Double-barrel technology will revolutionise road construction.
The double-barrel technology is a result of intensive research done by Astec Inc on road construction techniques, the voice of the customer, the need of a sustainable road construction methodology, and most importantly, conserving the environment,? says R Nandagopal, Vice President, Equipment & Project Solutions, TIL. In an exclusive interview with EQUIPMENT INDIA, Nandagopal explains the changing trends in the hot-mix technology and elucidates the advantages of double barrel technology. Excerpts from the interview.
To what extent have we shifted towards drum-type mixing from the batch-type?
The major shift in technology was initiated by NHAI and MORTH when the infrastructure boom began in India in the 90s. At that point of time, the batch technology was preferred to the drum-mix technology with the objective of producing consistent mix and quality roads. The drum- mix technology is still in use in India and is predominantly used in the PMGSY roads/ state highways. This technology has evolved over the last couple of decades and many countries have adopted this technology whole heartedly in view of the inherent benefits it offers over a batch plant.
The success of double-barrel technology globally is a classic example of the evolution of the drum-mix technology. The capability of the equipment to use up to 50 per cent RAP without any modification and the ease with which the plant can be operated is the reason for the success of the double-barrel technology. In India, this technology has been approved for use by NHAI and the motivation to use RAP with ease is encouragement enough for a customer to embrace this offering as it would substantially lower the cost of road construction and also help preserve the environment. As proved in many countries, the drum-mix technology will pave the way for the future in India as well.
What are the major advantages a road contractor can get while opting for a ?six pack??
The double-barrel technology is a result of intensive research done by Astec Inc on road construction techniques, the voice of the customer, the need of a sustainable road construction methodology and most impor?tantly, on conserving the environment. The ability to use up to 50 per cent RAP without any modification to the plant, the fuel efficie?ncy the plant offers, the ability of the plant to produce consistent asphalt mix are the key differentiators of the double- barrel techn?ology has over other techno?logical offerings.
However sophisticated and advanced the machine is, the quality output also depends on the mix designer. What is your take on this?
For the success of a technology which is a very profitable proposition, the partnership of the seller and the user of the technology is critical. At TIL, our engagement with the users and consultants has been very high and this will enable us to ensure the absorption of the technology at an operational level. We have been getting great support from Astec Inc, not only in advocating this technology but also in technology absorption process. Ignorance, more than intention, has been the reason for failure of many a technology. This paves the way for training and capability development.
At TIL, we intend to leverage this opportunity through our regular training programmes, the on-site support options and the global expertise with Astec Inc to educate the user for the success of this technology. We also believe that our engagement with the customer will help in creating a platform for the man and the technology to work together rather than at cross purpose.
What are the present technological trends in this segment?
We, at TIL, create as well as optimise every opportunity to engage with the customer and also share the best practices and case studies that are being followed globally. With the size of the projects growing under PPP/BOT, it would only be prudent to save on the project costs by adopting the right technology.
The features like Accuswipe, dual fuel modulating burners, infrared sensors to maintain heating of aggregate at specified temperature, ability to handle larger dust/ exhaust volumes, ease of operation and maintenance, availability of spare parts, ability to run up to 50 per cent RAP and the optional attachment to produce warm- mix asphalt with foamed bitumen, all give the leading edge to this technology.
How environment-friendly are the plants in terms fuel/power consumption, fewer pollutants, etc?
Specific to the hot-mix asphalt plants, the double-barrel technology uses the combination dryer and mixer drum to ensure the highest fuel efficiency in the segment. The bag house is critical to ensure compliance to pollution norms. The bag house design used in the double-barrel is designed for usage up to 50 per cent RAP and the efficiency of the bag house is 99.9 per cent, making it the most environmentally friendly solution. The double-barrel uses the PLC-based controls with manual overrides makes it one of the most user-friendly plant. The Windows- based PLC control system is the latest in this segment and the controls can be even tailormade to suit customer requirement.
The double-barrel green system uses water as additive for producing warm-mix asphalt ? the cost of water is all it takes to produce the warm-mix asphalt. Built on the principle of long lifecycle, the Astec plant will offer the lowest cost per tonne of hot-mix asphalt produced.
Tell us about the steps initiated to impart training of operators of these plants by TIL.
Training is a very important aspect as apart from ensuring lower breakdowns, this will also enable us to keep our costs down. Our new state-of-the-art facility at Khar?agpur is equipped with a training centre which will enable us to impart our exper?ience to the customer. Our endeavour will be supported by our principals and we can assure the customer world-class training.
