allowing visitors to the
booth to see the flighting and
mixing paddles, helping communicate the unique capabilities of the Double Barrel®
drum. The Asphaltica show
focuses specifically on
asphalt, providing a unique
opportunity to get to know
and share the latest information and various techniques
for production and laying road
surfaces.

HOT-MIX MAGAZINE
Terra Select Awards
Peterson Pacific as a Master
Distributor for USA and
Canada
Terra Select, Inc. (TSI), a manufacturer
of screening equipment headquartered
in Sassenberg, Germany, announced
Peterson Pacific Corp. as the master
distributor of its products in the United
States and Canada as of May 1, 2014.
Astec exhibited a 1/8-scale model of a relocatable plant and a large model of
a Double Barrel® drum dryer/mixer.
“Peterson and Terra Select products are a
perfect fit complementing each other, as
many of our customers have both grinders and screening equipment—so this is
a great relationship for us with enormous
growth potential,” said Larry Cumming,
president of Peterson.
Terra Select products will continue to
be retailed by existing U.S. dealers in
Maryland, Virginia, Delaware, New York,
Utah, Nevada, and South Eastern Idaho.
Astec, with sister company Roadtec, exhibited in the booth of its Italian
dealer MS Tecnologie.
44 VOLUME 19 NUMBER 2
Peterson specializes in developing delivery and processing equipment that turns
low-grade organic materials into highvalue products. Since 1981, Peterson has
manufactured equipment for customers
in over 25 countries.

NEWS
Vig Retires from
KPI-JCI and Astec
Mobile Screens
Astec, Inc. Breaks Safety Record
Joe Vig retires from KPI-JCI
and Astec Mobile Screens
as of July 1. His long tenure
with Astec was successful
and memorable. In 2001,
Vig became president of
Kolberg-Pioneer, Inc., and
later in 2008 became
Joe Vig retires from KPI-JCI and Astec Mobile Screens.
group vice president over
Kolberg Pioneer, Johnson
Crushers International, and Astec Mobile Screens. In 2013, he became group
president over KPI-JCI and Astec Mobile Screens, as well as Astec Industries
subsidiaries Peterson Pacific and Telestack Ltd. Until his retirement, Joe was
responsible for five of Astec Industries’ 18 divisions, and nearly 1,200 of the
corporation’s 4,000 employees.
On June 6, 2014, Astec, Inc. broke its all-time safety
record of 92 days without a medical recordable accident.
This is quite an accomplishment and a very important one.
Astec president Malcolm Swanson said, “The really great
thing is to have all of us able to go home to our families
for the last 93 days without anyone being hurt.”
Astec celebrated that accomplishment, and the establishment of a new record of 97 days worked without a recordable incident, with a cookout for all employees on June
20, 2014. During the festivities, employees raised money
for T.C. Thompson’s Children’s hospital in Chattanooga,
Tennessee, by purchasing tickets for a chance to dunk
Astec Industries, Inc. CEO and president Ben Brock, who
graciously agreed to enter the dunk tank. In all, Astec
raised $1,720.


Astec Industries Promotes
Elliott to Group Vice President
Astec Industries names Jeff Elliott
as group vice president of the Astec
Aggregate Mining Group (AAMG). His
responsibilities will include direct
oversight of KPI-JCI and Astec Mobile
Screens, and Telestack Ltd. in Omagh
County, Tyrone, Northern Ireland.
Previously, Elliott served as president of
Johnson Crushers International, KPI-JCI
and Astec Mobile Screens’ Oregon manufacturing facility.
Astec enjoyed a cookout in June to celebrate breaking its safety record
of 92 days.

Jeff Elliott
Schwarz Becomes President
of Johnson Crushers
International
KPI-JCI and Astec Mobile Screens names
Jeff Schwarz president of Johnson
Crushers International, the company’s
Oregon manufacturing facility. Since
2011, Schwarz has served as general
manager of Astec AggReCon West, an
authorized KPI-JCI and Astec Mobile
Screens dealer headquartered in Eugene,
Oregon.

