RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 RA 100 – The new dimension in use of RAP Rolf Jenny Senior Vice President Ammann Group Chairman Ammann Australia Pty. Ltd. 1 AAPA Technology Tour 18 th June 2012

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Road construction in Europe and Australia 2 Many similarities Europe Australia 1.European market is extremely competitive Coal dust is used as fuel -> big reduction in energy cost High % of recycling -> big reduction in material cost Latest technologies -> reduction in operating cost 2.European Road Construction requires maximum flexibility Asphalt mix are adjusted to all kind of needs (>100 recipes) 3.European environmental standards are different CO, NOX, C, dust ( applicable at all location ). Wet washers/wet scrubbers are impossible to use in Europe Important differences

RA The new dimension in use of RAP | © Ammann GroupJune, 18th Intact living spaceHigh Mobility Sustainable road construction means:

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 It means also well maintained road network 4 Well maintained roads

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Improvements of construction equipment 5 Speed of Change 1.Environmental Requirements 2.Shift from “New Roads” to “Maintenance” 3.Improved Quality Requirement 4.Economical Crisis 5.Competitive Market

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 These methods have gone a long time ago… 6 In the Mountains of Nepal in 2002

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 The good old days 7

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Today’s clean asphalt manufacturing 8

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Shift from new roads to maintenance 9 Road Maintenance Total global Asphalt Production Tonnes per year 1980 Construction of New Road Growth of 4.1% each year 2.2 billion tonnes in ,3 to p.a and Inhabitant North America 650 Mio. to p.a 5% of the world population using 1/3 of the global prduction China 440 Mio. tonnes p.a

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 The 3 segments of global road construction markets 10 India, South America, Africa Characteristics low investment mobility projects Total Asphalt Production Maintenance New Road Rural to Paved Road

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 The 3 segments of global road construction markets 11 India, South America, Africa Characteristics low investment mobility projects Total Asphalt Production Maintenance New Road Rural to Paved Road Maintenance Total Asphalt Production New Road Rural to Paved Road China, Russia, Eastern Europe, Asia Pacific Characteristics open for new technologies environment coming improved quality

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 The 3 segments of global road construction markets 12 India, South America, Africa Characteristics low investment mobility projects Total Asphalt Production Maintenance New Road Rural to Paved Road Maintenance Total Asphalt Production New Road Rural to Paved Road China, Russia, Eastern Europe, Asia Pacific Characteristics open for new technologies environment coming improved quality Maintenance Total Asphalt Production New Road USA, Western Europe, Australia Characteristics environment flexibility quality

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Ammann’s answer to the 3 segments 13 Total Asphalt Production Maintenance New Road Rural to Paved Road Maintenance Total Asphalt Production New Road Rural to Paved Road Maintenance Total Asphalt Production New Road EasyBatch Speedy Batch Blackmove 25-60% Recycling % Recycling

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 The future is already here 14 AC 0/11 Recycling (0/11) 92 % Mineral (8/11) 8 % Wearing coarse with 92% RECYCLING in Hamburg Germany

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Strategy: Recycling and Economy of scale 15 Production:1000 ‘ 000 t.p/a Recycling:600 ‘ 000 t.p/a Very well sorted Reclaimed Asphalt Consolidation: 100  50 plants High volume production High recycling ratios High flexibility

RA The new dimension in use of RAP | © Ammann GroupJune, 18th Hot and Cold Recycling up to 75% Proven technology (Batch & Conti) 500 Parallel Drums for 60% 1000 Cold Additives for 30% Limitations: Super-heating Emissions RA outlet temperature

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Strategy: 100% Recycling 17 Highly Competitive thanks to RAP High RAP storage volume High flexibility Quality Assured RAP

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Ammann developed a new asphalt recycling concept for 0% - 100% reclaimed asphalt RAH 100% Reclaimed Asphalt Hot 100%

RA The new dimension in use of RAP | © Ammann GroupJune, 18th World’s 1 st Plant Using up to 100% Recycling Asphalt 100% Recycling Device Why up to 100% recycling? Excess of reclaimed asphalt Ecological requirement to preserve natural resources Economical to reuse available material

RA The new dimension in use of RAP | © Ammann GroupJune, 18th % Recycling Device Process Air Heater RA Dryer Process Air Circulation

RA The new dimension in use of RAP | © Ammann GroupJune, 18th % recycling device (protected) 21 Process Air Heater (combustion chamber) Raw Gas to Filter (95°) Drying Drum (turning) Process Air Circulation Gas Mixing Heated Reclaimed Asphalt (165°C) Low ageing of bitumen No radiation heat Soft heat exchange High efficiency Counter flow dryer Process air circulation Low emissions (TOC) Indirectly heated Low temp. heat exchange

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 RAH 100% drying drum 22

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Process air heater 23

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Treatment of reclaimed asphalt 24 Binder4,0 % Filler10,6% Sand45,8% > 2 mm43,6% Binder3,6 % Filler6,9% Sand24,7% > 2 mm68,4% Binder5,1 % Filler12,4% Sand52,5% > 2 mm35,1% RA 0/22 RA 0/8 RA 8/22 Screening

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Well sorted recycling materials 25 0/8 8/16 16/32

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Blending of reclaimed asphalt 26 0/8 8/16 16/32 Scalping screen

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Bitumen characteristics after heating 27 sample A (cold) taken at RA feeder through-put time approx. 10 min. sample B (hot) taken at drum outlet Determination of the parameter in the laboratory: Bitumen content Grading curve Softening point ring & ball R&B Penetration Fraaß breaking point to guarantee match of sample A and B characteristic to evaluate thermal stress of bitumen

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Bitumen characterstics after heating (guide values) 28 Softening point ring & ball: Average: Increase of the temperature of softening point R&B of 3°C.

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Bitumen characterstics after heating (guide values) 29 Penetration values: Average: Decrease of penetration value of 0,5 mm; respectively 21%

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Intelligent, fully integrated road construction 30 Closing the Loop: from Road to Road High quality, reduced costs and construction time Ecology, Economy, Safety

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 AAPA resolution Australia Leader in Sustainable Road Construction –What we take out of the road, we put back! –Green Asphalt preferred in tenders –Government adopts performance based principles –Phase out processes that are not environmentally friendly.

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Leadership in sustainable road construction 32 National and state road authorities Supporting new technologies Road construction companies Investing in new technologies Equipment Manufacturing R&D new technologies AAPA Resolution 2011

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Thank you very much for your attention Productivity Partnership for a Lifetime 33

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Drivers for sustainbalbe road construction 34 Asphalt back to asphalt Sustainable Road Construction Shift of Focus: - From new roads to Maintenance Government: - Emissions -Recycling Financial: - Lack of Funding - Market competitiveness Tier IV „TA Luft“

RA The new dimension in use of RAP | © Ammann GroupJune, 18th Direct and indirect emissions considered, without transport 0 50 kg CO 2 per t of Asphalt Traditional Production 2 Asphalt Recycling Low Temperature Mix Lower Moisture Cont. -25% CO New Technology Alternative Energies Ecology SW tools, Integrated Constr. Technologies to come

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Solar heated bitumen farm 36

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Global solar radiation 37 Many countries in best solar area

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Wood dust fired burner 38 CO 2 neutral fuel Cost savings

RA The new dimension in use of RAP | © Ammann GroupJune, 18th 2012 Wood availability 39