this issue pdf - Mix Equipment Magazine

General contractor benefits from
Roadtec fleet for mill and lay
Astec’s depth of control offerings provide
innovation for plant operations
Navigating Australia’s Barrow Island
with portable asphalt plant
Dillman branches out into new markets
for industrial sales
YOUR DEPENDABLE SOURCE FOR NEWS ABOUT HMA TECHNOLOGY
PUBLISHED BY ASTEC INDUSTRIES, INC.
VOLUME 18 NUMBER 2 - 2013
10
16
VOLUME 18 NUMBER 2
Copyright © 2013
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.
22
30
Editorial Staff
Editor:
Donna Campbell
Staff Writer:
J. Campbell
Staff Photographers:
Paul Shelton (Astec)
Brandon Meredith (Astec)
Scott Lee (Roadtec)
Sam Anselmi (Astec)
5 Point of View
22 In the Heart of Texas
Subscription Services:
Diane Hunt
6 Plant 17
Iowa contractor excels by replacing old with new
26 Every Day is Recycle Day
10 Change is the Only Constant
30 The Power of Portability
12 In Demand and In Control
34 Wake Up the Echoes
14 The Shape of Things to Come
38 Branching Out
16 Mobility Down Under
39 Hot-Mix News
Directors of Advertising:
Paul Shelton (Astec)
Frank Eley (Heatec)
Stephanie Rider (Roadtec)
Editorial Board:
Dr. J. Don Brock
Ben Brock
Tom Baugh
Paul Shelton
Norman Smith
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
Words from Sergio Cinerari, AAPA Chairman
Company excels and mill and lay with Roadtec fleet
Astec’s warm mix system enhances new asphalt plant
Astec’s training schools continue to evolve
Tennessee contractor welcomes efficiency with portable plant
Astec’s latest plant controls—PMIII
Asphalt plant completes retrofit
Astec uses 3D printing to bring ideas to life
Dillman ventures into new territory for industrial sales
Astec Australia delivers asphalt portability to civil contractor
What’s happening at Astec Industries
21 On Your Side
Earning a customer’s trust is job #1 for Astec’s Travis Sneed
ON THE FRONT COVER
LL Pelling Company, Inc. set up the relocatable Astec Double Barrel ® plant
in Cedar Rapids, Iowa. The plant features the 72,457 CFM Pulse Jet
baghouse, a 10 ft x 14 ft (3.05 m x 4.27 m) eight-compartment cold feed
system, and three 200-ton (181 tonne) silos.
Here’s how to get all future issues
of 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 18 NUMBER 2
POINT OF VIEW
More Than Just
Sticky Black Stuff
Words from Sergio Cinerari,
Chairman, AAPA (Australian Asphalt Pavement Association)
B
itumen is a unique
substance that starts
as crude oil, is refined,
and then combined with
aggregate to make asphalt
and sprayed seal road
surfaces. These surfaces
provide safe, quiet, and longlasting pavement that connect
people, goods, and services
right across Australia.
Asphalt surfaces are 100-percent
recyclable and save significant
amounts of new material.
Without these durable
surfaces, society would be vastly different, but most
people take asphalt pavements for granted. Those
of us who work in the pavement industry know the
significance of asphalt pavements, and I encourage
each of you to be proud of the work we do. I also
encourage you all to promote the importance of
what we do to others around us.
Even more importantly, we should ensure that
all stakeholders in our industry are aware of the
environmental advantages of asphalt over other
paving materials.
pavement surfaces once,
and then if it is recycled,
can only be used for lower
value purposes, such as
fill or road base.
Asphalt surfaces are
therefore 100-percent
recyclable and save
significant amounts of
new materials.
REDUCES GREENHOUSE GAS EMISSIONS
Sergio Cinerari, Chairman, AAPA
PROCESS CAN BE REPEATED
Firstly, asphalt paving is 100-percent recyclable and can be recycled
over and over again.
A deep lift asphalt pavement or perpetual pavement that is over
20 years of age may have suffered some surface damage, but
generally this damage is only “skin deep.” The minor surface
damage in a wearing course can be milled off and quickly replaced
with a new wearing course, with minimal interruption to traffic
flows and at low cost.
Asphalt removed from a road pavement remains asphalt, a valuable
combination of bitumen and high-quality aggregates. This material is
referred to as reclaimed asphalt pavement or RAP. RAP can be readily
returned to an asphalt plant where it can be combined with virgin
materials and applied to another road or pavement project. In another
20-plus years, the same process can be repeated.
Asphalt is not consumed, but remains asphalt indefinitely. This
is unlike other materials, such as concrete, that can be used for
Using RAP not only reduces the demand for new
materials, it also greatly reduces greenhouse gas
emissions. The manufacture of bitumen is a low
source of greenhouse emissions, but some energy
is used in its manufacture and in the extraction,
crushing, and transport of aggregates. The use
of RAP reduces the greenhouse emissions by
removing the need to make and supply new
materials. The use of RAP in asphalt readily
reduces greenhouse emissions by at least 10 to 20
percent. RAP also has great synergies with warmmix asphalt providing even more environmental
benefits, as well as performance benefits.
Those of us working in our industry can be proud of the part we
play in society, not only as we build quality roads and pavements,
but also because we are a green industry. An industry that produces
low greenhouse emissions compared to other road surfaces and an
industry that can recycle asphalt over and over again.
BENEFITS ARE CLEAR
The benefits of asphalt as an environmentally friendly product
are clear, and we should help to educate communities and all
stakeholders that asphalt is more than sticky black stuff, letting
them know that, as asphalt is 100-percent recyclable, it is one of the
greenest construction materials available on the market today.
As an industry that takes its impact on the environment very
seriously, we should continue to encourage the use and development
of green pavements through practices such as the increased use of
RAP and low-energy technologies such as warm mix.

