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Taylor County Airport

ACE XP Polymer Fiber helps a new pavement design achieve a higher standard in crack prevention

By ACE XP, Asphalt, Case Studies No Comments
Taylor County Airport

Taylor County Airport in Kentucky (Photo by Palmer Engineering)

A custom asphalt mix design utilizing ACE XP polymer fibers has given a general aviation airport the long-term solution it sought for a nagging pavement cracking problem. Initial results show the custom design, which combined both a binder layer and a surface layer reinforced with ACE XP, will exceed expectations by greatly reducing cracking potential.

The six-year-old runway pavement at Taylor County Airport in Kentucky was failing. Airport authorities called on Palmer Engineering to provide a desperately needed 15-year-plus solution to the pavement’s micro-cracking problem. Working with Haydon Materials, the team turned to an expert with long-standing experience in designing crack-resistant asphalt pavements.

custom asphalt mix design utilizing ACE XP polymer fibers“Haydon Materials brought in Phil Blankenship from Blankenship Asphalt Tech & Training,” said Joe Dennis, Surface Tech’s chief technology officer for asphalt.

“The airport authorities were concerned that numerous cracks in the existing pavement could lead to failure, a common failure in airport pavements as aging occurs can create FOD — Flying Object Debris — causing a danger to the aircraft and potentially the traveling public.”

No milling was done on the runway pavement prior to re-paving. This meant the existing cracks would be exposed to the bottom of the  binder layer and would ultimately  reflect upward through the new pavement. The solution called for an inordinately crack resistant and resilient binder layer that either needed to be custom-designed, or an expensive two-dimensional geosynthetic rolled interlayer product.

“As a member of Surface-Tech’s Technical Advisory Committee, Phil is well versed on the capabilities of ACE XP, and he set about designing a completely new binder layer asphalt mix using it.”

Blankenship was able to deliver a design that Haydon could produce in its plant and pave with existing paving equipment. Using ACE XP in the new binder layer design gave Haydon Materials an effective crack resistant solution, while maintaining cost control for this demanding application.

The customized ACE XP mix achieved a new level of flexibility for the binder layer. The new binder layer design — a finely graded, highly asphalted crack resistant mixture — greatly reduced the potential for cracks to reflect upward from the base through the new pavement.

An  ACE XP reinforced surface mix was also designed utilizing a higher-than-normal asphalt content to provide even greater crack resistance than a typical FAA asphalt mix design,

“The development of this unique combination of mix designs for the binder and surface layer is an exciting advancement for the paving industry that holds great promise for dramatically improving crack prevention,” said Dennis.

“With this new approach, contractors can also control the quality in both production and installation, as the new mix design is simply incorporated into the contractor’s production processes, thus eliminating third party contractors to install the 2-dimentional geosynthetic rolled interlayer product.”

For more information on ACE XP  crack resistant designs, contact us.

custom asphalt mix design utilizing ACE XP polymer fibers

Rugged & Ready: MD3.0+ answers the call for plant integration

By Asphalt No Comments

MD3.0 Automated Dosing Machine for ACE FibersNow that asphalt producers have seen and used the new MD3.0 Automated Dosing Machine for ACE Fibers, the response has been overwhelmingly positive. In fact, many now want to integrate the MD3.0 into plant operations. We heard them, and we now offer the improved MD3.0+.

It’s more rugged, with upgraded welded and wiring connections, capable of withstanding tough, everyday use. And we now offer both pilot house control integration and a super sack feeder option for producers that want to integrate the MD3.0+ permanently into their plant operations.

ACE Fiber Mixing Process“From the comments we’ve received, it’s clear that plant integration is a big deal to asphalt producers. Integrating the MD3.0+ with both pilot house controls and a super sack feeder makes the system more automated at the plant, similar to how producers are used to producing asphalt,” says Joe Dennis, Vice President & Chief Technical Officer. “We have the technology to achieve the integration, for those who want it.”

The new and improved MD3.0+ will also prove to be more rugged for all producers, whether at the plant or transported to the job site.

“We’ve answered customer requests to make the MD3 sturdier, ensuring a longer life and greater dependability,” says Dennis. “The MD3.0+ is the new standard moving forward.”

For more information, contact Joe Dennis.

New and improved! MD3 now designed for specific sizes of ACE Fiber

By Asphalt No Comments

MD3 mixing ACE FibersThe latest version of Surface Tech’s Micro Doser system, the MD3, takes the process of mixing ACE Fibers into produced asphalt to a new level. Most notably, an improved onboard computer interface now allows operators to specify either 19mm or 38mm sizes of ACE Fiber to feed through the system. While the MD3 still allows for either bulk or sprinkle feeding, the new size-specific setting yields more exacting data and further improves the system’s efficient and thorough distribution of fibers.

An added feeder tray and improvements in controlled vibration ensure steady material flow and dosing accuracy, both critical to ensuring the long-term performance of ACE Fiber reinforced asphalt.

The MD3 can also be retrofitted to connect directly into existing asphalt plant controls to allow producers to permanently add the MD3 to the plant’s operational capabilities.

MD3 Micro Doser systemWith all the improvements, operators will find the system more user friendly than ever. However, some features needed no improvement. The system can still fit in a cargo trailer, can be set up in minutes, and can still be operated by one person. Moreover, producers can be easily trained and certified to operate the MD3 system if they opt to manage the QA/QC themselves.

Like its predecessor, the MD3 only requires 90psi and 185 CFM of compressed air and 110 volts electric to run, which means it can be easily included in the asphalt mixing process at both batch and drum plant facilities.

The computer interface still tracks cycle weight and time to ensure the accurate dosing of 4.2 ounces of ACE Fiber into each ton of produced asphalt. Data continues to be kept onboard and can be retrieved by USB, or sent via internet if available.

The MD3 continues the excellent tradition of the MD2 — delivering a perfect mix, every time! See video of MD3 in action at https://surface-tech.com/portfolio/ace-fiber-mixing-process/

For more information, contact Joe Dennis at 513-444-5080, or joe.dennis@surface-tech.com.

MD3