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

Equipment
6% 2012 1950
Labor
4%
FOH FOH
3% Rock Rock 3%
Admixtures Fuel
1% 18% Labor Rock
8% Sand Rock
19% 26%
Asphal Sand
t Asphalt
Admix
Sand tures Admixtures
Fuel
13% Equip 6% Equipment
ment
Fuel Fuel
Equipment
Labor 11% Labor
Asphalt Sand
FOH FOH
47% 22%
Asphalt
Admixtures 13%
0%
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