HOT-MIX MAGAZINE
5 VOLUME 18 NUMBER 2
Plant 17
Iowa contractor excels by
replacing old with new
T
here comes a time in any
venture when moving
forward requires change.
Whether it’s transitioning to the
latest technology or acquiring
new partners, company growth is
earmarked with new decisions.
LL Pelling Company, Inc. is one
company that understands what
it takes to reach the next level of
expansion, and it includes Astec’s
equipment and innovation.
HOT-MIX MAGAZINE
“The ability to recycle using the
Astec Double Barrel® drum mixer
sets us apart from the competition.”
HUMBLE BEGINNING
Lloyd Pelling, Sr. started the LL
Pelling Company, Inc. in 1948 in
the Williamsburg, Iowa, area. It
began oiling roads as road sur-
6 VOLUME 18 NUMBER 2
faces began moving away from
mud to gravel and eventually
to pavement. In the late 1960s,
Lloyd Pelling, Jr. became president
and moved the company to Iowa
City to allow for expansion into
the asphalt business. During the
60s and 70s, LL Pelling traveled
throughout Iowa with batch plants
or continuous mix plants. The decision to put down roots happened
in 1975 and the traveling stopped.
An asphalt batch plant was erected
in Coralville, Iowa.
FORWARD PROGRESS
In the late 80s, Russ Rhinehart
purchased the company from the
Left: LL Pelling Company, Inc. set up the relocatable Astec Double Barrel ® plant in Cedar Rapids, Iowa. Top: 10 ft x 14 ft
(3.05 m x 4.27 m) eight-compartment cold feed system. Bottom: LL Pelling’s plant features the 72,457 CFM Pulse Jet baghouse.
Pellings. Rhinehart and his partner,
Manatts (a diversified heavy highway construction company based
in Brooklyn, Iowa) took the company into the 21st century. It was
Rhinehart who purchased the first
Astec plant in 1997 for the Iowa
City location. The 400 TPH (363
MTPH) Astec Double Barrel® plant
replaced an old 6,000 lb (2,721
kg) batch plant. This was quite a
change for LL Pelling.
“We knew technology had
advanced beyond what we were
currently using,” said Chuck
Finnegan, current president of LL
Pelling. “It was the vision and input
of new people leading to new decisions for the direction of the company, and the path forward looked
promising.”
LL Pelling had three asphalt plants:
the Astec Double Barrel® plant in
Iowa City (purchased in 1997); a
small 4,000 lb (1,814 kg) batch
plant in Marion; and a 16,000 lb
(7,257 kg) batch plant in Cedar
Rapids. In addition to its asphalt
paving, concrete curb and gutter,
chip and sealcoat, pavement marking, and oil transportation, being
able to supply its own hot-mix
asphalt (HMA) to its projects created a full-circle operation.
Dillman DuoDrum and put up this
new plant in Marion. The plant
replaced the small 4,000 lb (1,814
kg) batch plant.
THE NEXT PHASE
“This replacement was five or six
years overdue,” said Finnegan.
In 2001, LL Pelling purchased a
HOT-MIX MAGAZINE
In 2012, LL Pelling purchased an
Astec Double Barrel® plant for the
Cedar Rapids location to replace
the old 16,000 lb (7,257 kg) batch
plant. The plant was operational
mid-April 2013.
7 VOLUME 18 NUMBER 2
Relocatable Astec Double Barrel® drum.
“We had a five-year plan probably
10 years ago to put the new Astec
plant in place, but with economic
times as they were, and still are, it
just didn’t work out according to our
original timetable.”
“We knew technology had
advanced beyond what we were
currently using … with Astec, the
direction of the company looks
promising,” said Finnegan.
LL Pelling purchased 40 acres (19
hectares) of land outside its sister
quarry in Cedar Rapids to set up the
new plant, named Plant 17 by the
accounting department’s numbering
system.
“Using reclaimed asphalt pavement (RAP) and recycled asphalt
“We viewed the location as opporshingles (RAS) is a capability that
tunistic,” said Finnegan. “We can
sets us apart from the competition
haul much of our material to the
and helps us control costs,” said
plant and don’t have to travel on a
Finnegan. “Anytime we can recycle,
public road. This saves on hauling
it’s a benefit to the environment and
and trucks.”
the community. The Astec Double
Barrel® at Plant 17 uses RAP and
A GOOD POSITION
RAS.
This saves on landfilling; we
Astec equipment allows LL Pelling
even grind our own shingles. These
to be in a good position, especially
with the ability to recycle. This was cost-saving factors allow us to cut
cost for our consumers. And in a
an area the company wanted to
pro-portland cement state, we need
improve.
to control costs to stay competitive.”
HOT-MIX MAGAZINE
8 VOLUME 18 NUMBER 2
LL Pelling generates a lot of RAP
from its road construction projects. One project is Interstate 380
(southbound) where a recycled
mix is being utilized (4 percent
RAS and 12 percent RAP).
“We do a lot of night work in the
corridor between Cedar Rapids
and Iowa City, about 25 mi (40
km) apart, connected by I-80 and
I-380,” said Finnegan. “There’s a
lot of congestion through this area,
so having a ready supply of material enables us to work quickly.”
Plant superintendent Rod Haerther,
who has been with LL Pelling
for 23 years, oversaw the construction/setup of Plant 17 from
concept to completion. According
to Haerther, Plant 17 uses up to
25 percent RAP (alone in a mix),
and when using RAS with RAP, the
recycle amounts are 2 to 3 percent and 9 percent, respectively.
RAS is not currently used alone in
a mix.
“We are finishing up the I-380
southbound project and already
have a contract for the northbound
section of I-380, plus a project at
the Cedar Rapids airport,” said
Finnegan. “Business is looking
good moving into 2014.”

FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
Astec’s training school classes continue to evolve, expand and excite
S
ervice coordinator Troy
Norris’s enthusiasm is
contagious. And with his
responsibilities, he needs the
energy. As Astec Industries’ training school administrator, he is
tasked with maintaining the high
standards attendees expect of the
Astec Advanced Customer School.
Whether Troy is laying out the
direction of new classes for coming
years or discussing improvements
HOT-MIX MAGAZINE
and additions for current training
training center] and there is a new
sessions, he has to move as quickly facility across the street with a fullas the pace of technology.
size Astec Double Barrel® drum and
a range of scale models.”
Over the years, the look and focus
of the Astec Advanced Customer
In the 1980s, the Astec Advanced
School has changed to reflect
Customer School moved to its perthe needs of customers and the
manent home on-site. Astec cusdemands of the industry. “When we tomers spent much of the training
started, we were having training
sessions in a single meeting room,
classes in hotels—the Chattanooga with breakout classes that expandChoo Choo, in the train car,” Troy
ed throughout the facility. From that
noted. “Now we are here [at Astec’s small initial footprint, the classes
10 VOLUME 18 NUMBER 2
grew in scope, scale, and reputation. Word of the school’s benefits
spread throughout Astec’s customer
base, which led to more customers
asking for training specific to their
needs. “We add new classes all the
time,” Troy said. And as the needs
of customers changed, so too did
the facility.
As the classes’ popularity increased
among customers, the school
recognized the need for a bigger
learning space to accommodate the
influx of new attendees. In 2009,
Astec Industries opened its expanded training center. For the first time,
trainers and customers were able
to work in a hands-on environment,
all-in-one dedicated area, providing
immediate feedback from instructors and collaboration between
attendees. New equipment was
moved in to facilitate the increased
range of class offerings.
In 2011, the current facilities for the
Astec Advanced Customer School
took shape. “From where we
began to where we are now—with
Training Center East and Training
Center West—it’s amazing to see
where the school has come,” Troy
added. Conveniently located across
the street, the new training center
is large enough to accommodate a
full-size Astec Double Barrel® for
hands-on drum classes, as well as
scale models of existing plants. The
scale models are the same ones
carried by Astec to different trade
shows around the world.
Gun Class,” is for returning students. Any attendee of prior Astec
basic customer schools meets the
prerequisite to join Astec’s in-depth
training on four critical categories:
New for 2014, Astec will be offering
burners, drums, controls, and electwo levels of training. Level I will
trical systems. With a narrowed
be an enhanced and expanded verfocus on these four main categosion of basic training for first-time
ries, Astec can delve deeper into
students. The new Level I training
critical areas of plant performance
promises to be even more handsand offer more advanced operating
on and include technical training for
and troubleshooting tips.
power houses. Level II, or the “Top

HOT-MIX MAGAZINE
11 VOLUME 18 NUMBER 2
In Demand
and In Control
F
rom burners to silos, from
motors to drums, each component of a hot-mix production plant can either be a trusted
collaborator in increasing the plant’s
efficiency or—with access to timely
information or ability to fine-tune its
operation—a frustrating adversary
to a plant’s capability. The main
way plant operators and managers interact with the full range of
their plant’s production process is
through the plant control system.
Developed with customers in mind,
PMIII is Astec’s newest plant
control system.
Controls have looked at how plants
use their various control systems
and developed answers based on
real-world demands. Their latest
design, called the PMIII, has just
been introduced and is earning
The human element—how comfort- praise from customers as a responable users are with this system—is sive and intuitive system for today’s
often as important as its technihot-mix production.
cal aspects in determining how
LAYING THE FOUNDATION
efficiently a control system works
within the plant. Over the years, the Of Astec’s legacy systems, the
PM96—commemorating the year
designers and engineers at Astec
PM96 system overview
HOT-MIX MAGAZINE
12 VOLUME 18 NUMBER 2
of its release, 1996—was an
early version of a single-bore or
multi-bore control system. It provided reliable service for hot-mix
plants throughout America for
years. However, with new technology came changing expectations. Operators were pleased
with the PM96’s ability but as
more demands were put on the
system, newer controls would
need to be integrated as well.
NEW EXPECTATIONS
The next generation release, the
PMII, was designed to be its
replacement. It maintained the
same level of control but replaced
the PM96’s specialized user-interface with a standard PC terminal,
which relied on a so-called soft
PLC and ran in Windows. The benefits to the plant’s machinery were
the same, but the benefits to operators were exponentially improved:
necessary training time decreased,
plant control increased.
Just before the release of the
PMII, Astec released the TCII, a
highly automated and exceedingly
detailed plant control system. “This
is the Cadillac of control systems,”
said Al Williams, one of Astec’s
PMII system overview
senior control engineers and
head of the Industrial Control
Group. Williams has over three
decades’ experience with
Astec’s asphalt control systems
and has seen many of them
put to the test—and pass with
flying colors. “With a system
like the TCII, for example,” he
explained, “it can do whatever a
plant operator needs. It’s almost
as if, if something has an on/off
switch, the TCII can automate
it.”
burner. If someone out there
still wants to use the old PM96
push-button control panel
for one part of the plant, that
customer can still install PMIII
modules everywhere else.”
The PMIII’s modules can be
installed individually to specify
the options to a unique asphalt
facility or they can be installed
together as a package, similar
to the TCII.
LEARNING BY DOING
The TCII’s chief advantage over
earlier systems is its capacity to learn and communicate
with smart motors, variable
frequency drives (VFDs), and
other equipment. In addition to
allowing operators easy manual
control options and automated
operations within preset limits,
the TCII records and reports
information about the plant’s
efficiency from various points
within the hot-mix production
process. Thus, the TCII allows
operators to use that information
in realtime, establishing a more
responsive and productive control system.
However, not every plant
requires that level of intricate
data-management. Also, for
some plants, a system like the
TCII might be their ideal model,
but perhaps management has
not allocated enough resources
to afford a “Cadillac” control
system. With those customers’
needs in mind, Astec Controls
developed their latest version
of plant control systems—the
streamlined PMIII.
PMIII system overview
PMIII burner controls
Lastly, the PMIII’s built-in diagnostics reduce plant downtime,
helping operators probe for the
source of any problems along
the production line. Also, the
system’s improved reporting
makes a greater variety of data
available, which will assist
management in long-term
plant decisions.
“Instead of just sending a signal to start or stop, the PMIII
can read current on motors,”
Williams added. “This is normally a feature you would only
find on a larger, more expansive control system. Now that
a more streamlined system
can provide this level of data,
more and more plants will have
a level of control they never
thought possible.”
MADE WITH CUSTOMERS
IN MIND
Developed by Astec’s in-house
controls engineers, the PMIII
is a PLC-based control system
comprised of separate modules
for burners, silos, motor controls,
and blending and loadout. With
these features, the PMIII can
be as robust or as simplified as
plant operators desire. Williams
noted, “Customers can purchase
CPUs for each part of the plant
or just one for the motor or the
Some plant operators complain
of “information overload” in
competing control systems.
With that in mind Astec updated the PMIII user interface to
rely on minimal graphics on
each screen, reducing distraction and increasing an operator’s ability to find information
with speed and clarity. Also,
even though each individual
screen may appear simple, the
PMIII retains the ability to drill
down for more information.
This layered approach to data
management allows the PMIII
to provide abundant information that an operator may need
without overwhelming users.

FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
PMIII silo controls
HOT-MIX MAGAZINE
13 VOLUME 18 NUMBER 2
The Shape of Things to Come
3D printing capability brings
ideas into reality for Astec, Inc.
I
nnovation, by its nature, tends
to outpace resources. In custom
manufacturing, ingenious solutions and next-generation ideas are
sometimes put on hold because the
cost of the equipment and materials to make them a reality are cost
prohibitive or too rare to produce
them in a widely accessible manner. Even building a prototype of
a new machine part can require
dedicated hours and expense with
no guarantee of success. However,
by using state-of-the-art 3D printing
technology to create prototype burners, Astec, Inc. has narrowed the gap
between what can be imagined and
what is possible.
THOROUGH PROCESS,
PRECISION EQUIPMENT
Working both with outside partners
and engineers inside Astec, the
3D printing process is overseen by
Michael Swanson, P.E., manager of
the Astec Burner Group. First, the
engineer presents a problem and
the idea for a new part, and it is
designed and drawn as a 3D CAD
model. Depending on the part, virtual tests are performed to assess
the design’s performance using
computational fluid dynamics (CFD),
discrete element method (DEM),
and other analysis software. Then, a
physical prototype is built in the 3D
printer and testing of the prototype
determines if a new iteration is
needed.
The Astec Burner Group relies on a
3DSystems ProJet 5000, a largescale, precision 3D printer that the
team operates on an almost daily
basis. The ability to create prototypes
in precise detail meeting the design’s
The 3DSystems ProJet 5000 professional 3D printer provides detailed
prototypes for Astec.
impossible to find a shop with the
equipment capable of machining
them,” said Swanson.
As Astec’s ability to prototype ever
more intricate parts increases, so
too is their opportunity to solve problems. Swanson noted that requests
to build prototypes continue to
increase and he sees no ceiling on
3D printing’s potential. “If it can be
drawn,” he noted, “it can be built.”
NEW IDEAS, NEW OPTIONS
The prototype printed nozzle part before test firing.
needs is key to Astec’s successful
use of 3D printing. “Every part is different,” said Michael Swanson, “and
when building a prototype, even the
smallest change in a design can
yield different results. The more
exact we can build a test part, the
more accurate the tests will be.”
OUT WITH THE OLD
Historically, Astec outsourced such
quick turnaround prototype manufacturing to third-party suppliers,
a process that limited the amount
of testing that could be performed
and the number of prototypes that
Testing of the burner with its 3D prototype is successful.
could be produced. “The old method
of drawing a part and individually machining it took two weeks,”
Swanson added. “The current technology has cut that time down to, on
average, two days.”
When Astec brought 3D printing inhouse, Swanson’s group now had
the technology to machine more
prototypes, quicker and at greater
savings. With the lag time between
iterations reduced to a mere couple
of days, engineers can now finetune their tests and see immediate
results. Today, Astec can build a prototype, assess it, and manufacture a
new version for testing in a fraction
of the time it would have taken to
machine just one prototype using
the old method.
COMPUTATIONAL FLUID
DYNAMICS
Accurate implementation of CFD
is key to a 3D-printed prototype’s
success, but it is also the starting
point for innovative and cutting-edge
designs. “In the past, some of the
parts we’ve tested for burners would
not have been possible to prototype.
The complexity and intricacy of the
design would have made it nearly
Astec, Inc.’s use of 3D printing for
prototype parts and sales and marketing display models benefits the
entire company. Testing is now possible for more parts with increased
complexity, leading Astec engineers
to implement more concepts that
would once be deemed too farfetched or prohibitively expensive
for the real world. In the future of 3D
printing, however, the real world is
what you make it.

FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
Mobility
Down Under
Astec Australia delivers asphalt
portability to major civil
contracting company.
I
n 2012, Fulton Hogan
Industries transported its new
highly portable Astec asphalt
plant to Barrow Island, a remote
island off the western coast of
Australia. Fulton Hogan Industries
is a very prominent business
“down under,” which specializes in
building and maintaining transport
and civil infrastructure in Australia,
New Zealand, and the South
Pacific so that communities can
operate safely and efficiently.
The plant was custom-designed
and built for Fulton Hogan’s
Asphalt Surfacing Operations to
provide them with a highly portable asphalt plant which could be
moved easily from state to state
and offshore.
Kellog Joint Venture Gorgon
The Kellog Joint Venture Gorgon, an unincorporated joint venture
between KBR, JGC, Hatch, and Clough, is the Gorgon’s Project’s
downstream engineering, procurement, and construction management contractor. The scope of work includes three LNG trains,
LNG storage, and load-out facilities, including a jetty, domestic
gas plant, utilities, materials offloading facility, and a construction
village.
HOT-MIX MAGAZINE
16 VOLUME 18 NUMBER 2
The Astec portable asphalt plant allowed Fulton Hogan
to meet the requirements for working on Barrow Island.
The first and biggest test for
the plant’s “ease of portability”
came when Fulton Hogan won
the supply of hot-mix asphalt for
the Gorgon Project on Barrow
Island. To undertake the project,
Fulton Hogan would need to move
its new highly portable asphalt
plant through four of Australia’s
six states over 4,345 km (2,699
mi) by road across the breadth
of Australia and then by sea to
get to the remote Barrow Island.
The plant was moved along the
project route using ten trailers to
transport the plant components.
Each trailer customized to meet
strict Australian standards for
safety and registration. Thanks to
innovative engineering by Astec,
Inc. engineers, the trailers met the
transport solution required to keep
Fulton Hogan’s Gorgon Project
moving forward.
Astec Australia’s head office facility for pre-commissioning work
and registration with Queensland’s
Department of Transport, something difficult to achieve if the
plant does not comply with ADR
regulations and Australian standards. Thanks to the efforts of
Astec’s engineering team and
liaising with Astec Australia, this
was a successful task.
THE PLANT’S ARRIVAL
In Perth, the asphalt plant was
shrink-wrapped and quarantined
in order to comply with Barrow
Island’s stringent environmental
quarantine regulations, which
applies to all buildings, materials, and equipment introduced to
Barrow Island. The requirements
Fulton Hogan’s portable asphalt
plant was originally bound for
Brisbane, Queensland (Eastern
Coast of Australia), which is the
Port of Arrival of the portable
asphalt plant. It was stored at
After the arrival of the plant into
Brisbane, Fulton Hogan was then
awarded the Barrow Island project
in partnership with the Kellog Joint
Venture Gorgon. The portability
of the plant was showcased as it
was transported from Brisbane,
Queensland, through New South
Wales, South Australia, and all the
way through to Perth in Western
Australia.
TRANSPORT PREP
Barrow Island
Home to Australia’s largest operating onshore oilfield, Barrow Island
is a Class “A” Nature Reserve. This brings the highest level of protection under State legislation for the island’s plant and animal life.
Approvals for work on the island underwent an intense assessment
before being granted. State and Federal Governments put measures
in place to protect the area throughout the life of the project.
The Gorgon
Project
The Gorgon Project is a
$43 billion joint venture
developing the Greater
Gorgon Area gas fields.
Touted as the largest
resources project in
Australian history, it will
also be the single largest investment of its
kind in the world. The
Greater Gorgon Area
gas fields contain about
40 trillion cubic feet of
gas. This is the nation’s
largest undeveloped gas
resource. The Gorgon
Project is owned by the
Gorgon Joint Venture,
which includes the
Australian subsidiaries
of Chevron, ExxonMobile,
Shell, Osaka Gas, Tokyo
Gas, and Chubu Electric.
The venture will process
15 million tonnes (16.5
million tons) per year
of liquefied natural gas
(LNG) and 300 terajoules
per day of domestic gas
on Barrow Island, 70
km (43 mi) off Western
Australia’s Pilbara Coast.
The gas processing portion of the project will be
located on Barrow Island,
limited is size to 300
hectares (741 acres), or
1.3 percent of the island.
Fulton Hogan acquired the portable 180 MTPH (198 TPH) Astec 6 ft x 33 ft
(1.83 m x 10.06 m) Double Barrel ® plant in 2012 and features the following:
portable 8 ft x 11 ft (2.44 m x 3.35 m) three-compartment cold feed system;
portable 24 in x 50 ft (61 cm x 15.24 m) conveyor/static scalping grizzly;
Whisper Jet ® burner; portable Pulse Jet baghouse for 30,384 ACFM draft
system; portable compact self-erecting 40 ton (36 tonne) surge bin; PM
Continuous Mix Blending Controls; Heatec 15,000-gal (56,781 l) portable
tank; and a Heatec 500-gal (1,893 l) horizontal calibration tank all tailored for
transport on ten trailers through Barrow Island. All the components and trailers
met the stringent compliance measures for doing work on the Gorgon Project.
HOT-MIX MAGAZINE
17 VOLUME 18 NUMBER 2
10 Trailers
Trailer One:
1 PCF-811-3E-A portable
8 ft x 11 ft (2.44 m x 3.35 m)
three-compartment
cold feed system
1 x spare wheels and racks
to each trailer
Trailer Two:
1 PCF-811-3E-B portable
8 ft x 11 ft (2.44 m x 3.35 m)
three-compartment cold feed system
1 x spare wheels and racks to
each trailer
Trailer Three:
1 PIC-2450E-SG portable
24 in x 50 ft (61 cm x 15.24 m)
conveyor/static scalping grizzly
1 x spare wheels and racks
to each trailer
Trailer Four:
1 PDB-633E portable 6 ft x 33 ft
(1.83 m x 10.06 m) Astec Double
Barrel® drum
1 DB-GRN001 Astec warm mix system
Trailer Five:
1 PBH-30E portable Pulse Jet
baghouse for 30,384 ACFM draft
system
1 x spare wheels and racks
to each trailer
HOT-MIX MAGAZINE
Trailer Six:
1 DA-275 275 BBL Dry Additive
System (10 ft, 6 in wide)
(3.05 m, 15.24 cm wide)
1 x spare wheels and racks
to each trailer
Trailer Seven:
1 SEB-4024C portable compact
self-erecting 40 ton (36 tonne)
surge bin/24 in (61 cm) drag
(10 ft, 6 in wide)
(3.05 m, 15.24 cm wide)
1 x spare wheels and racks
to each trailer
Trailer Eight:
1 PMII-B Continuous Mix Blending
Controls with 30 in (76 cm) console
1 WM2000PB Profibus loadcell
truck management system
1 PCH-27.SP Pilot control center,
9 ft, 8 in x 30 ft, 6 in (2 rooms)
(2.74 m, 20.32 cm x 9.14 m,
15.24 cm)
1 ELIF-PM PMII electrical
interface (MCC panels, main breaker, etc.)
1 DNSWITCH day night switch
1 TES-20 power and control
cables with plugs and receptacles
1 SPCL-ELEC special voltage
electrical system 380/50/3
1 x spare wheels and racks
to each trailer
18 VOLUME 18 NUMBER 2
Trailer Nine:
1 TA-15PD.SP special design
15,000-gal (56,781 l) portable
tank (9 ft, 6 in diameter)
(2.74 m, 15.24 cm diameter)
1 MACC-2024 2.5 in (6.35 cm)
twin pump asphalt metering
system (10 hp pump)
1 HACC-1437 3 in (7.62 cm) piping
tank to asphalt metering package
1 HACC-1440A Australia 3 in (7.62 cm) jacketed piping from metering package outlet
1 HACC-1446 3 in (7.62 cm)
piping - second compartment to
metering package
1 HACC-1451 3 in (7.62 cm)
piping - AC unloading pump to second compartment
1 SPEC-PPG special ball joint
piping from trailer to TA-15PD
1 x spare wheels and racks
to each trailer
Trailer Ten:
1 HC-120 1,200,000 BTU/hr (output)
gas/oil heater with manifold
1 SPEC-TRLR portable trailer for
transport of Heatec and Astec components
1 CAL-1HE 500-gal (1,893 l)
horizontal calibration tank
(mounted on trailer)
1 Astec Australia fibre feeder
1 x spare wheels and racks
to each trailer
include thorough cleaning and
disinfection treatment of all items
prior to transportation. After treatment, small items are placed in
shipping containers and larger
items, such as building modules
and plant components, are shrinkwrapped to prevent contamination during transport. Shipping to
Barrow Island is carried out by
barges departing from both Perth
and Dampier.
In order to commission the plant,
every employee and subcontractor to Astec Australia had to be
approved and participate in an
extensive induction program.
The program consisted of an
initial thirteen-page application
to be inducted onto the project.
Documentation included all licenses and tickets relevant to the person and the work to be completed.
All inductees were flown to Perth,
Western Australia, to attend inductions for Kellogs Joint Venture,
Fulton Hogan, and Ertech. Each
person had an extensive medical exam and an elevated work
platform ticket check and competency demonstration. Upon arrival
onto Barrow Island, the induction
included a campsite and environmental inspection. The plant was
commissioned on Barrow Island in
October 2012.
“
portability null and void. The main
challenge was to ensure that no
trailer was wider than 3.2 m (10 ft,
5 63/64 in).
Fulton Hogan also acquired two
Roadtec Pavers (RP170 and
RP190) for paving on Barrow
Island. Both pavers also endured
the stringent shipping, quarantine,
and commissioning requirements.
Astec Australia is devoted to continuously meeting the needs of its
customer—and by working hand
in hand with Fulton Hogan’s people
were able to design, build, deliver,
install, and commission this highly
portable asphalt plant even under
the extreme logistical challenges
Fulton Hogan acquired two Roadtec pavers (RP170 and RP190) for night-paving projects
presented by the Gorgon Project
on Barrow Island.
on Barrow Island.
Michael Thompson, who is Fulton
Hogan’s national operations manager, airports, enjoys the challenge
of tackling these logistically difficult projects. Michael said that
the old saying “the devil is in the
details” is very true, especially
when it comes to the amount
of planning, preparation, and
management that is required to
be successful on these types of
projects. Michael also said that the
key ingredients for success are
safe, dedicated, reliable, and persistent people supported by high-
Astec stands by its equipment
and provides unwavering
support no matter the
endeavor …
Fulton Hogan’s portable asphalt plant featured a burner and drum equipped for the Astec
warm mix system.
”
TRAILER-MOUNTED MOBILITY
The Astec, Inc. portable asphalt
plant for Fulton Hogan is comprised of various components
that are all trailer-mounted on ten
trailers for complete compliance
with the strict ADR compliance
rules in Australia. If the plant does
not comply with ADR standards,
the plant will not be allowed to be
transported and would make the
ment, and that they will always be
there to support us wherever and
whatever we do. Sure, there will
be the odd occasions when things
don’t go quite as you expect, but
with Astec we know that they have
a very good understanding of our
business, and we know that we
are dealing with very honest and
quality reliable equipment. Michael reliable people that will always
continued that with Fulton Hogan’s respond and support us,” said
Astec plant and equipment, he felt Michael.
extremely confident that Fulton
To further test the portability and
Hogan was working with a comreliability of its new highly portable
pany that listened intently to its
Astec Double Barrel® asphalt
needs, and had designed and built plant, following the completion of
a plant accordingly.
its Barrow Island project, Fulton
Hogan plans to transport back to
“Not only that, I know that Astec
Australia’s east coast to tackle the
stands by its plant and equip-
HOT-MIX MAGAZINE
refurbishment of the runway on
Brisbane’s International Airport.
Fulton Hogan knows that when
they do, Astec will be there to support them.

