Recycle Systems (RAP)

Recycling Work Horse

Take advantage of the savings realized through the use of recycled asphalt pavement (RAP) with Astec RAP systems. The systems are offered in a range of configurations, with a variety of conveyors, screens, grizzlies and crushers. The simplest system consists of one bin, a scalping screen and a conveyor that goes directly to the drum mixer.

The RAP system can be portable, stationary or relocatable. Options include bulkheads, wing walls, screens and grizzlies.

Materials separated by a screen can be crushed. Some systems can then separate lumps, break them up, and deliver that material to the drum along with the portions that passed through the screen.

Features & Benefits

  • A walkway behind the bulkhead provides easy access for maintenance.
  • Bin walls are made from 1/4 inch (.635 cm) thick steel plate with reinforced top openings.
  • The very steep side walls of the RAP bins aid free flow.
  • Standard air cannons keep RAP from compressing in the bin.
  • System can be customized with any number of bins.

Stationary Recycle

Astec stationary recycle systems come in a range of capacities to suit any production requirement. Stationary systems also offer flexibility for future add-ons or alterations. Stationary RAP bins are anchored to concrete foundations.

Relocatable Recycle

The Astec relocatable recycle system is set in place on a paved site that has at least 2,500 pounds per square foot (12,206 kg per m2) soil bearing pressure. It is supported by its heavy-duty, tublar steel foundation pads. Modular construction eliminates on-site fabrication. Bulkheads and hinged wing walls are safer and eliminate expensive concrete bulkheads.

Portable Recycle

The portable recycle system can be set up without cranes in less than an hour, which saves considerable time and money. No concrete or asphalt foundations are required, only compacted soil able to bear 2,500 pounds per square foot (12,206 kg per m2). Comes with built-in bulkhead and wing walls.

Choose Any Number Of Bins For Your Operation


Recycle Bin
FEATURES

Access For Maintenance

A walkway in-between the bulkhead and collecting conveyors gives you safe access to the back of the bins and conveyors for maintenance.

Bulkheads

Bulkheads with hinged wing walls are included on relocatable systems.

Cable Trays

Cable trays* keep power and control cables organized and off the ground.
*standard on portable and relocatable, optional for stationary


Recycle Bin
CONSTRUCTION

RAP/RAS Bin Design

Recycle bins are designed for free flow of RAP even with fine RAP in hot weather. The very steep side walls of the RAP bins aid free flow. One end-wall is vertical and the other is angled at 75 degrees. Air cannons are standard and keep RAP from compressing within the bin.

The bin discharge opening is tapered to make it self-relieving. It is wider than that of cold feed bins and uses a wider belt feeder. Bin walls are made from 1/4 inch (6 mm) thick steel plate with reinforced top openings.

Multiple RAP Bins

Recycle bins are designed for free flow of RAP even with fine RAP in hot weather. The very steep side walls of the RAP bins aid free flow. One end-wall is vertical and the other is angled at 75 degrees. Air cannons are standard and keep RAP from compressing within the bin.

RAP Conveyor / Feeders

Astec conveyors and belt feeders for RAP have the same high-quality features as feed systems for virgin aggregate. Belt idler rollers are extra-large and closely spaced for reliability and long service life. Large, variable speed drive motors assure precision control.

Break Rock & Hard Rap

A Telsmith horizontal shaft impactor (HSI), can be used for breaking the asphalt bond between aggregates in hard pieces of RAP.

Recycle Plants

Large plants for RAP and roofing shingle processing are available. Astec works with its sister companies KPI-JCI, Astec Mobile Screens and Peterson Pacific to custom-design these plants for each application.


Recycle Bin
CONVEYORS

Astec conveyors, with vulcanized rubber belts, efficiently move material from the bins to the drum.

Collecting Conveyor

The collecting conveyor runs under the belt feeders to collect material from all the bins. The tail section unbolts, then easily reattaches to the collecting conveyor extension when adding future bins. The upturned end empties onto a scalping screen (if used) or onto an incline conveyor.


Belt Feeders & Idlers

You can assure accurate mix formulas with variable-speed belt feeders. They let you change the production rate while keeping the mix formula unchanged. Each feeder is powered by a vari- able speed motor with a Danfoss® controller and Sumitomo® right angle reducers. These drives provide precise control of belt speed.

Troughing idlers are standard with Astec conveyors. The troughing design results in a longer belt life and reduces material spillage. The troughing idler belt is supported on nine-inch (22.56 cm) centers. Flat idlers are optional.

Head pulleys on both are covered with rubberized traction material that makes firm contact and moves the belt without slippage.


Inclined Conveyor

Inclined conveyors with rubber belts take the aggregate from the cold feed unit RAP bins to the drum mixer. The inclined conveyor is available in relocatable, stationary or portable designs.

Most often, the inclined conveyor incorporates a scalping screen at the front end. On portable units, a transfer conveyor is used as the deck selector on two-deck screens. Pneumatically activated belt scrapers are standard on every Astec inclined conveyor. A walkway can be added as an option.

Collecting conveyors collect material from all bins.
No sheaves or belts on the Sumitomo drives means reduced maintenance time.
The inclined conveyor incorporates a scalping screen to remove oversized material.

Recycle Bin
ADDITIONAL FEATURES

Bin Vibrator

Dancing plate bin vibrators provide better material flow than common weld-on vibrators.


Bypass Chute

A bypass chute can be incorporated to collect calibration samples.


Belt Scales

A load cell in the belt scale accurately indicates the weight of a section of belt running over a weigh idler. Load cell information, combined with the belt speed, shows how much material is entering the drum mixer. The scale includes a remote operated test weight for easy calibration. As material is run across the scale, a sample is routed to a truck via the cylinder operated drum bypass chute, then veried on a truck scale. All Astec belt scales come with wind guards to maximize accuracy.


High-Density Polyethylene Liners

Optional high-density polyethylene liners can be installed inside the bins for added wear protection. Liners also signi cantly reduce the friction between bin walls and material, producing ultrasmooth material flow.