Asphalt recycling insulation box is a professional equipment for repairing asphalt pavement potholes. It is mainly used for the insulation and transportation of fresh hot materials in mixing stations, the heating and insulation of cold materials in finished asphalt mixtures (without relying on asphalt mixing stations), and the repair of asphalt pavement potholes. Provide sufficient hot asphalt mixture in a timely manner to ensure that the mixture remains at a constant temperature during long-term and long-distance maintenance operations to ensure maintenance quality. This device can achieve heating, insulation, and transportation of hot asphalt mixture, which is simple, convenient, energy-saving, and environmentally friendly.
1. Dual-mode heating integrates cold-material heating and hot-material heat preservation. Two heating options including 220V mains power and diesel thermal-oil burner are available. On-site recycling of reclaimed asphalt mixture reduces raw material cost for maintenance. Year-round construction is available without seasonal restrictions.
2. Indirect zoned flexible heating by thermal oil realizes large-area uniform heating and prevents scorching and aging of asphalt mixture. Integrated thermal-insulated tank heats ambient-temperature mixture to 140-160℃ within 3-4 hours with high heating efficiency and excellent heat retention performance.
3. Intelligent integrated control system adopts dual-limit digital automatic temperature control together with mechanical dual over-temperature protection. Functions include fault light alarm & diagnosis, rapid preheating and scheduled timing heating for easy operation and low maintenance cost.
4. Hydraulic screw automatic discharging with output capacity of 3 cubic meters per 15 minutes. Bin gate operated by electric push rods meets maintenance requirements of rapid deployment, quick repair and fast evacuation.
5. Specialized night-time construction package: LED working lamps and LED warning arrow lights with effective warning visibility over 200 meters. External power outlet supplies power for peripheral electric tools, ideal for night emergency repair on heavy-traffic sections.
6. Modular tank unit fits truck chassis with load capacity of 6 tons and above. Suitable for minor and medium-scale repair of asphalt pavement on high-grade highways, municipal roads and airports, featuring low energy consumption and low operation pollution.
This project covers sections of Kuala Lumpur International Airport (KLIA) access roads and Malaysia Federal Route FT02. Situated in tropical rain‑forest climate, the site features high temperature and heavy rainfall all year round. Pavements are suffering from frequent distresses including potholes, crocodile cracking, pumping and local settlement. The airport access road bears heavy traffic with a large volume of heavy‑duty freight vehicles. Distant stationary asphalt mixing plants result in long hauling time for fresh asphalt mixtures and high disposal cost for milled waste asphalt. The contract requires rapid mobilization, quick repair and fast evacuation to minimize lane‑occupying duration. Several emergency patching tasks must be performed overnight. The local maintenance contractor deployed three sets of FND‑CB‑3500 modular hot‑recycling insulated units mounted on 6‑ton payload truck chassis for field operation.
Project Challenges
1. No nearby asphalt mixing plant on‑site. Long‑distance transportation causes severe temperature loss of fresh mixtures and high material cost for pavement maintenance.
2. Large diurnal temperature variation and frequent monsoon rains in tropical zone. Conventional storage equipment suffers poor heat retention and rapid temperature drop of asphalt mixtures, making it difficult to guarantee paving and compaction quality.
3. Extremely heavy daytime traffic on airport access roads and federal highway. Most pothole repair work can only be carried out at night, which imposes strict requirements for working illumination and safety warning performance.
4. Green maintenance philosophy is required for the project. Milled Reclaimed Asphalt Pavement (RAP) shall be reused on‑site to cut virgin material procurement cost and solid‑waste outward‑transport disposal expenditure.
Equipment Deployment & Operational Outcomes
Adopting thermal‑oil indirect zoned flexible heating, the equipment can heat ambient‑temperature cold asphalt mixture and maintain temperature for hot‑mixed asphalt delivered to site. Milled reclaimed asphalt pavement is fed into the bin for on‑site recycling, significantly reducing consumption of virgin asphalt mixtures. Ambient‑temperature mixtures can be heated to working temperature 140‑160 ℃ within 3‑4 hours. Hydraulically‑driven screw conveyor delivers stable material output at 3 cubic meters per 15 minutes, ideal for batch rapid pothole patching.