FOR INFORMATION
Contact David Smale
General Manager Australia
+61 7 3714 8800
+61 419 969 335
[email protected]
or Robert Messner
Regional Sales Manager
+61 419 965 202
[email protected]
19 VOLUME 18 NUMBER 2
On
T
Your
Side
he lead-up to Independence
Day weekend is a quiet one
for Travis Sneed, Astec’s
regional sales manager for the
Southeast. While people throughout his territory—from Florida up
through Alabama, from Mississippi
east to Georgia—will be buying
fireworks and setting up backyard
barbeques, Travis and the ten other
regional sales managers are completing a safety training course at
Astec headquarters. “On holiday
weeks like this, a lot of our customers are off work,” Travis explained,
“so that makes it a good time for
us to come in and take care of
in-house business like I’m doing
today.” Before the week is out,
Travis will not only complete more
training courses but also familiarize himself with Astec’s newest
product catalog and equipment
changes, as well as deliver news
on how products in the field are
meeting expectations and where
they can improve. Then he’s back
on the road, because customers are
expecting him.
A NEW LEVEL OF SERVICE
Travis Sneed has been with Astec
in one position or another for over
two decades, but back in February
of 2001 his unofficial position was
guinea pig. He was named the
Earning a customer’s trust
is job #1 for Astec’s Travis Sneed
first regional sales manager for
parts, meaning that he was now
responsible for maintaining Astec’s
customer relationships for a large
section of the country, not just a
few clients here or there.
the customers,” Travis added. He
travels his territory constantly,
meeting with customers across
the Southeast to answer their
questions, provide solutions,
and generally make their parts
experience as easy as possible.
“I remember having a few weeks to
Over time, customers know they
see if we could get it off the ground
can trust Travis to advocate their
before we wanted to commit everyneeds.
one’s effort to it,” Travis recalled.
Since then, the regional sales sup- “Without that level of trust,” Travis
port system did not just get off the continued, “believe me, there is
ground, but took flight. Today, Astec no sale.”
divides all of the United States and
RELATIONSHIPS WORK
sections of Canada into eleven
BOTH WAYS
parts regions—each one with its
Through Travis Sneed and the ten
own support person like Travis.
other regional sales managers, the
SUPPORT FOR CUSTOMERS
relationship between Astec and
“I consider myself a liaison
its parts customers is mutually
between Astec and the customer.
beneficial. “We spend three or four
I understand that this is a sales
days of each work week with our
job,” Travis noted, “but I’m on the
customers,” Travis added, “and they
customer’s side. That is my most
are the real-life test labs for our
important job.”
products.” With access to that raw
amount of hands-on experience,
Other than three or four weeks a
year for training, being on the cus- Travis and his colleagues can report
tomer’s side could be taken literally. back to Astec’s engineers on the
latest needs from the field—which
“We serve as a support team for
HOT-MIX MAGAZINE
is sometimes the easiest way to
communicate. “Many times I’m
the messenger of a great idea, one
our customers brings to the table,”
Travis said.
“When our customers have information our engineers need, I
want them to know that I’m there
for them,” Travis continued. “My
number one goal is to build that
relationship.” Building relationships and building trust, improving
service and improving products, the
Astec Parts Regional Sales team
is a major reason Astec customers expect and receive superior
service.

21 VOLUME 18 NUMBER 2
In the Heart
xas
of Te
A
ccording to Corey Clark,
director of asphalt and
fleet operations with Clark
Construction of Texas, Inc., the
family-owned and operated road
construction’s bread and butter is
“mill and lay.”
Company excels at mill and lay
projects with Roadtec equipment.
the tack coat just seconds before
putting down mix.
This method, according to Clark, is
more efficient. “Using the SP-200
is cleaner, faster, and requires a
and we also have the SP-200 Spray County. Clark Construction of Texas, smaller crew.” The spray paver
used on Hwy 281 was the second
Paver™, SB-2500c Shuttle Buggy, Inc. was awarded the road repair
In operation since 1978, Clark
machine Clark Construction had
RP-190 Paver, RX-60c Cold Planer, project in January 2013. Work
Construction specializes in seal
purchased from Roadtec. According
and the RX-600e Cold Planer,” said began in May on Highway 281
coat and hot-mix asphalt projto Roadtec’s Texas service techniCorey Clark. “On a recent job, we
from the Burnet County Line to
ects across Texas. With innovacian James “JW” Whittington, Clark
rented the Roadtec RX-600e and
US 290 West in Johnson City. The
tive approaches to the chip seal
Construction was instrumental in
liked the milling machine so much 15.051 miles (24.22 km) were set
industry and asphalt paving, the
that we purchased it for future
to be repaired using the traditional helping Roadtec develop the first
company has excelled in areas of
spray paver and purchased the unit
projects.”
method of putting down the oil
safety, quality, and performance.
in March 2005. Clark Construction
application (tack coat) ahead of
What has been a contributing factor The project Clark referred to was
putting down mix and sealing with traded this older machine for the
to its success? A fleet of equipment the Marble Falls job northwest of
a top coat. Clark Construction was SP-200 Spray Paver in its current
Austin, Texas.
manufactured and supported by
able to have the application method fleet.
Roadtec.
changed to use a membrane
BLANCO COUNTY HWY 281
MILL AND LAY
underseal and a Roadtec SP-200
“We purchased the Roadtec
Marble Falls in centrally located in
Spray Paver. The SP-200 puts down The top 1.75 in (4.44 cm) of the
RX-700 Cold Planer in June 2011,
Texas on Highway 281 in Blanco
highway was milled and replaced
HOT-MIX MAGAZINE
22 VOLUME 18 NUMBER 2
Roadtec SP-200 Spray Paver
The SP-200 Spray Paver sprays tack and
applies hot-mix asphalt seconds later.
Combining spraying and laydown produces
a high-quality mat with a strong bond
between layers. A spray bar just in front
of the paver’s auger distributes the liquid
through computer-controlled, self-cleaning
valves. An onboard microprocessor precisely controls the rate of flow. Valves can
also be controlled manually. Valves are
arranged in sets of three, providing plenty
of spray capacity so you can move fast.
To cut down on refill stops, the SP-200 is
equipped with a 2,100-gal (7,949 l) tack
tank. The spray bars extend as needed
with the screed and each nozzle can be
manually shut off for partial passes. For
paving at any time, a material transfer vehicle (MTV), such as the Roadtec
SB-2500c Shuttle Buggy, delivers mix to
the spray paver’s gravity-fed hopper, which
has a capacity of 11 tons (9 tonnes). The
spreading augers deliver the mix to the
hydraulically extendable, vibrating screed.
with 2 in (5.08 cm) of special
specification 3224 dense-graded
hot-mix asphalt. The road repair
was approximately 15 mi (24.14
km) long and consisted of four lanes
(two north and two south). The
Texas Department of Transportation
(TxDOT) approved SS 3224 for use
in May 2011.
Once the milling was finished, the
Roadtec SB-2500c Shuttle Buggy
fed the Roadtec SP-200 Spray
Paver as 2 in (5.08 cm) of hot-mix
asphalt was put down. This process
of pavement preservation is one of
the most cost effective, efficient,
and versatile options available on
the market. The benefits include
reduced noise levels, enhanced
skid resistance, and improved ride,
drainage, and aesthetics. Overlays
can be placed in varying thicknesses, allowing flexibility to design
according to the needs of the
highway. Future maintenance of the
roadway exists through the recycling
of materials. Hot-mix asphalt (HMA)
consists of well-blended aggregate
and asphalt cement—a 100-percent
recyclable product.
The road work took Clark
Construction through the small
town of Round Mountain, population of 182 (according to the 2011
census). A few weather-related
delays hampered progress, but
with the Roadtec equipment, Clark
Construction kept pace and completed the project on time.
“The project took about two
months,” said Clark. “We experienced some rain delays and were
pushed on the schedule, but with
the Roadtec equipment, we finished
the project on time near the end of
July.”
Clark continued, “We put down
approximately 60,000 tons (54
HOT-MIX MAGAZINE
tonnes) of asphalt on the project.
The Roadtec machinery held up well
and we experienced fast production. The support we receive from
Roadtec is essential to our success,
and having a Roadtec fleet of equipment provides the right tools for
what we love to do best ... mill and
lay.”

