Views: 0 Author: Site Editor Publish Time: 2026-09-08 Origin: Site
The traditional pothole repair mode for roads requires transporting hot asphalt mixture from a mixing plant to the construction site. Long-distance transportation leads to rapid temperature loss of the mixture. Repairs with cold-patch materials deliver short service life for restored pavement. Milled waste asphalt mixture needs to be transported off-site for disposal. Material hauling and waste stockpiling raise maintenance costs while creating environmental concerns.
The mobile asphalt recycling mixing unit is developed to solve the above-mentioned pain points. Installed directly onto truck beds, the equipment travels to defect sites. It is applicable for the following pavement distress scenarios:
1. Repair of potholes, alligator cracking, pavement bumps and wide cracks on asphalt pavements
2. Local damage restoration around manhole covers and road intersections
3. Emergency rush repairs when mixing plants shut down with no hot-mix supply available
4. On-site production of fresh asphalt mixture for small-scale new paving projects
Equipment alternative terms (for diversified wording on foreign websites): truck-mounted drum recycling mixer, on-site RAP recycling agitator, hot-in-place pavement repair vehicle, mobile asphalt remixing unit, truck-based road hot-recycling workstation.
The complete set consists of five modules: drum mixing main unit, heat source heating assembly, asphalt supply & spraying unit, intelligent electric control system, as well as power and auxiliary safety components. All modules cooperate independently.
The drum mixing tank serves as the heart of the equipment, offered in 1000L and 1500L horizontal drum configurations, capable of processing 800-1000 kg asphalt mixture per batch.
· The drum supports 360-degree bidirectional rotation. Forward rotation completes heating and mixing; reverse rotation enables screw-type automatic discharging. Full batch material unloading finishes within 0.5-1 minute to reduce manual shoveling workload.
· Double-layer ceramic fiber insulation layer: asbestos-free and eco-friendly. It blocks high-temperature heat leakage from the tank, improving thermal efficiency and preventing operator burns caused by hot outer housing.
· A worm-gear reduction motor supplies rotary torque for the drum. The PLC program dynamically adjusts rotating speed: low-speed rotation runs during heating-recycling to avoid asphalt mixture segregation; higher rotating speed activates during discharging for fast material release.
An imported diesel burner delivers thermal power up to 120 kW, with 0# diesel as fuel.
1. Heat transfer logic: The burner generates high-temperature hot air to heat the drum cavity. Continuous drum rotation tumbles asphalt mixture inside to form material curtains. Aggregates make full contact with hot air for even temperature rise. Flames never directly burn aggregates and asphalt to prevent premature asphalt aging and deterioration.
2. Heating efficiency: The first batch of cold or reclaimed material takes merely 15-20 minutes for heating. For continuous operations, each subsequent batch only needs 10-15 minutes, outperforming other compact recycling devices on the market.
3. Temperature measurement: Imported thermocouples collect real-time material temperature data inside the tank and feed readings back to the PLC control system for closed-loop temperature regulation. An independent 45L diesel tank stores heating fuel for prolonged continuous construction.
Users can select the emulsified asphalt spraying system, hot asphalt system, or integrate both sets to match diverse construction requirements.
1. Hot asphalt system: Equipped with a 100L asphalt storage tank with thermal-oil circulating heating and automatic constant-temperature control for liquid hot-asphalt storage. Hot asphalt can be supplemented when reclaimed RAP materials suffer binder loss, restoring bonding performance and extending repaired pavement service life. Fully electric-heated delivery hoses prevent asphalt solidification during conveyance.
2. Emulsified asphalt spraying system: It includes a 25L emulsified-asphalt tank, air compressor and 7.5-meter hose reel. It fulfills two key functions. First, it sprays emulsified asphalt onto old pavement before repair to build bonding courses between original pavement and new mixtures. Second, it injects emulsified asphalt into oil-deficient milled reclaimed materials to replenish asphalt binders. Hoses support diesel flushing after work to avoid blockage from solidified emulsified asphalt.
The touch-screen PLC electronic control system coordinates all movements, marking a key difference from simple mixing machines.
1. Dual-dimension control logic: It combines time parameters and real-time temperature readings to govern heating and mixing workflows, instead of relying purely on single temperature thresholds. Local overheating inside the tank is avoided to prevent asphalt thermal aging and coking.
2. Intelligent rotating-speed linkage: The drum maintains low rotating speed in recycling-heating mode to prevent aggregate segregation. High-speed reverse rotation triggers automatically once discharging is activated.
3. Human-machine interaction: The LCD touch screen displays temperature and operational status. Physical pushbuttons, fault indicator lamps and emergency stop buttons guarantee site safety. Automatic fault alerts lower operator training barriers.
1. Independent generator set: The 6.5 kW truck-mounted generator supplies 380V three-phase power. Complete equipment operation is achievable without external power sources on job sites. Gasoline or diesel fuel options are available.
2. LED night-construction lighting: Folding rotary high-power lamp assemblies support remote control with 360-degree angle adjustment. Lamps fold back after work for night emergency repair missions.
