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Warm-mix asphalt

Warm-mix asphalt is asphalt that is produced and processed at a lower temperature without any impact on its properties.

The crucial difference compared to conventional hot asphalt is the processing and installation temperature. Expressed in numbers, that is a temperature reduction of 20 to 40 °C. The effects in production and application include the improved energy footprint, lower emissions during production and the reduced workplace exposure during installation of the asphalt.

Focus on temperature.

* Deutscher Asphaltverband e.V., asphalt Leitfaden, Temperaturabgesenkte Asphalte [Asphalt Guideline, Reduced-Temperature Asphalts]

Facts at a glance.

Warm-mix asphalt

Economy

> Extends the delivery range
> Longer transport times possible

Conserving resources

> Lower total energy demand
> Reduced fuel consumption

Health and safety

> Reduced vapours and aerosols during hot processing of bitumen
> Reduced workplace exposure
> Protects workers during production, transport and installation
> Less thermal stress for personnel
> Complies with new workplace exposure limits

Gentle on the material

> Less ageing of bitumen binder material
> Gentler on components due to lower thermal stress
> Reduced wear on the asphalt mixing plant

The paths to warm-mix asphalt

The desired temperature reductions in asphalt production are achieved through a temporary reduction in bitumen viscosity, which can be achieved by the addition of water or additives.

Bitumen (the binder) cannot actually wet/envelope the mineral component below about 140 °C – its viscosity is simply too high at lower temperatures. The fluidity or viscosity also depends on the specific bitumen used and can vary widely between different types of bitumen. Since viscosity depends on temperature and type, hard bitumen has a higher viscosity at the same temperature than soft bitumen. A standard temperature range is between 140 and 180 °C and typically around 150 – 160 °C.

The reason for achieving a low enough binder viscosity is to ensure good wetting and enveloping of aggregates in the mixer. In addition, the elasticity of the asphaltic mixture plays an important role during the asphalt installation process and compactability during laying.

Low bitumen viscosity can be achieved, on the one hand, through foam bitumen technology or with additives.

Foam bitumen module

When hot bitumen is mixed with water in the foam bitumen module, the bitumen foams up to many times its original volume. This temporarily reduces its viscosity. In addition, the wettability of the stone materials is also improved, due to the larger surface area.

For the technical implementation, the weighing and mixing section simply has to be expanded with the FOAM BITUMEN MODULE which is additionally flanged onto the mixer cabinet and the bitumen weigh hopper.

Uncomplicated connection using PLUG & WORK ensures fast installation and commissioning.

Solid additives

For adding smaller amounts of solid additives, BENNINGHOVEN offers the technical solution of the powder/granulate dosing system. Depending on the material and added quantities, additives can be dosed into the mixer with a stream of air.

The multivariable dosing system is another option, This patented technology features precision dosing (exact weighing) and allows larger additive quantities to be fed into the mixer. Material is added using an elevator or inclined conveyor.

Liquid additives

Up to two liquid additives can be added to the process with the liquid additive system. The system is equipped with two feed pumps that dose the liquid additives into the bitumen weigh hopper and/or into the mixer.

The system is has excellent chemical and thermal stability.

BENNINGHOVEN is your reliable partner for this as well. From our FOAM BITUMEN MODULE to dosing systems for feeding a wide variety of additives into your process, we have the answer to your individual requirements. With Plug & Work, the system can be quickly retrofitted on any plant at any time.

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Benninghoven value

Using technology to work towards a more efficient use of energy and raw materials is the challenge of today and tomorrow. Solutions from Benninghoven can support the reduction of energy consumption and emissions while enabling asphalt mixing plants to run with a high reclaimed asphalt pavement (RAP) content to ensure the future of the facility.

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BENNINGHOVEN technologies

Asphalt production, recycling systems, combustion technology, control systems and bitumen technology – with BENNINGHOVEN technologies, every customer can find the right solution for their location, according to the specific requirements and conditions.

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