What should determine the choice of a new hot-mix plant?
Any investment will need to sustain the current and future requirements. Hot-mix plants today are conventional but the customer expectation is that they should handle RAP as well. Going forward, the same plant will be expected to handle the warm-mix as well. While manufacturers are working to lower the cost and offering better technology, it will be important for the customer to evaluate the possible future requirements while taking a purchase decision. As manufacturers, it is our responsibility to constantly update ourselves as well as the customer of the various developments and emerging trends.
The NHAI has not specified, rather it has rejected the use of drum-mix plants. What is your take on this?
NHAI has accorded its approval for the double-barrel hot-mix plant. The point to be noted is that approval for double- barrel technology. Comparing a drum-mix plant to a double-barrel plant is comparing the premium with an economy version in a car segment.
Even though the size of the aggregate is specified for a project, often the sizes may differ, What is your take on this?
The double-barrel plant is equipped with a real-time belt sampler called the Accuswipe, which enables the operator or plant control to sample the cold aggregate mix being fed into the double-barrel and check its gradation. It doesn?t matter if the technology is batch/continuous, ineffi?ciencies can only pull the profitability down. If a technology is successful globally, why can?t India adopt it? Global road construction companies are here in India and they are going to adopt the best practices to keep their cost down; if we need to be successful, we need to react before it?s too late. This principle is applicable to the road construction companies as much as it is to the domestic manufacturers.
What is the possibility of the change of structure of the aggregates in the hot-mix drum?
The double-barrel plant is equipped with a screen before the heating chamber which enables the over-sized aggregates to be sepa?rated. As regards the change in the job mix of the hot-mix asphalt, the double-barrel is well equipped to handle the same.
SIX PACK BENEFITS
?Truly portable plants which can be erected and commissioned within 36 to 48 hours. All that would be required is only levelled, compacted ground, thus reducing recurring costs of civil foundation.
?Protects the environment from pollutants and other toxic ingredients which are present in dumped, milled bituminous pavement.
?Protects the environment by preventing deforestation and helps conserve natural resources by using RAP.
?Helps offset the increasing cost of fuel, bitumen and aggregate and, overall, lowering the project costs.
?Reduce carbon foot print of the road construction.
?Make sustainable asphalt pavement.
?The double-barrel technology uses the combination dryer and mixer drum to ensure the highest fuel efficiency in the segment."
To what extent have we shifted towards drum-type mixing from the batch-type?
The major shift in technology was initiated by NHAI and MORTH when the infrastructure boom began in India in the 90s. At that point of time, the batch technology was preferred to the drum-mix technology with the objective of producing consistent mix and quality roads. The drum- mix technology is still in use in India and is predominantly used in the PMGSY roads/ state highways. This technology has evolved over the last couple of decades and many countries have adopted this technology whole heartedly in view of the inherent benefits it offers over a batch plant.
The success of double-barrel technology globally is a classic example of the evolution of the drum-mix technology. The capability of the equipment to use up to 50 per cent RAP without any modification and the ease with which the plant can be operated is the reason for the success of the double-barrel technology. In India, this technology has been approved for use by NHAI and the motivation to use RAP with ease is encouragement enough for a customer to embrace this offering as it would substantially lower the cost of road construction and also help preserve the environment. As proved in many countries, the drum-mix technology will pave the way for the future in India as well.
What are the major advantages a road contractor can get while opting for a ?six pack??
The double-barrel technology is a result of intensive research done by Astec Inc on road construction techniques, the voice of the customer, the need of a sustainable road construction methodology and most impor?tantly, on conserving the environment. The ability to use up to 50 per cent RAP without any modification to the plant, the fuel efficie?ncy the plant offers, the ability of the plant to produce consistent asphalt mix are the key differentiators of the double- barrel techn?ology has over other techno?logical offerings.
However sophisticated and advanced the machine is, the quality output also depends on the mix designer. What is your take on this?
For the success of a technology which is a very profitable proposition, the partnership of the seller and the user of the technology is critical. At TIL, our engagement with the users and consultants has been very high and this will enable us to ensure the absorption of the technology at an operational level. We have been getting great support from Astec Inc, not only in advocating this technology but also in technology absorption process. Ignorance, more than intention, has been the reason for failure of many a technology. This paves the way for training and capability development.
