Download PDF - Hot-Mix Magazine

General contractor benefits from 

Roadtec fleet for mill and lay 

Navigating Australia’s Barrow Island 

with portable asphalt plant 

Astec’s depth of control offerings provide 

innovation for plant operations 

Dillman branches out into new markets 

for industrial sales 

YOUR DEPENDABLE SOURCE FOR NEWS ABOUT HMA TECHNOLOGY 

PUBLISHED BY ASTEC INDUSTRIES, INC. 

VOLUME 18 NUMBER 2 - 2013

10 16 

VOLUME 18 NUMBER 2 

Copyright © 2013 

Hot-Mix Magazine is published by 

the family of companies known 

as Astec Industries, Inc. 

Our mission is to provide members 

of the HMA industry with up-to-date 

news about HMA and WMA 

technology and the recent advances 

in the industry. 

22 

30 

Editorial Staff 

Editor: 

Donna Campbell 

Staff Writer: 

J. Campbell 

Staff Photographers: 

Paul Shelton (Astec) 

Brandon Meredith (Astec) 

Scott Lee (Roadtec) 

Sam Anselmi (Astec) 

Subscription Services: 

Diane Hunt 

Directors of Advertising: 

Paul Shelton (Astec) 

Frank Eley (Heatec) 

Stephanie Rider (Roadtec) 

Editorial Board: 

Dr. J. Don Brock 

Ben Brock 

Tom Baugh 

Paul Shelton 

Norman Smith 

Contact Information 

If you would like to be added 

to our free subscription list, 

just call, fax, or write: 

Hot-Mix Magazine 

c/o Astec 

P.O. Box 72787 

Chattanooga, TN 37407 

Phone: 423.867.4210 

Fax: 423.867.3570 

Website: www.astecinc.com 

www.hotmixmag.com 

5 Point of View 

Words from Sergio Cinerari, AAPA Chairman 

6 Plant 17 

Iowa contractor excels by replacing old with new 

10 Change is the Only Constant 

Astec’s training schools continue to evolve 

12 In Demand and In Control 

Astec’s latest plant controls—PMIII 

14 The Shape of Things to Come 

Astec uses 3D printing to bring ideas to life 

16 Mobility Down Under 

Astec Australia delivers asphalt portability to civil contractor 

21 On Your Side 

Earning a customer’s trust is job #1 for Astec’s Travis Sneed 

22 In the Heart of Texas 

Company excels and mill and lay with Roadtec fleet 

26 Every Day is Recycle Day 

Astec’s warm mix system enhances new asphalt plant 

30 The Power of Portability 

Tennessee contractor welcomes efficiency with portable plant 

34 Wake Up the Echoes 

Asphalt plant completes retrofit 

38 Branching Out 

Dillman ventures into new territory for industrial sales 

39 Hot-Mix News 

What’s happening at Astec Industries 

ON THE FRONT COVER 

LL Pelling Company, Inc. set up the relocatable Astec Double Barrel ® plant 

in Cedar Rapids, Iowa. The plant features the 72,457 CFM Pulse Jet 

baghouse, a 10 ft x 14 ft (3.05 m x 4.27 m) eight-compartment cold feed 

system, and three 200-ton (181 tonne) silos. 

Here’s how to get all future issues 

of Hot-Mix Magazine absolutely free! 

To have your name added to our mailing list at no charge, 

just call 423.867.4210 and ask for Diane Hunt, 

or you can email your request to dhunt@astecinc.com. 

HOT-MIX MAGAZINE 3 VOLUME 18 NUMBER 2

Bitumen is a unique 

substance that starts 

as crude oil, is refined, 

and then combined with 

aggregate to make asphalt 

and sprayed seal road 

surfaces. These surfaces 

provide safe, quiet, and longlasting 

pavement that connect 

people, goods, and services 

right across Australia. 

Without these durable 

surfaces, society would be vastly different, but most 

people take asphalt pavements for granted. Those 

of us who work in the pavement industry know the 

significance of asphalt pavements, and I encourage 

each of you to be proud of the work we do. I also 

encourage you all to promote the importance of 

what we do to others around us. 