Jeff Schwarz
Astec employees purchased tickets for a chance to dunk Ben Brock,
CEO and president of Astec Industries, Inc.
HOT-MIX MAGAZINE
45 VOLUME 18 NUMBER 1
Astec’s Greg Painter
wears many hats while
assisting his customers
L
ast month, regional parts
sales manager Greg Painter
celebrated his thirty-first
year with Astec, Inc., which means
that customers in Virginia and the
Carolinas—Greg’s territory (one
of eleven Astec territories that
cover all of the United States and
Canada)—can count on a wealth
of experience when he’s at their
plants. It’s an advantage stemming from his familiarity with Astec
equipment and parts from his
early days as a parts technician,
an advantage he shares with his
customers and the rest of the Astec
team.
ATTENTION TO DETAIL
“I am meticulous about having
information from the plants for
my parts technicians,” Greg said.
“I was an estimator for twelve
years and came out of the parts
department. I’ve got a heart for the
people who sit behind the phone
and sell parts because I’ve been
there.”
HOT-MIX MAGAZINE
Greg noted that is it critical to collect as many details as he can from
each plant to make it easier for
parts technicians to find the correct
parts a customer needs. “I try to get
pictures of the plant and the parts,”
he added, to ensure his customers
know he’s looking out for them by
getting the right part when they
need it.
other parts people feel the same
way.”
WEARING MANY HATS
Relationships are built on a daily
basis, and all of the regional parts
sales managers play an important role in maintaining a positive
experience for their customers.
Sometimes this means stepping
outside the letter-by-letter definition
of their job description.
mixers and silos—constantly
checking the status of different
parts in use at the plants, checking
their wear, and providing quotes for
equipment.
“I was with a customer putting
a gas train on a burner,” Greg
recalled. “I worked with the service
department to help him install it on
the piece of equipment before the
service tech came out to complete
A FACE THEY KNOW
the final hook up. We wear so many
Being on the road four or five days
“Those of us who have been with
hats out here. For example, I’ve
per week, Greg is the face of Astec,
Astec for a number of years—many taken pictures of plants and situaInc. for most of his customers.
are like me who actually came up
tions to help our service technicians
Customer relationships in the field
through the shop,” Greg noted.
better prepare for what they’ll find
are key when customers need to
“While we’re on the road, we’re
once they’re at the plant.”
communicate large amounts of
actually service men, not only parts
critical parts information rapidly in
A TRUE PARTNERSHIP
people and sales people. We’re
order to meet their goals. Having a
part of the service department and Having a person in the field at their
face they can trust helps greatly.
part of manufacturing because we customers’ plants is an advantage
can look in the field and gather the of working with Astec, Inc. Regional
“I enjoy getting out and meeting
people—it works best for the cus- information they may need.”
parts sales managers like Greg
tomers,” Greg shared, “and I can
Painter are more than just a sales
Greg emphasized that regional
say that today most of my family
contact or a toll-free number to the
parts sales managers perform
and friends are people out here
service department, they are the
routine inspections for no charge.
on the road in my territory. I enjoy
eyes on the ground of a committed
Because they’re out in the field,
working with them, and I know the
partner.
they can inspect customer drum
46 VOLUME 19 NUMBER 2

Astec parts salesman TRAVIS SNEED
is passionate about working with his
UKC Grand Nite/ PKC Champion coon dog
Cannonball. It’s a passion matched only by his
dedication to working with his customers.
Anyone can stock parts and ASTEC stocks
a lot of parts. In fact, it’s the world’s largest
inventory of parts for asphalt plants. But
ASTEC doesn’t just stock parts. ASTEC has a
team of people who are focused on delivering
the industry’s best customer service.
The common thread among all these people
is passion. It’s passion that drives them to be
the best at everything they do. And it’s passion
that sets ASTEC apart from the competition.
Any part, any brand. We can help.
ASTEC PARTS
half page