At TIL, we intend to leverage this opportunity through our regular training programmes, the on-site support options and the global expertise with Astec Inc to educate the user for the success of this technology. We also believe that our engagement with the customer will help in creating a platform for the man and the technology to work together rather than at cross purpose.
What are the present technological trends in this segment?
We, at TIL, create as well as optimise every opportunity to engage with the customer and also share the best practices and case studies that are being followed globally. With the size of the projects growing under PPP/BOT, it would only be prudent to save on the project costs by adopting the right technology.
The features like Accuswipe, dual fuel modulating burners, infrared sensors to maintain heating of aggregate at specified temperature, ability to handle larger dust/ exhaust volumes, ease of operation and maintenance, availability of spare parts, ability to run up to 50 per cent RAP and the optional attachment to produce warm- mix asphalt with foamed bitumen, all give the leading edge to this technology.
How environment-friendly are the plants in terms fuel/power consumption, fewer pollutants, etc?
Specific to the hot-mix asphalt plants, the double-barrel technology uses the combination dryer and mixer drum to ensure the highest fuel efficiency in the segment. The bag house is critical to ensure compliance to pollution norms. The bag house design used in the double-barrel is designed for usage up to 50 per cent RAP and the efficiency of the bag house is 99.9 per cent, making it the most environmentally friendly solution. The double-barrel uses the PLC-based controls with manual overrides makes it one of the most user-friendly plant. The Windows- based PLC control system is the latest in this segment and the controls can be even tailormade to suit customer requirement.
The double-barrel green system uses water as additive for producing warm-mix asphalt ? the cost of water is all it takes to produce the warm-mix asphalt. Built on the principle of long lifecycle, the Astec plant will offer the lowest cost per tonne of hot-mix asphalt produced.
Tell us about the steps initiated to impart training of operators of these plants by TIL.
Training is a very important aspect as apart from ensuring lower breakdowns, this will also enable us to keep our costs down. Our new state-of-the-art facility at Khar?agpur is equipped with a training centre which will enable us to impart our exper?ience to the customer. Our endeavour will be supported by our principals and we can assure the customer world-class training.
What should determine the choice of a new hot-mix plant?
Any investment will need to sustain the current and future requirements. Hot-mix plants today are conventional but the customer expectation is that they should handle RAP as well. Going forward, the same plant will be expected to handle the warm-mix as well. While manufacturers are working to lower the cost and offering better technology, it will be important for the customer to evaluate the possible future requirements while taking a purchase decision. As manufacturers, it is our responsibility to constantly update ourselves as well as the customer of the various developments and emerging trends.
The NHAI has not specified, rather it has rejected the use of drum-mix plants. What is your take on this?
NHAI has accorded its approval for the double-barrel hot-mix plant. The point to be noted is that approval for double- barrel technology. Comparing a drum-mix plant to a double-barrel plant is comparing the premium with an economy version in a car segment.
Even though the size of the aggregate is specified for a project, often the sizes may differ, What is your take on this?
The double-barrel plant is equipped with a real-time belt sampler called the Accuswipe, which enables the operator or plant control to sample the cold aggregate mix being fed into the double-barrel and check its gradation. It doesn?t matter if the technology is batch/continuous, ineffi?ciencies can only pull the profitability down. If a technology is successful globally, why can?t India adopt it? Global road construction companies are here in India and they are going to adopt the best practices to keep their cost down; if we need to be successful, we need to react before it?s too late. This principle is applicable to the road construction companies as much as it is to the domestic manufacturers.
What is the possibility of the change of structure of the aggregates in the hot-mix drum?
The double-barrel plant is equipped with a screen before the heating chamber which enables the over-sized aggregates to be sepa?rated. As regards the change in the job mix of the hot-mix asphalt, the double-barrel is well equipped to handle the same.
SIX PACK BENEFITS
?Truly portable plants which can be erected and commissioned within 36 to 48 hours. All that would be required is only levelled, compacted ground, thus reducing recurring costs of civil foundation.
?Protects the environment from pollutants and other toxic ingredients which are present in dumped, milled bituminous pavement.
?Protects the environment by preventing deforestation and helps conserve natural resources by using RAP.
?Helps offset the increasing cost of fuel, bitumen and aggregate and, overall, lowering the project costs.
?Reduce carbon foot print of the road construction.
?Make sustainable asphalt pavement.
?The double-barrel technology uses the combination dryer and mixer drum to ensure the highest fuel efficiency in the segment."
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