Crude oil, or petroleum, is put through a distillation process that separates the various components of the oil into several byproducts, one of which is asphalt. Asphalt, in its basic form, is just the heavy deposits left over from the oil-refining process.
The process of refining asphalt is initiated by rapidly heating crude oil for initial distillation. Once heated, the crude is moved into a distillation container where the more volatile and lighter-weight components, called fractions, are removed by a series of condensing and cooling mechanisms.
The crude is then separated for producing products like gasoline, diesel fuel, kerosene and other petroleum products. The heavy deposit left over from distillation process is referred to “topped” crude that is used to make heating oil or made into other products like asphalt.
Asphalt may be blended, known as "cutting back," with a volatile substance that produces a product that is more malleable at a reduced temperature than chaste asphalt. When the blended asphalt is exposed to heat or air, such as when used for paving or in construction, the volatile elements evaporate, leaving just the solid asphalt. The speed of evaporation of the cutting agent determines the curing rate of the asphalt.
Asphalt may also be emulsified to create a product that is easier to mix with aggregate, pumped through pipes or use in spray-on applications. During emulsification the asphalt is ground into globules smaller than five microns and mixed with water. The emulsifying agent is then added to reduce the capacity of the asphalt and water to separate. Emulsifying agents used to produce asphalt may include clay, silicates, soap or vegetable oils.
Hardened asphalt is sometimes crushed to produce a powdered form. The asphalt is pulverized and then passed through a sequence of sieves to produce uniform-sized granules. Powered asphalt is usually mixed with oil and aggregate for the construction of pavement. Heat and pressure work to slowly amalgamate the powder, aggregate and oil, hardening the mixture to a cement-like consistency.
TYPE OF ASPHALT WE SUPPLIES
Premium Grade Asphalt
Stone Mastic Asphalt (SMA)
Porous Asphalt (PA)
Open Graded Asphalt (OGA)
Sand Asphalt (SA)
Colour Asphalt (CA)
Polymer Modified Asphalt (PMA)
Very Thin Overlay (VTO)
Fuel Resistant Asphalt (PRA)
Gap Graded Asphalt (GGA)
Multigrade Bitumen Asphalt (MBA)
CONVENTIONAL ASPHALT PREMIX
ASPHALT PREMIX ENABLE US TO ADDRESS A WIDER RANGE OF MARKET SEGMENTS.
WITH OUR IN-HOUSE FACILITIES AND EXPERTISE,
WE ARE ABLE TO PRODUCE THE FOLLOWING TYPES OF ASPHALT PREMIX:
Macadam Asphalt (MA).
Asphaltic Concrete Binder Course (ACBC)
Asphaltic Concrete Wearing Binder (ACWC)
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Realizing the importance of product quality and customer expectation, KRP aim to continuous improvement product quality innovation, enhancing KRP future growth for more decades to come.
Manufacture of Asphalt Premix
In general, the process flow for our manufacture of asphalt premix is depicted in the diagram:
The first step in the asphalt installation process is to remove the existing surface, whether it is asphalt, concrete or pavers.
Demolition and removal is completed using heavy machinery, including small bobcats and forklifts and when necessary, front loaders and large dump trucks.
Debris is removed and in most instances, Wolf Paving recycles the old asphalt and concrete in our asphalt plants, turning deteriorating waste into strong, usable new asphalt.
In fact, Wolf Paving typically recycles nearly 100% of the materials removed from a job site, making the choice to use Wolf Paving both green and environmentally friendly.
With a clean slate, technology helps Wolf Paving asphalt professionals prepare the surface for appropriate water drainage.
Using laser guided transits and automatic motor graders, the Wolf Paving team grades the surface to be paved to ensure that water will run-off appropriately.
Proper water drainage is vital to your asphalt, because water is a major cause of damage, including potholes, cracks and heaving.
You’d never guess that the most important part of your new asphalt surface is actually the sub base.
The sub base provides a stable surface to support new pavement.
The sub base is a frost barrier to help reduce winter damage due to freezing and thawing.
During the installation, base thickness, base stability and compaction are important steps. If the sub base is not appropriately compacted, the asphalt surface on top will not provide years of durability.
Once the sub base is fully graded and compacted, Wolf Paving completes an extra step, called a proof roll, to ensure the underlying surface is strong and ready to support new asphalt.
A Wolf Paving proof roll involves driving a quad-axle dump truck, loaded with 72,000 pounds, row by row over the entire surface.
If the gravel flexes more than an inch under the weight of the truck, it means that the base is not properly supported.
If the proof roll finds soft areas in the sub base, Wolf Paving makes the necessary repairs in compromised areas to ensure the entire sub base is supportive.
Undercutting can be used to repair soft spots. This process involves digging down below the surface 2 or 3 feet and replacing the underlying soft clay or soil with stronger aggregate material.
Wolf Paving also offers alternative options, like using geo-grid, instead of undercutting. Using geo-grid involves digging only 16 inches below the surface and laying grid down to bridge base materials together. This creates a solid support structure for new asphalt at a fraction of the cost of traditional undercutting.
Wolf Paving has also pioneered a new process called plowing. This process involves undercutting the sub base, but instead of removing all of the soft clay and soil, it is instead mixed with added aggregate to improve the strength of the compromised areas.
Once the sub base is laid and any soft areas are identified and repaired, it is time to add the binder.
The binder layer is large aggregate mixed with oil, making it very strong and durable.
The binder layer can be thought of as the strength of any new asphalt surface.
Once the supportive structures of a new asphalt surface are installed, the top layer of fresh asphalt is added to provide a clean, smooth ride.
Surface asphalt is made up of small aggregate, sand and oil.
This combination of materials creates jet-black asphalt that when installed appropriately, provides a smooth ride and a shiny, attractive finished surface.
Step 7: Butt Joints and Transitions
It is very rare to install an asphalt surface that does not connect to existing driveways, roadways or parking lots. As such, asphalt-paving contractors must find a way to smooth the transition from old surface to new.
Butt joints are areas were old asphalt or concrete meets new asphalt pavement.
These transitional areas require special attention to ensure that the grading and water run-off is appropriate.
Butt joints are important to ensure drivers and pedestrians don’t notice a difference in the surfaces.
Once the asphalt and butt joints have been laid, the entire surface is smoothed and compacted.
Using a roller truck, the new asphalt pavement surface is compacted and smoothed.
This process step ensures that no small bumps of aggregate or stone are left poking through the smooth new surface.
Your asphalt paving contractor should follow these installation steps to make sure your new asphalt surface will provide years of durability and functionally for your home, business, city or town.
But remember that installation process should only follow a proper surface inspection and a complete estimate. Take a look at the articles below that explain those processes completely.