Even more importantly, we should ensure that 

all stakeholders in our industry are aware of the 

environmental advantages of asphalt over other 

paving materials. 

PROCESS CAN BE REPEATED 

Firstly, asphalt paving is 100-percent recyclable and can be recycled 

over and over again. 

A deep lift asphalt pavement or perpetual pavement that is over 

20 years of age may have suffered some surface damage, but 

generally this damage is only “skin deep.” The minor surface 

damage in a wearing course can be milled off and quickly replaced 

with a new wearing course, with minimal interruption to traffic 

flows and at low cost. 

POINT OF VIEW 

More Than Just 

Sticky Black Stuff 

Words from Sergio Cinerari, 

Chairman, AAPA (Australian Asphalt Pavement Association) 

Asphalt removed from a road pavement remains asphalt, a valuable 

combination of bitumen and high-quality aggregates. This material is 

referred to as reclaimed asphalt pavement or RAP. RAP can be readily 

returned to an asphalt plant where it can be combined with virgin 

materials and applied to another road or pavement project. In another 

20-plus years, the same process can be repeated. 

Asphalt is not consumed, but remains asphalt indefinitely. This 

is unlike other materials, such as concrete, that can be used for 

Asphalt surfaces are 100-percent 

recyclable and save significant 

amounts of new material. 

Sergio Cinerari, Chairman, AAPA 

pavement surfaces once, 

and then if it is recycled, 

can only be used for lower 

value purposes, such as 

fill or road base. 

Asphalt surfaces are 

therefore 100-percent 

recyclable and save 

significant amounts of 

new materials. 

REDUCES GREENHOUSE GAS EMISSIONS 

Using RAP not only reduces the demand for new 

materials, it also greatly reduces greenhouse gas 

emissions. The manufacture of bitumen is a low 

source of greenhouse emissions, but some energy 

is used in its manufacture and in the extraction, 

crushing, and transport of aggregates. The use 

of RAP reduces the greenhouse emissions by 

removing the need to make and supply new 

materials. The use of RAP in asphalt readily 

reduces greenhouse emissions by at least 10 to 20 

percent. RAP also has great synergies with warmmix 

asphalt providing even more environmental 

benefits, as well as performance benefits. 

Those of us working in our industry can be proud of the part we 

play in society, not only as we build quality roads and pavements, 

but also because we are a green industry. An industry that produces 

low greenhouse emissions compared to other road surfaces and an 

industry that can recycle asphalt over and over again. 

BENEFITS ARE CLEAR 

The benefits of asphalt as an environmentally friendly product 

are clear, and we should help to educate communities and all 

stakeholders that asphalt is more than sticky black stuff, letting 

them know that, as asphalt is 100-percent recyclable, it is one of the 

greenest construction materials available on the market today. 

As an industry that takes its impact on the environment very 

seriously, we should continue to encourage the use and development 

of green pavements through practices such as the increased use of 

RAP and low-energy technologies such as warm mix. 


Plant 17 

Iowa contractor excels by 

replacing old with new 

There comes a time in any 

venture when moving 

forward requires change. 

Whether it’s transitioning to the 

latest technology or acquiring 

new partners, company growth is 

earmarked with new decisions. 

LL Pelling Company, Inc. is one 

company that understands what 

it takes to reach the next level of 

expansion, and it includes Astec’s 

equipment and innovation. 

“The ability to recycle using the 

Astec Double Barrel ® drum mixer 

sets us apart from the competition.” 

HUMBLE BEGINNING 

Lloyd Pelling, Sr. started the LL 

Pelling Company, Inc. in 1948 in 

the Williamsburg, Iowa, area. It 

began oiling roads as road surfaces 

began moving away from 

mud to gravel and eventually 

to pavement. In the late 1960s, 

Lloyd Pelling, Jr. became president 

and moved the company to Iowa 

City to allow for expansion into 

the asphalt business. During the 

60s and 70s, LL Pelling traveled 

throughout Iowa with batch plants 

or continuous mix plants. The decision 

to put down roots happened 

in 1975 and the traveling stopped. 

An asphalt batch plant was erected 

in Coralville, Iowa. 