FOR INFORMATION
Contact Roadtec Sales
800.272.7100
[email protected]
23 VOLUME 18 NUMBER 2
Every Day is
Recycle Day
Upgrade to new
asphalt plant
brings Astec’s
warm mix system
to the forefront
HOT-MIX MAGAZINE
26 VOLUME 18 NUMBER 2
Callanan Industries’ Dillman
UniDrum plant features a 600
ton (544 tonne) New Generation
Storage System.
“With the counterflow design, we run recycle every day …
and with the service we receive from Astec and Dillman,
we are happy operators in the asphalt industry.”
C
allanan Industries, Inc. is a
leading supplier of paving
materials and construction
services in New York. Founded in
1883 by Peter Callanan in South
Bethlehem, the company focused on
aggregate mining. In 1895, Callanan
won the first road building contract
let by New York State. A forwardthinking man, Callanan pioneered the
concept of a state highway system.
Callanan Industries was acquired by
Oldcastle, Inc. in 1985 and continues
its mission to be cost competitive
while providing high-quality materials today.
Double Barrel® plant had served
them well, the company decided it
was time to trade it in and upgrade
to a newer model.
“It made sense to upgrade and put
in a new plant with the upcoming
move to a new location,” said Jeff
When it comes to asphalt, look no
Frani, general manager of asphalt
further than Callanan Industries’
purchase of a Dillman UniDrum plant operations with Callanan Industries.
“We were new to Dillman and were
in 2012. Although the 1994 Astec
FRESH START
HOT-MIX MAGAZINE
27 VOLUME 18 NUMBER 2
Callanan Industries’ new Dillman UniDrum plant features a Pulse Jet baghouse, TCII controls, a low-profile truck scale, and a seven-compartment cold feed system.
impressed with the counterflow
design of the UniDrum.”
• Dual 10 ft x 14 ft (3.05 m x
4.26 m) recycle feed bins
BRAND NEW PLANT
• Pilot control center with TCII
control system
Callanan purchased a stationary
400 TPH (362 MTPH) 9 ft x 54 ft
(2.74 m x 16.46 m) Dillman Unified
counterflow drum plant for the
South Bethlehem, New York, location.
• Astec warm mix system
COUNTERFLOW DESIGN
What separates the Dillman
UniDrum from other plants? It’s the
unique nature of producing quality
The plant features the following:
hot-mix asphalt at a high produc• 10 ft x 14 ft (3.05 m x 4.27 m) tion rate with a high percentage
seven-compartment cold feed
of recycle. The extra-long drum
system
length maximizes mixing and drying times to reduce fuel usage and
• 5 ft x 12 ft (1.52 m x 3.65 m)
provide optimal mixing. The system
dual deck scalping screen
eliminates the time-consuming
• 68,194 CFM Pulse Jet baghouse process of trunnion alignment and
ensures the equipment operates
• 600 ton (544 tonne) New
correctly. Centered around a large
Generation Storage System
20 in (50.8 cm) trunnion, fitted with
• 11 ft x 100 ft (3.35 m x 30.48
adjustable double-row Timken™
m) low-profile truck scale
bearings and ring fitters, this
system is an industry exclusive,
HOT-MIX MAGAZINE
28 VOLUME 18 NUMBER 2
according to Dillman. The key is
its unique pivot pin system, which
allows the asphalt operator to easily dial in the dryer in a matter of
minutes without the need of any
special equipment. In the end,
the dryer rotates properly without
excess wear to the tires, trunnions, and thrust roller assemblies.
Frani is a fan of the patented
flighting design on the Dilman
UniDrum. The flights are adjustable to better control the baghouse temperature and moisture
removal from the aggregate. Its
unique recycle entry is also a plus.
The inlet into the drum allows
immediate mixing of recycle
with the hot aggregate, bringing
the recycle up to temperature
and removing moisture quickly.
Maintenance is made easy with
the clean-outs in the collar around
the drum.
“The Dillman UniDrum is operating
well for us; we’re using 20-percent
recycle on state surface mix and
30-percent recycle on base mix,”
said Frani. “We have several entities that we are supplying mix to
for various projects around our
area; we range anywhere from
2,500 tons to 3,000 tons a day
(2,267 tonnes to 2,721 tonnes)
depending on the job.”
Frani continued: “The combination of quality equipment with
top-notch service from Astec
and Dillman makes our partnership worth its weight in
asphalt.”

FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
The
Power of
Portability
HOT-MIX MAGAZINE
30 VOLUME 18 NUMBER 2
Tennessee contractor
welcomes efficiency with
portable Astec plant
Hoover, Inc.’s 7 ft
(2.13 m) Astec
Double Barrel®
plant uses the
PMIII controls
and features a
portable 10 ft x
14 ft (3.05 m x
4.27 m) five-bin
cold feed system.
Y
ou can’t miss the Omaha
Orange blazing the skyline
in Lebanon, Tennessee. The
brilliant orange hue is the signature
color of Hoover, Inc., and adorns
all of the components of its new
hot-mix asphalt plant.
THE EARLY DAYS
The Omaha Orange paint color
stems from Tom Hoover, Jr.’s great
grandfather Ephriam Hoover, Sr.
Ephriam ran a motor freight company and the orange color was on
all the trucks. Ephriam continued
With a portable plant, Hoover, Inc.
is able to bid on projects otherwise
passed over; portability is an
added benefit.
the use of the color when he
started his crushed stone business.
He expanded into ready-mix concrete, hot-mix asphalt, and grading
(construction in general). Even after
product. With devoted employees
(some spanning employment over
decades), the operations still focus
on crushed stone and asphalt.
NEW AND EFFICIENT
The 7 ft (2.13 m) portable Astec
Double Barrel® plant has been in
operation since December 2012. It’s
not the only Astec plant that Hoover,
the passing of Ephriam in 1979, the Inc. has in operation.
company remains family-owned
“We’ve been impressed with Astec
and operated. Through the years,
since our introduction in the early
the company has delivered on
2000’s,” said Tom Hoover, Jr., assisits dedication to provide quality
tant construction manager with
HOT-MIX MAGAZINE
31 VOLUME 18 NUMBER 2
Hoover, Inc. has a 400 ton (362 tonne) New Generation Storage System with two 200-ton (181 tonne) silos, and an Astec warm mix system with a Phoenix® Talon burner.
Hoover, Inc. has three asphalt
plants located within quarry sites
in Tennessee, which are able to
provide competitive prices on
quality hot-mix asphalt.
Hoover, Inc. “Astec’s reliable service
and top-quality product led us to
purchase a new plant; it’s a relationship that has served us well.”
Set up of the plant was smooth.
Calibrating and troubleshooting the
plant with PMIII controls took a bit
longer. An Astec technician stayed
over a period of three months to
ensure operations were functioning
at peak performance and the crew
overcame the learning curve of the
new plant. The Hoover, Inc. plant
was one of the first plants to have
the PMIII controls in use.
“Once the guys had the controls
figured out, they loved the functionality and ease of use for plant
operations,” said Hoover. “Having
on-site Astec training was a plus.”
PERKS OF PORTABILITY
The Hoover, Inc. plant is outfitted
with an Astec warm mix sys-
HOT-MIX MAGAZINE
32 VOLUME 18 NUMBER 2
tem. According to the Tennessee
Department of Transportation
(TDPT), 10 to 35 percent of fractionated recycle is allowed in mixes.
Producing 250 to 300 TPH (226
to 272 MTPH), Hoover, Inc. is supplying material for I-40 in Wilson
County and a TDOT job (State Route
141).
“Having the portable plant gives
us the flexibility to bid on more
projects,” said Hoover. “The ability to move when we need to
and the added efficiency of the
Double Barrel® drum and the
Phoenix® Talon burner set us up for
success.”

FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
Wake Up
the Echoes
At Walsh and Kelly’s
South Bend plant, the past
prepares for the future.
The Dillman UniDrum allows Walsh and Kelly’s South Bend
plant to run a higher percentage of recycle than before.
F
or most people, South Bend,
Indiana, is best known as
the home of the University of
Notre Dame and its famed Fighting
Irish football team. The Irish fans
always hope the season ends with
a chance to play for a national
championship, but the operators
at Walsh and Kelly’s South Bend
plant were watching a different
type of season come to its close.
Just as Notre Dame’s fans cherish
their program’s storied history, the
team at Walsh and Kelly would
also rely on their past to build a
successful future.
HOT-MIX MAGAZINE
TIME FOR A CHANGE
Walsh and Kelly noticed a growing problem—one that would
require a careful decision and
serious investment. The South
Bend plant’s CMI triple drum was
approaching the end of its lifecycle. Compounding the issue, the
stainless steel ring between the
recycle and the burner was wearing away. That component alone
could cost the plant’s budget
upwards of $50,000. Needing a
new drum, in addition to a significant repair, the time was right to
consider a major retrofit for the
plant.
34 VOLUME 18 NUMBER 2
Walsh and Kelly decided to
replace their CMI triple drum
with a Dillman unified drum. The
Dillman UniDrum is often used for
new plant packages but can also
be used for retrofit jobs, making
it a perfect choice for the South
Bend replacement. Furthermore,
with a capacity ranging from
from 200 to 600 TPH (181 to
544 MTPH), the Dillman UniDrum
would be an improvement over
the plant’s old drum.
BIGGER AND BETTER
Another consideration was that
triple drums are notorious for
filling up with reclaimed asphalt
pavement (RAP) in the outer
chamber. This had been an ongoing problem for the South Bend
plant, one they could eliminate
with the right replacement. The
Dillman unified drum presents a
high quality counterflow design.
The inlet into the drum allows
immediate mixing of recycle with
the hot aggregate, bringing the
recycle up to temperature and
removing any residual moisture.
This creates a natural moisture
barrier for the recycled material
and prevents deposits. Using this
new drum, the South Bend plant
The Dillman unified drum is a high
quality counterflow design offered
in both portable and stationary
arrangements.
could expect to expand its use of
RAP to between 40 and 45 percent without any problems.
Walsh and Kelly was also able to
make use of the existing frame
by extending it to fit the Dillman
UniDrum’s extra-long drum. The
drive chain assembly, motor,
and reducer were built the same
as existing double drum plants,
which greatly reduced the downtime and allowed for the drum to
be fitted into place within a brief
window. In addition to accommodating a high percentage of recycle, the extra-long drum length
cut back on the amount of fuel the consumption, as it approached
plant requires because it maxithe end of its lifecycle, the Dillman
mized mixing and drying times.
UniDrum is expected to remain a
consistent and efficient ingredient
A GOOD SWAP
to the South Bend plant’s future
Another advantage presented by
success.
the Dillman unified drum is its
For all its new advantages,
reduced maintenance costs over
though, the Dillman UniDrum
its expected lifecycle. Dillman
looks
perfectly at home at the
introduced the UniDrum as an
South
Bend plant. The total retrofit
option for both portable and staand
upgrade
of the plant lasted
tionary arrangements, making it
one of the sturdier mixers found in until April, making the relative
today’s plants. Whereas the plant’s ease of the drum’s quick installation all the more impressive to
old CMI triple drum was increasWalsh and Kelly. With the plant
ing its operational costs in both
upgrade complete, Walsh and
routine maintenance and energy
HOT-MIX MAGAZINE
Kelly plans to make full use of
their new Dillman UniDrum, routinely running a high percentage
of recycle at a higher capacity.
Building on a strong foundation
and taking advantage of new
innovations, Walsh and Kelly’s
South Bend plant is poised for
continued success.

FOR INFORMATION
Contact Diane Hunt
423.867.4210
[email protected]
35 VOLUME 18 NUMBER 2
The Dillman Service Department
disassembles a fertilizer tower
in preparation for a new
tower to be erected.
Branching
Dillman Out
reaches
into new
markets for
industrial sales
a preferred vendor list. Being on an
approved vendor list enables the
ability to bid on jobs closed to those
not pre-approved.
“To get on a true vendor list with
companies that typically don’t
think of a HMA manufacturer as a
resource will be a step in the right
direction as we branch out and
apply our expertise, quality service,
and quality parts to new markets,”
said Schwab.
I
t’s been a busy year for Dillman,
and it’s not over yet. The
company known in the asphalt
industry as a hot-mix asphalt (HMA)
plant manufacturer is breaking new
ground into the industrial and agricultural markets.
source those parts for industrial,
agricultural, and power generation
industries,” said Tony Schwab, vice
president and general manager with
Dillman, a division of Astec, Inc.
“Our knowledge of setting up new
plants and handling retrofits can
easily be applied to companies in
“At Dillman, we are more than just
other markets needing large, metal
a hot-mix asphalt plant manufacturer;
structures torn down or needing
we know our parts and expertise
help with operational setup.”
have crossover ability into other
“
There will be groundwork
needed to create brand awareness
in new markets.
markets using components and
services we know well. Whether
it’s an electric motor, bearing, or
belts, we have the expertise to
HOT-MIX MAGAZINE
”
NEW MINDSET
New to industrial sales, Dillman’s
main focus is agricultural co-ops
and industrial companies that use
38 VOLUME 18 NUMBER 2
As an example: Wisconsin is a
strong agricultural state and the
transition in farming over that last
10 years has been bigger, bigger,
and bigger.
“Farming is big business; mom
and pop farmers don’t really exist
anymore; it’s a big enterprise with
corporations and investors spending
money,” said Schwab. “The booming business of farming opens the
door for us to introduce ourselves
and share what we have to offer,
and it doesn’t stop there—our
expertise and services make sense
for power plants and those in the oil
and gas industry.”
BREAKING NEW GROUND
Dillman is in the infancy stage of
breaking into new markets. There
will be obstacles, but Dillman is
ready and willing to overcome the
hurdles of expanding its reach.
“There will be groundwork needed
to create brand awareness for
Dillman as more than just an
asphalt company building HMA
equipment,” said Schwab. “To create the mindset in the consumer
‘I’m calling Dillman for an electric
motor’ will take time and positive persistence. We know we can
service those in other industries
needing the same parts, wanting quality service, and needing
comparable expertise with setup
and tear down of machinery and
operational equipment. “
In an effort to build an additional
customer base, Dillman will be
attending some farm shows and
industrial trade shows to educate
new markets on what Dillman has
to offer.
“We’ll do what is needed to be
vetted as an approved vendor
and we’ll continue doing the
upfront work to be recognized,”
said Schwab. “We want to be a
business partner; we want to be
the vendor that is called in an
emergency; we want to be a ‘true’
dependable resource; we want
to be an expert for industrial and
agricultural markets.”

FOR INFORMATION
Contact Tony Schwab
608.326.4820
[email protected]
NEWS
Astec Names
Claude
Executive Vice
President
Astec Inc. announces the year-end
promotion of Steve
Claude to the position of executive
vice president.
Steve Claude
holds a Bachelor
of Science degree
Steve Claude
in marketing from
the University of
Northern Iowa and has broad experience in global and
domestic Fortune 500 sales. He joined Astec as vice
president for sales, international, in 2007. In 2011, he
was promoted to senior vice president, sales.
Astec Customer Unveils New Project
In June 2013, Posillico Materials announced the unveiling of their new rail siding
and materials transfer depot in Farmingdale, New York. A ribbon cutting ceremony
took place to showcase this and other energy saving and carbon reduction measures in the completion of phase one of this major capital project in conjunction
with the Town of Babylon Industrial Development Association.
The project completion enables most of the materials that are required for asphalt
production to be shipped via rail rather than truck. The new rail system and
improved plant layout reduces fugitive dust and also eliminates 5,000 truck trips
from local streets and highways annually. These changes result in reduced net fuel
consumption and less CO2 emissions.
Astec Industries has been working with Posillico’s engineering and material experts
since 1971 to help lead the region with asphalt recycling technologies and other
beneficial reuses of materials that would otherwise require landfilling as waste.
Astec’s vice president of national accounts Gail Mize said, “This recent expansion
into receiving aggregates by rail will remove a considerable amount of traffic from
the roads and goes far to demonstrate how good a neighbor Posillico is for the citizens of Babylon Township. Removing traffic count from the roads is always a good
thing for the public, but is seldom possible.”

