Benninghoven and Tarmac – an example of a longstanding and successful customer relationship

Overcoming changing market conditions together.

More than 40 years ago, Tarmac invested in Benninghoven technology for the first time: It all started with a burner and developed into an intensive cooperation between the British building materials and construction solutions company and the German specialist for asphalt mixing plants. The latest plant, a TBA 4000, was installed directly adjacent to a large construction site near Birmingham, where it produces asphalt for the expansion of a motorway.


Current reference: A-road project with a TBA 4000

Tarmac is the UK's leading sustainable construction materials, road contracting and building products business and has successfully collaborated with Benninghoven for over 20 years. During these two decades, Tarmac and Benninghoven not only reacted to changing market conditions, but also, always took on a pioneering role. Specifically, this applied and still applies to reducing emissions, achieving high recycling input rates and targeting the most sustainable possible operation of the plants.

The latest joint project is an excellent example of this: Tarmac was recently awarded the contract for expanding the A47 Heartlands Parkway road in the Birmingham conurbation. To produce sufficient asphalt for this large project and to keep the transport distances short, the company invested in a new asphalt mixing plant of type TBA 4000.

Benninghoven

“The quality of a partnership becomes particularly evident when it comes to customer service. The team of the Wirtgen Group in the UK is always ready with help and advice when we need support.”

Anthony Smith, Technical Director at Tarmac

Several Benninghoven plants supply asphalt for Tarmac

Tarmac is a leader in the supply of construction material comprising aggregates, asphalt, cement, lime, concrete, road contracting, building products and recycling services. The company currently has 7,000 employees at 400 sites. Tarmac has a range of mixing plants and, therefore, needs the flexibility Benninghoven offers. It is no coincidence that all these plants were supplied by Benninghoven. One reason for this is that Benninghoven plants can meet a range of different requirements for the asphaltic mixture recipes, but also for the sustainable operation of the plants. Sustainability is at the centre of many businesses plans in the UK, as well as Tarmac’s. In addition to this, the relationship between Tarmac and Benninghoven is based on mutual trust and cooperation. “The quality of a partnership becomes particularly evident when it comes to customer service. The team of the Wirtgen Group in the UK is always ready with help and advice when we need support,” says Anthony Smith, Technical Director at Tarmac.

“In addition, the Benninghoven plants support us in our efforts to achieve sustainable and efficient operation. They are energy efficient, produce ever lower emissions and allow for ever higher recycling input rates,” explains Miles Dobson, Head of Manufacturing at Tarmac.

“Our Benninghoven plants support us in our efforts to achieve sustainable and efficient operation. They are energy efficient, produce ever lower emissions and allow for ever higher recycling input rates.”

Miles Dobson, Head of Manufacturing at Tarmac

Transportable Benninghoven plant (TBA) at the Tarmac site in Washwood Heath.

Rubber granulate from car tyres saves resources

Tarmac’s new TBA 4000 near Birmingham had a quite demanding job: As the first asphalt mixing plant in the Midlands, it processed rubber granulate from recycled car tyres as an ingredient to keep the pavement more elastic.

In addition to virgin mineral and reclaimed asphalt as well as bitumen, the asphaltic mixture for the A47 also contained this special additive. The new recipe type not only protects resources, but also has another advantage: The recipe can be produced as reduced-temperature asphalt or as a warm mixture. As the name indicates, the temperature is lower compared to conventional mixtures. While the latter is usually mixed at 160 °C, reduced-temperature asphalt is produced at temperatures between 100 and 110 °C. Compared to conventional hot mixes, this saves fuel and CO₂ during the production process.


Reduced-temperature asphalt reduces CO₂ emissions

“The innovative asphalt contributes to sustainability,” explains Anthony Smith from Tarmac. “There is an eight to twelve percent reduction in CO₂. Contributions such as these are a central requirements for the British construction industry. We are encouraged to find new solutions that are more environmentally friendly. This has been a successful example.” A foam bitumen module from Benninghoven enables the production of reduced-temperature asphalt: When hot bitumen is mixed with water, the bitumen foams up to many times its original volume, temporarily reducing the bitumen viscosity, therefore enabling the customer to produce and lay asphalt at lower temperatures – without affecting the asphalt properties.

Anthony Smith, Technical Director at Tarmac

“The innovative reduced-temperature asphalt contributes towards improved sustainability. We reduce CO₂ by eight to twelve percent. The mixing process is no problem at all for our TBA 4000.”

Anthony Smith, Technical Director at Tarmac

Significantly improved environmental balance

The environmental balance is also significantly improved: With a daily output of 2,000 t reduced-temperature asphalt, this saves hot mix 1,800 l of heating oil or an energy equivalent, as well as 6 t less CO₂ emissions compared to a hot mix. “The mixing process for our innovative recipe is no problem at all for the TBA 4000.” Road users can also benefit from this: Reduced-temperature asphalt cools down faster and the road can therefore be reopened more quickly.

Learn more about reduced-temperature asphalt here.

Learn more

Asphalt recycling with Benninghoven plants

Cold feed is the preferred technology for asphalt recycling in the UK. Up to 30% reclaimed asphalt is incorporated into the new mixture. The moisture content is often around four percent or higher. This is where the Benninghoven cold feed system with multi-variable feed shows its strengths: It doses the material into the mixing process gradually and prevents water hammer events to protect the plant. This also guarantees high-quality asphaltic mixtures with a recycled material content.

Tolles Produkt
TBA plants in operation at Tarmac

The all-round talent: Benninghoven plants of type TBA

  • High-tech plant performance with a mixing output of up to 320 t/h
  • Plug & work principle for faster installation, modular expansions and clear interfaces between Benninghoven and the customer, for more sustainable plant technology
  • Recycling technologies
  • User benefits from high ergonomics and safety standards

Meeting market requirements with TBA technology

The TBA plant type stands for sophisticated asphalt mixing plants at a high-quality level. In addition to this, the technology can be adapted to a variety of different market conditions. This was also true in the UK, as these examples show – going beyond Tarmac.

Market requirement covered feed hoppers

Covered feed hoppers to keep the virgin mineral as dry as possible, ensuring energy-efficient, low-emission and gentle production – not a problem with Benninghoven. The steel structure meets a variety of different customer requirements while helping to save energy: A 1% moisture reduction in the mineral reduces the consumption by 1 l of fuel for each ton of finished asphalt. For a daily production of 2,000 t, this equates to a saving of 2,000 l of oil or gas. This corresponds to the heating requirement for a detached house.

Market requirement key transfer system

Key transfer system for more safety and increased productivity during maintenance work (with Benninghoven standard).

Market requirement skimmer unit on the dust collection system

Skimmer unit instead of a pre-cleaner on the dust collection system for higher separation accuracy of the reclaimed filler – for high-quality recipes.

Market requirement multi-fuel burner

Burning several fuels at the same time. Depending on the model, the EVO JET burners can be operated with up to four different fuels – without any mechanical conversion. The changeover only requires the press of a button.

Market requirement precision weighing

Precision weighing (± 50 kg) ensures optimum loading of the lorries for the asphaltic mixture, to utilise the payload while avoiding overloading. This also contributes to safety and to less wear on the vehicles.

Market requirement blending bitumen

Option for blending bitumen to save tanks: Only a small number of basic bitumen types are stocked and then blended in the bitumen weigh hopper in varying quantities, depending on the requirement at hand.