FORWARD PROGRESS 

In the late 80s, Russ Rhinehart 

purchased the company from the 


Left: LL Pelling Company, Inc. set up the relocatable Astec Double Barrel ® plant in Cedar Rapids, Iowa. Top: 10 ft x 14 ft 

(3.05 m x 4.27 m) eight-compartment cold feed system. Bottom: LL Pelling’s plant features the 72,457 CFM Pulse Jet baghouse. 

Pellings. Rhinehart and his partner, 

Manatts (a diversified heavy highway 

construction company based 

in Brooklyn, Iowa) took the company 

into the 21st century. It was 

Rhinehart who purchased the first 

Astec plant in 1997 for the Iowa 

City location. The 400 TPH (363 

MTPH) Astec Double Barrel ® plant 

replaced an old 6,000 lb (2,721 

kg) batch plant. This was quite a 

change for LL Pelling. 

“We knew technology had 

advanced beyond what we were 

currently using,” said Chuck 

Finnegan, current president of LL 

Pelling. “It was the vision and input 

of new people leading to new decisions 

for the direction of the company, 

and the path forward looked 

promising.” 

LL Pelling had three asphalt plants: 

the Astec Double Barrel ® plant in 

Iowa City (purchased in 1997); a 

small 4,000 lb (1,814 kg) batch 

plant in Marion; and a 16,000 lb 

(7,257 kg) batch plant in Cedar 

Rapids. In addition to its asphalt 

paving, concrete curb and gutter, 

chip and sealcoat, pavement marking, 

and oil transportation, being 

able to supply its own hot-mix 

asphalt (HMA) to its projects created 

a full-circle operation. 

THE NEXT PHASE 

In 2001, LL Pelling purchased a 

Dillman DuoDrum and put up this 

new plant in Marion. The plant 

replaced the small 4,000 lb (1,814 

kg) batch plant. 

In 2012, LL Pelling purchased an 

Astec Double Barrel ® plant for the 

Cedar Rapids location to replace 

the old 16,000 lb (7,257 kg) batch 

plant. The plant was operational 

mid-April 2013. 

“This replacement was five or six 

years overdue,” said Finnegan. 


Relocatable Astec Double Barrel ® drum. 

“We had a five-year plan probably 

10 years ago to put the new Astec 

plant in place, but with economic 

times as they were, and still are, it 

just didn’t work out according to our 

original timetable.” 

LL Pelling purchased 40 acres (19 

hectares) of land outside its sister 

quarry in Cedar Rapids to set up the 

new plant, named Plant 17 by the 

accounting department’s numbering 

system. 

“We viewed the location as opportunistic,” 

said Finnegan. “We can 

haul much of our material to the 

plant and don’t have to travel on a 

public road. This saves on hauling 

and trucks.” 

A GOOD POSITION 

Astec equipment allows LL Pelling 

to be in a good position, especially 

with the ability to recycle. This was 

an area the company wanted to 

improve. 

“We knew technology had 

advanced beyond what we were 

currently using … with Astec, the 

direction of the company looks 

promising,” said Finnegan. 

“Using reclaimed asphalt pavement 

(RAP) and recycled asphalt 

shingles (RAS) is a capability that 

sets us apart from the competition 

and helps us control costs,” said 

Finnegan. “Anytime we can recycle, 

it’s a benefit to the environment and 

the community. The Astec Double 

Barrel ® at Plant 17 uses RAP and 

RAS. This saves on landfilling; we 

even grind our own shingles. These 

cost-saving factors allow us to cut 

cost for our consumers. And in a 

pro-portland cement state, we need 

to control costs to stay competitive.” 

LL Pelling generates a lot of RAP 

from its road construction projects. 

One project is Interstate 380 

(southbound) where a recycled 

mix is being utilized (4 percent 

RAS and 12 percent RAP). 

“We do a lot of night work in the 

corridor between Cedar Rapids 

and Iowa City, about 25 mi (40 

km) apart, connected by I-80 and 

I-380,” said Finnegan. “There’s a 

lot of congestion through this area, 

so having a ready supply of material 

enables us to work quickly.” 

