AN OVERVIEW OF

ASPHALT PLANTS

Introduction

• Shawn A. Riley – VP of APAC Kansas City & Missouri

• Career– Hall & Riley Construction – APAC– Oldcastle

Who is APAC?

• Until 2006– Leading Construction Company in U.S.• #1 Asphalt• #5 Quarry

History of APAC

• 1900 Warren Brothers Company, the forerunner of APAC, was founded February 5, 1900 in Nashville, Tennessee.

• 1900 Frederick J. Warren filed a patent for "Bitulithic" pavement, a mixture of bitumen and aggregate.

• 1901 The first modern asphalt production facility was opened by the Warren Brothers in East Cambridge, MA.

• 1968 Ashland Oil, Inc. acquired Warren Brothers and the name changed to Ashland-Warren, Inc.

• 1980 the Ashland-Warren name was changed to APAC, Inc. still under the ownership of Ashland.

• 2006 APAC was acquired by Oldcastle Materials Group.

Who is Oldcastle?

• Subsidiary of CRH, Inc. – Dublin, Ireland• 2 Division– Oldcastle Products Group• Oldcastle Glass• Oldcastle Architectural Products• Oldcastle Distribution• Oldcastle Precast• Oldcastle Merchants Metals

– Oldcastle Materials Group

Oldcastle Materials Group

• Supplies aggregates, asphalt, and ready-mix concrete, and provides paving services.

• Over 1200 locations• Employees 17,500 • 44 states• Over $6 billion Revenues

Locations

Why Asphalt Plants?

Original Design

First Plants

Modern High Production?

Today’s Plants

Types of Plants

• Drum Plant– Parallel Flow– Counter Flow– Double Barrel

• Batch Plant

Components of Asphalt Plant

Material Blending (bins)

• Keeps materials separated• Allows operator to blend materials at

rates/percentages dictated by mix design• Weighs aggregate as it enters drum

dryer• Screens Aggregate

Drum Dryer

The Aggregate Dryer Performs Two Functions:

Drying and Mixing

Burner

• Types of Fuel• Diesel• Recycled Fuel Oil• Natural Gas• Propane• Coal• Glycerin• Bio fuel• Industrial By-products• Food Industry By-products

Environmental Controls

Baghouse

Baghouse Flow

Early System

Silo System

Silo Systems

• Multiple Silos

Systems

• 250 tons each

• Load Trucks

• Ticket System

Controls

Fully Integrated Computer Systems

• Fully Automated Systems

• System Cost $250k

• High Speed Internet

Connection

• Integrated with Accounting

Software

• Remote Troubleshooting

Costs of Production

Rock18%

Sand13%

Asphalt46%

Ad-mix-tures1%

Equipment6%

Fuel7%

Labor4%

FOH3%

Rock

Sand

Asphalt

Admix-tures

Equipment

Fuel

Labor

FOH

2012

Rock26%

Sand22%

Asphalt13%

Equipment11%

Fuel6%

Labor19%

FOH3%

RockSandAsphaltAdmixturesEquipmentFuelLaborFOH

1950

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