3. Safety warning configuration: Eight flash warning lights plus bi-directional arrow indicator lights activate during work to warn passing vehicles and safeguard field workers.
Three operational modes are supported: waste asphalt recycling mode, cold finished mixture reheating mode, and on-site fresh asphalt mixture mixing mode.
1. Feed milled and broken waste RAP asphalt chunks into the drum mixing tank.
2. Activate the PLC program. The drum rotates forward at low speed. The diesel burner starts heat output. 360-degree tumbling of materials proceeds inside the drum, while ceramic-fiber insulation reduces heat loss.
3. Thermocouples monitor mixture temperature continuously. The system adjusts burner firepower accordingly. Emulsified asphalt or hot asphalt is injected if reclaimed materials lack asphalt content.
4. Waste materials are heated evenly up to construction-standard temperature for activated asphalt recycling, achieving 100 % on-site reuse of reclaimed asphalt.
5. Operators send discharging commands. The drum rotates in reverse, and spiral vanes push all recycled mixture out rapidly for direct pothole paving repairs.
Pre-produced cold finished asphalt mixture from mixing plants is loaded into the drum for reheating. This addresses industry pain points such as shutdown of mixing plants and temperature drop caused by long-distance hot-mix transportation when hot material is urgently needed on-site. No extra aggregates are added. Reheated mixture can be discharged directly for construction.
Crushed stone, sand aggregates and asphalt are fed directly into the drum. Heating and mixing complete simultaneously on-site to produce new asphalt mixture for small-area paving work.
Key technical point: Indirect heating is adopted across the whole workflow. Materials tumble inside the rotating drum without direct flame impingement on asphalt. Combined with PLC time-temperature dual-strategy control, asphalt thermal aging is minimized, which directly determines the service life of recycled repaired pavement.
The complete on-site repair workflow is coherent, consisting of six steps:
1. Pavement distress pretreatment: Remove all loose asphalt from potholes and damaged zones with breakers to form regular repair cavities.
2. Reclaimed material collection and feeding: Load broken waste asphalt chunks from demolition work into the drum mixing tank.
3. Equipment heating, recycling and mixing: Start the equipment for rotary heating. Inject emulsified asphalt or hot asphalt as required and wait until materials reach construction temperature.
4. Original pavement interface treatment: Spray emulsified asphalt tack coat inside potholes to strengthen bonding between old and new pavement layers.
5. Discharging and paving: Reverse the drum for material unloading. Spread hot recycled mixture into potholes and level manually.
6. Compaction and forming: Compact repaired zones with small-sized rollers to finish distress restoration. Roads can reopen to traffic within a short period.
1. Resource conservation and environmental protection: 100 % on-site recycling of milled waste asphalt eliminates waste transportation demand, cuts procurement of fresh aggregates and asphalt, and lowers carbon emissions and waste-disposal costs.
2. Independence from fixed mixing plants: Maintenance and emergency repairs can proceed in field locations, at night or during mixing-plant shutdowns, removing the requirement for long-haul hot-mixture transportation.
3. Flexible multi-configuration selection: Buyers may choose only the emulsified asphalt system, only the hot asphalt system, or integrate both assemblies to control procurement expenditure.
4. Light-weight truck-mounted design: The whole unit is mounted onto standard truck cargo beds instead of requiring custom special-purpose chassis, delivering high mobility for job-site transfers.
5. Night-time construction capability: Built-in power generation, illumination and warning systems deliver outstanding performance for night-time emergency maintenance.
1. Asphalt anti-aging control: Uneven temperature distribution inside drums easily causes local overheating and asphalt coking. Simple thermostat switches cannot resolve this issue. PLC compound time-temperature control strategies paired with optimized drum rotating speeds form the performance gap between premium-grade equipment and low-end simple agitators.
2. Risk of mixture segregation: Excessively high drum rotating speed triggers separation of coarse and fine aggregates. Destroyed mixture gradation leads to recurring damage on repaired pavements, hence low-speed operation is mandatory during recycling cycles.
3. Pipeline anti-clogging challenge: Emulsified asphalt and hot asphalt solidify quickly upon cooling. Pipeline heating assemblies and diesel-flushing mechanisms are indispensable to avoid equipment breakdown caused by blocked pipelines.
Against the global trend toward low-carbon, on-site recycling and lightweight rush repair for road maintenance, truck-mounted drum-type on-site asphalt recycling mixing equipment fills the market gap between large-scale hot-in-place recycling trains and basic cold-patch materials.
Large hot-in-place recycling trains are suitable for full-lane large-scale continuous reconstruction with high investment costs. Cold-patch materials merely deliver temporary emergency repairs with poor construction quality. In contrast, the mobile RAP recycling mixing workstation targets scattered point-shaped distresses including potholes, damage around manhole covers, local pavement bumps and cracks. It produces qualified hot-mixed asphalt mixture on-spot with full on-site waste recycling, balancing construction quality, cost control and low-carbon environmental benefits. It fits scattered maintenance tasks for municipal roads, highways and county-level highways.
With growing popularity of eco-friendly road-maintenance concepts, such on-site recycling equipment eliminating large-scale material transportation will become standard equipment for road-maintenance contractors.
