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Production

PRODUCTION

The methods for producing road materials, particularly hot mix asphalt, are changing significantly in response to directives and guidelines in industrial countries looking to reduce the ecological footprintof road activities.

> Bituminous binders remain the most commonly used.

> Traditional hot-mix asphalt (150°C) is the global benchmark. However, the warm-mix asphalt and recycling fields are developing fast.

Energy savings of 30 to 40% are achieved with warm mix production. At the same time, rational recycling can allow for average savings of 15 to 20% in raw materials.

The FAYAT Group’s asphalt production facilities constitute the largest range of products on the market, integrating proven technology and solutions adopted for both mature and emerging markets.

The future therefore lies in more technology and flexibility in production, as there is no all-round solution.

SAE PACKLINER for cold mix asphalt, single coating

  • Cold production

Cold mix plants are a long-standing speciality of the FAYAT Group, since SAE invented a wide range of machines (SAM, ROADLINER, PACKLINER, etc). This skills centre is at the service of such international and operational brands as MARINI.

Sequences comprise the metering of components – aggregates, water, hydraulic or bituminous binders, mixing and possibly storage. The high-modulus base layers of carriageways are integrated by calculating the structures, which reduces the thickness regarding bituminous asphalt. Cold foundation and base layers therefore cut costs, as well as the carbon footprint of the final construction – all the while increasing its life cycle.

Mobile HMA production plant RF 500 MARINI-ERMONT

  • Continuous hot production à chaud

Since ERMONT's invention in 1976 of the parallel-flow dryer drum mixer, continuous hot mix asphalt plants have got better and better. Extension of drums, counter-flow technology, hypermobility, extreme production rates, very high-rate recycling and warm asphalts are just some of the visible fruits of the FAYAT Group's innovative mindset and commitment to supporting road builders in their constant search for controlled production and meeting the requirements of sustainable roads.

There are two advantages:

Economical: simple solution, low operating cost, wide rate range, diverse degrees of mobility.

Environnemental: energy savings, high recycling rates, one of the most ecological solutions on the market.

MARINI E-Tower, batch HMA production plant

  • Batch hot production

The "batch-mix" production mode is the most universal mode. The batch supply of the mixer is the key stage in the procedure and confers immense flexibility: weight of batches, mixing time, introduction of specific components, etc. Upstream, the production installations are fitted with cold metering bins and, for the fullest equipped units, with hot bins storage, enabling customer demand to be anticipated. Downstream, the asphalt produced is offloaded directly into lorries or stored depending on the formula in storage areas that can reach up to several hundred tons.

Production tools are being developed under three technical influences:

- Energy savings and the reduction of emissions in general (dust included), and CO2 in particular.

- Recycling of bituminous asphalts, a market that is growing significantly worldwide.

- Low-energy warm asphalts, with a tendency to be produced at around 120°C.

The FAYAT product range comprises two main product lines:

- Stationary and/or transferable plants centred on MARINI TOP TOWER and e-TOWER.

- Mobile and hypermobile plants with ROADSTAR and ROADBATCH.

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Bauma China 2016

Bauma China 2016