A large – scale road infrastructure project in Indonesia is situated in the remote mountainous area of Sumatra, with a total length of 180 kilometers. It traverses dense forests, rivers, and volcanic rock zones, making the transportation of materials extremely difficult. As a key project to promote regional economic development, the entire road paving work must be completed before the start of the monsoon season to ensure smooth transportation and avoid damage to the roadbed caused by heavy rains. However, the traditional asphalt mixing scheme encounters two major issues:
Poor adaptability to remote locations: The project site is 500 kilometers away from the nearest asphalt mixing plant. Due to the lack of well – developed roads in the area, transportation vehicles can only travel at an average speed of 30 kilometers per hour. This not only leads to a long transportation time, but also the high temperature of the asphalt mixture is difficult to maintain, resulting in a large number of mixtures that cannot meet the paving requirements, with a waste rate of up to 20%.
Imbalance between time and progress: The traditional mixing plant has a fixed production site. Considering the transportation time and the need for frequent maintenance of the equipment, the daily asphalt supply can only meet the paving of 5 kilometers of road. According to this progress, it is impossible to complete the entire project before the monsoon, which will bring huge economic losses.
In this context, the project team introduced the Indonesia Asphalt mixing plant LB1200, hoping to achieve efficient on – site production of asphalt mixture through the “on – site mixing, immediate paving” model, ensuring the smooth progress of the project.
LB1200 asphalt mixing plant + scientific production process to create “high – quality and efficient” asphalt mixture
Equipment model: The Indonesia Asphalt mixing plant LB1200 is adopted. It has a compact structure, is equipped with a powerful diesel engine and an advanced control system, and can adapt to the complex climate and terrain conditions in the project area, with a stable operation capability in high temperature and high humidity environments.
Deployment strategy: The equipment is divided into several modules for transportation. Special transport vehicles are used to transport the modules to the site in batches. The on – site assembly and commissioning can be completed within 72 hours, ensuring that the equipment can be put into production quickly.
Raw material proportioning: According to the geological conditions and climate characteristics of the project area, the proportion of asphalt, aggregate, and mineral powder is scientifically adjusted. The asphalt content is controlled at 5.2% – 5.8% to ensure the high temperature stability and low temperature crack resistance of the mixture.
Dust removal system: The plant is equipped with a high – efficiency dust removal device, which can reduce the dust emission to below 30mg/m³, meeting the local environmental protection standards and protecting the health of construction workers.
Intelligent control: The control system can accurately control the feeding amount, mixing time, and temperature of each raw material. The mixing time is set to 45 seconds, ensuring that the mixture is evenly mixed, and the temperature control error is within ±5℃.
Step 1: After the equipment is in place, the raw materials (asphalt, aggregate, mineral powder) are transported to the storage bins on the site by trucks. The aggregate is screened by the vibrating screen to ensure that the particle size meets the requirements.
Step 2: The intelligent control system calculates the amount of each raw material according to the set proportion, and the materials are sent to the mixing drum in sequence. The mixing drum heats the materials to 160 – 180℃, and then mixes them evenly.
Step 3: The mixed asphalt mixture is directly transported to the paving equipment by dump trucks. The entire process from mixing to paving is controlled within 30 minutes to ensure the performance of the mixture.
High temperature stability: The asphalt mixture produced by the LB1200 asphalt mixing plant has undergone a rutting test. The dynamic stability is greater than 3000 times/mm, which is 25% higher than that of the mixture transported from the remote plant, ensuring that the road surface is not easy to rut under the high temperature in Indonesia.
Low temperature crack resistance: In the low – temperature bending test, the failure strain of the mixture is greater than 2500με, which can effectively resist the cracking of the road surface caused by temperature changes.
Water stability: The freeze – thaw splitting strength ratio is greater than 80%, ensuring that the road surface is not easy to be damaged by water erosion during the monsoon.
Cost reduction: The on – site mixing of the LB1200 asphalt mixing plant avoids the long – distance transportation of asphalt mixture. The transportation cost is reduced by 60% compared with the traditional scheme, and the waste rate of the mixture is reduced to 5%, which makes the overall cost of the project 25% lower than the budget.
Efficiency improvement: The LB1200 asphalt mixing plant has a mixer capacity of 1200kg/batch and a production capacity of 100t/h. It can provide asphalt mixture for paving 8 kilometers of road every day, which is 60% higher than the traditional scheme, ensuring that the project is completed 35% ahead of schedule.
Environmental protection: The high – efficiency dust removal system of the plant effectively reduces dust pollution. The noise during production is controlled below 75 decibels, which has been praised by the local environmental protection department.
The project manager said:
“The LB1200 asphalt mixing plant has completely changed our construction mode! In the past, we were always worried about the transportation of asphalt mixture and the quality problems caused by temperature loss. Now, with this plant on site, we can produce high – quality asphalt mixture at any time according to the paving progress. It can produce 100 tons per hour, which is much faster than the traditional way. The cost has also been greatly reduced, and the project can be completed ahead of schedule, which is really a great help!”
The LB1200 asphalt mixing plant is equipped with a double – shaft forced mixer, which has strong mixing capacity. It can fully mix the asphalt, aggregate, and mineral powder in a short time, ensuring the uniformity of the mixture. The mixer capacity of 1200kg/batch enables continuous and stable production, meeting the large demand for asphalt mixture in the project.
The plant is equipped with an advanced temperature sensor and control system, which can monitor the temperature of the asphalt, aggregate, and mixture in real time. It can automatically adjust the heating device according to the set temperature range, ensuring that the mixture temperature is always within the optimal range, thus guaranteeing the performance of the mixture.
The LB1200 asphalt mixing plant can adapt to different types of aggregates and asphalt. By adjusting the parameters of the control system, it can produce asphalt mixtures with different specifications and performances to meet the needs of different sections of the road, such as the road surface, road base, etc.
Through the “on – site mixing, immediate paving” model, the LB1200 asphalt mixing plant reduces the transportation links and time, ensures the quality of the asphalt mixture, and improves the construction efficiency. It is especially suitable for large – scale road projects in remote areas or with tight schedules.
The on – site production of the plant reduces the transportation cost and the waste rate of the mixture, effectively controls the project cost, and provides a new way for the cost management of road construction projects.
The high – efficiency dust removal and noise reduction design of the LB1200 asphalt mixing plant meets the requirements of environmental protection, promotes the green development of the construction industry, and sets a good example for similar projects.
From Indonesia to the world, the broad prospects of the LB1200 asphalt mixing plant
This project has verified the core value of the Indonesia Asphalt mixing plant LB1200 in road construction projects in remote and complex areas – it can flexibly respond to the challenges of remote locations and tight schedules, ensure the quality of asphalt mixture with high efficiency, and effectively control the project cost. At present, this type of asphalt mixing plant has been promoted to other Southeast Asian countries, contributing to the development of global road infrastructure towards a more efficient, high – quality, and environmentally friendly direction.
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