Intelligent dual‑limit temperature‑control system is equipped with fault light alarm function to lower skill requirements for field operators. LED working lamps plus LED warning arrow lights with over 200‑meter visible distance ensure operational safety for night‑time lane‑occupying emergency repair around the airport. Built‑in power‑output interface supplies electricity for on‑site electric tools such as cutters and vibratory compactors.
Modular tank unit supports quick mounting and dismounting onto qualified truck chassis for flexible site‑to‑site transit. After project execution, on‑site recycling ratio of reclaimed asphalt material is greatly improved, and virgin‑material procurement cost is reduced by approximately 27%. Lane‑occupying time for single‑spot repair is shortened remarkably, minimizing traffic disruption for airport commuter flow and federal‑route traffic flow. Repaired pavement maintains good service performance under Malaysia’s high‑temperature, high‑humidity monsoon conditions. The equipment successfully completes periodic minor and medium‑scale maintenance for KLIA access roads and Federal Route FT02.
Equipment name
FND-CB-3500
Effective capacity of material box
2.5 cubic meters
Maximum loading capacity
4000KG
Vehicle size
2400 × 1700 × 1250 MM L*W*H
Generator power
15 horsepower air-cooled electric starting diesel engine, battery 12V 80AH
Fuel tank capacity
60L
Heating method
Diesel burner heats the heat transfer oil, and the heat transfer oil circulates in different zones to heat the mixture
Heating time
3-4 hours
Burner
RIELLO
Temperature control
Dual limit digital automatic temperature control, mechanical temperature limit protection
Discharge method
The reducer controls the transmission and discharge of materials through a spiral feeding rod
Discharge speed
3 cubic meters/15 minutes
Intelligent control
Unique fast preheating and scheduled heating functions
Automatic unloading mechanism
Hydraulic motor drive
Other configurations
Safety warning
Equipped with LED arrow indicator lights to enhance construction safety
Auxiliary power
Equipped with a power output connector, it can provide power for external electric tools
Chassis Requirements
Trucks with a load capacity of over 6 tons
The heating system has the functions of cold material heating and hot material insulation. Depending on the construction site conditions, it can use 220V mains power or use a burner to burn thermal oil for indirect heating. The heating method conversion can be easily completed on the panel; This device can ensure that under no circumstances will it be unable to be repaired on the road due to the asphalt mixture. At the same time, it can recycle old materials on site, maximizing the savings of raw materials and costs. It has excellent effects on minor and medium repairs of the road surface.
Intelligent integrated control system. Centralize the control of heating material box temperature and box heating on the panel, and have indicator lights and alarm lights to diagnose faults.
Adopting indirect heating method with thermal oil and fully automatic temperature control system with thermal oil, it is easy to operate and maintain, has low usage cost, and has strong adaptability to the environment.
The box adopts an integrated insulation design with good insulation effect and high heating efficiency. It takes about 3-4 hours to heat the entire box of asphalt mixture at room temperature to 140-160 ℃. The electric push rod controls the opening and closing of the material box door.
The asphalt paving machinery bitumen hot box uses thermal oil as the heating medium, with flexible heating and a large heating area at the same time to avoid burning and aging of asphalt materials. The box body adopts a zoning design to achieve simultaneous heating inside and outside, saving heating time.
The asphalt mixture heating Insulation box equipped with dedicated LED construction lighting to meet the needs of night construction on road sections with high traffic flow. And it also equipped with LED safety warning lights, with an effective visual range of over 200 meters. It can effectively remind incoming vehicles to avoid during nighttime construction.
The equipment warranty period is 12 months, calculated from the date of equipment ex-factory. For product quality defects, the Supplier shall provide maintenance guidance via telephone; on-site service is not included under warranty. Should on-site service be required, it shall be subject to mutual negotiation between both parties, and the Buyer shall bear all relevant travel and accommodation expenses. For component-related quality failures occurring within the warranty period, free repair or replacement shall be available upon mutual agreement with the Supplier. Wear-and-tear parts are excluded from this warranty.