As executive vice president of Astec, Inc., Steve Claude
will work closely with incoming president Malcolm
Swanson to ensure the successful operation of Astec,
Inc.

Astec
Promotes
Pack
Astec, Inc. announces the appointment
of Steve Pack to the
position of manager,
inside sales, effective September 1,
2013. He will be
responsible for
managing all inside
sales activities,
including pricing,
Steve Pack
quotes, product
descriptions, and
direct coordination between field sales, engineering, and
manufacturing of all placed orders.
Most recently, Steve Pack has held the position of sales
coordinator as a member of the inside sales team. Steve
Claude, Astec senior vice president, sales, said, “Steve’s
extensive experience and understanding of the inside
sales position and its role will greatly support his efforts in
his new position.”

The ribbon cutting was well attended by several elected officials.
Rendition of the new rail siding and materials transfer depot.
HOT-MIX MAGAZINE
39 VOLUME 18 NUMBER 2
NEWS
Astec Welcomes Bush
McClure Joins
Astec Parts
Astec, Inc.
announces that Mike
McClure is joining
the Astec Parts team
to cover California,
Nevada, Arizona,
New Mexico, and
Hawaii. Prior to joining the Astec Parts
team, Mike worked
as a member of
the Astec Service
team.

Mike McClure
Williamson
to Represent
South Central
Territory
Astec, Inc. welcomes Ryan Bush as the
regional sales manager for the New
England states including: New York, Maine,
Vermont, New Hampshire, Massachusetts,
Connecticut, and Rhode Island. Ryan will
be based in the Syracuse, New York, area.
Tom Baugh, Astec vice president , North
America sales, says of Bush, “His enthusiasm and knowledge of both the asphalt and
aggregate sides of the business make him
a valuable asset. I am confident that he will
do well in his position as an Astec regional
sales manager, servicing current customers
and cultivating new ones.”

Ryan Bush
Brock Honored by Tennessee Road Builders Association
Dr. Brock was honored by the Tennessee Road Builders Association with the 2013
lifetime achievement award. The award was presented July 18 during a TRBA
meeting held in Chattanooga, Tennessee.
Given periodically, TRBA’s highest honor is given to individuals having demonstrated
extraordinary support of the road building industry and association. This year’s
recipient, Dr. J. Don Brock, only the 18th individual to receive the honor in TRBA’s
85-year history, is more than deserving of the acknowledgement.
Astec, Inc. announces that Adrian
Williamson will be
representing Astec
in Texas, Arkansas,
and Louisiana. He
will be based out of
the Dallas, Texas,
area.
Adrian Williamson
Adrian was previously the Astec
Parts representative in California, Nevada, Arizona,
New Mexico, and Hawaii.
An industry pioneer, Dr. J. Don Brock holds approximately 100 U.S. and foreign construction machinery and drying patents. His prowess goes way beyond
Tennessee’s state lines and the 180 different products that Astec Industries and its
subsidiaries provide, as Dr. Brock was recognized in 2012 by the American Road &
Transportation Builders Association (ARTBA). Last September, ARTBA renamed its
yearly Transovation Award, which recognizes innovative thinking in the transportation industry, after Dr. Brock.


Brock Honored
by Utah Asphalt
Pavement
Association
Astec Industries, Inc.
CEO and founder, Dr.
J. Don Brock, was
inducted into the UAPA
Dr. J. Don Brock
Hall of Fame at the
2013 Utah Asphalt
Conference. Each year, UAPA Hall of Fame plans to honor
one individual who has made a major impact on the asphalt
paving industry with the J. Don Brock Award.

HOT-MIX MAGAZINE
2013 TRBA President Tony Boals of Wright Bros. Construction presents award to Dr. J. Don Brock.
40 VOLUME 18 NUMBER 2
NEWS
Astec, Inc. Recap from bauma 2013
Built for Skanska, an Astec 8 ft
(2.44 m) Double Barrel® drum
mixer was on display at bauma
2013 in Munich, Germany,
showcasing the Astec warm mix
system, Whisper Jet® burner,
and Shaggy Dog system. The
drum service door was opened
to allow viewers to see the key
internal benefits of the features.
This allowed the Astec, Inc. rep-
resentatives to explain the Double
Barrel’s ability to produce up to
50-percent recycle with very low
emissions. This is made possible
by the patented design of heating
the recycle (RAP) on the outside
section of the drum, utilizing indirect heating.
The Astec stationary plant model
was displayed on the ground floor
of the interior part of the booth
with exceptional viewing from the
main area, as well as the second
floor above. The Astec, Inc. longterm storage silos displayed with
the plant model were the center
of many great discussions at the
show, focusing on the ability to
store multiple mixes produced
from one plant for up to four
days.
During the show, these capabilities sparked a lot of interests in a
region predominantly consisting
of batch plants, which produce
mix in a batch process that
typically don’t utilize the many
benefits of long-term storage. The
booth was well attended by key
industry leaders from around the
globe.

Left: The Astec
booth at bauma
2013 showcased
an open design
lending itself to
great conversational
opportunities.
Bottom Left: The
open door of the
drum allowed
visitors to see the
internal components
up close.
Bottom Right: The
Astec stationary
plant model was
displayed on the
interior portion of
the booth.
HOT-MIX MAGAZINE
41 VOLUME 18 NUMBER 2
NEWS
Astec Promotes
Renegar
Astec Names Swanson
President
Astec, Inc. announces the promotion of Greg Renegar to the position of vice president, engineering.
Greg Renegar brings a wealth of
experience, knowledge, and skill
with him to his new position.
Astec, Inc. announces the yearend promotion of Malcolm
Swanson to the position of
president of Astec, Inc. Swanson
will fill the position vacated by
Benjamin G. Brock who will
transition to the position of chief
executive officer and president
for Astec Industries, Inc. at the
end of the year.
Renegar joined Astec in
1985 after graduating from
the University Tennessee at
Chattanooga with a Bachelor of
Science in mechanical engineering. Since joining Astec, Renegar
Greg Renegar
has worked in the U.S., Canada,
and throughout Europe as a project engineer, field engineer, and design engineer. He was promoted
to the director of thermal systems position in 1998 and became chief
engineer in 2004. He will transition to vice president, engineering by
the end of the year, and will be responsible for the overall performance
of the Astec Engineering Department.

Malcolm Swanson holds a
Bachelor of Science degree in
Malcolm Swanson
mechanical engineering from the
Georgia Institute of Technology
and has broad experience in both engineering and management and
holds more than thirty patents.
As president of Astec, Inc., Malcolm Swanson will be responsible for
the overall performance of Astec, Inc. and Dillman.

KPI-JCI Celebrates 3,000 th Screen Sold
Johnson Crushers International,
Inc. (KPI-JCI) celebrated the shipment of its 3,000th screen earlier
this year, marking nearly $200
million in revenue for the company
from screen sales and providing
47 high-quality, U.S.-based jobs to
its skilled workforce.
“We are very proud that our success as an American manufacturer
has allowed us to create jobs in
Oregon and beyond,” said JCI
president Jeff Elliott. “We are also
very proud of our employees, who
have made this achievement possible through their commitment
to continuous improvement and
devotion to meeting the needs of
the customer.”
Today, as part of KPI-JCI and Astec
Mobile Screens, JCI is the global
technological and service provider
of the foremost horizontal screening equipment on the market. JCI
also specializes in roller-bearing
cone crushers and portable, stationary, and track-mounted plants.
HOT-MIX MAGAZINE
Johnson Crushers International, Inc. (KPI-JCI) celebrates its 3,000 th screen sold.
“We are incredibly thankful to JCI’s
founders for having the courage
and vision to design this product,”
Elliott said. “With the support of
42 VOLUME 18 NUMBER 2
Astec Industries, we have been
able to create a state-of-the-art
manufacturing facility to serve the
needs of the market.”
For more information about
horizontal screens, visit
www.kpijci.com.