Plant superintendent Rod Haerther, 

who has been with LL Pelling 

for 23 years, oversaw the construction/setup 

of Plant 17 from 

concept to completion. According 

to Haerther, Plant 17 uses up to 

25 percent RAP (alone in a mix), 

and when using RAS with RAP, the 

recycle amounts are 2 to 3 percent 

and 9 percent, respectively. 

RAS is not currently used alone in 

a mix. 

“We are finishing up the I-380 

southbound project and already 

have a contract for the northbound 

section of I-380, plus a project at 

the Cedar Rapids airport,” said 

Finnegan. “Business is looking 

good moving into 2014.” 

FOR INFORMATION 

Contact Diane Hunt 

423.867.4210 

dhunt@astecinc.com 


Astec’s training school classes continue to evolve, expand and excite 

Service coordinator Troy 

Norris’s enthusiasm is 

contagious. And with his 

responsibilities, he needs the 

energy. As Astec Industries’ training 

school administrator, he is 

tasked with maintaining the high 

standards attendees expect of the 

Astec Advanced Customer School. 

Whether Troy is laying out the 

direction of new classes for coming 

years or discussing improvements 

and additions for current training 

sessions, he has to move as quickly 

as the pace of technology. 

Over the years, the look and focus 

of the Astec Advanced Customer 

School has changed to reflect 

the needs of customers and the 

demands of the industry. “When we 

started, we were having training 

classes in hotels—the Chattanooga 

Choo Choo, in the train car,” Troy 

noted. “Now we are here [at Astec’s 

training center] and there is a new 

facility across the street with a fullsize 

Astec Double Barrel ® drum and 

a range of scale models.” 

In the 1980s, the Astec Advanced 

Customer School moved to its permanent 

home on-site. Astec customers 

spent much of the training 

sessions in a single meeting room, 

with breakout classes that expanded 

throughout the facility. From that 

small initial footprint, the classes 

grew in scope, scale, and reputation. 

Word of the school’s benefits 

spread throughout Astec’s customer 

base, which led to more customers 

asking for training specific to their 

needs. “We add new classes all the 

time,” Troy said. And as the needs 

of customers changed, so too did 

the facility. 

As the classes’ popularity increased 

among customers, the school 

recognized the need for a bigger 


learning space to accommodate the 

influx of new attendees. In 2009, 

Astec Industries opened its expanded 

training center. For the first time, 

trainers and customers were able 

to work in a hands-on environment, 

all-in-one dedicated area, providing 

immediate feedback from instructors 

and collaboration between 

attendees. New equipment was 

moved in to facilitate the increased 

range of class offerings. 

In 2011, the current facilities for the 

Astec Advanced Customer School 

took shape. “From where we 

began to where we are now—with 

Training Center East and Training 

Center West—it’s amazing to see 

where the school has come,” Troy 

added. Conveniently located across 

the street, the new training center 

is large enough to accommodate a 

full-size Astec Double Barrel ® for 

hands-on drum classes, as well as 

scale models of existing plants. The 

scale models are the same ones 

carried by Astec to different trade 

shows around the world. 

New for 2014, Astec will be offering 

two levels of training. Level I will 

be an enhanced and expanded version 

of basic training for first-time 

students. The new Level I training 

promises to be even more handson 

and include technical training for 

power houses. Level II, or the “Top 

Gun Class,” is for returning students. 

Any attendee of prior Astec 

basic customer schools meets the 

prerequisite to join Astec’s in-depth 

training on four critical categories: 

burners, drums, controls, and electrical 

systems. With a narrowed 

focus on these four main categories, 

Astec can delve deeper into 

critical areas of plant performance 

and offer more advanced operating 

and troubleshooting tips. 


In Demand 

and In Control 

From burners to silos, from 

motors to drums, each component 

of a hot-mix production 

plant can either be a trusted 

collaborator in increasing the plant’s 

efficiency or—with access to timely 

information or ability to fine-tune its 

operation—a frustrating adversary 

to a plant’s capability. The main 

way plant operators and managers 

interact with the full range of 

their plant’s production process is 

through the plant control system. 

The human element—how comfortable 

users are with this system—is 

often as important as its technical 

aspects in determining how 

efficiently a control system works 

within the plant. Over the years, the 

designers and engineers at Astec 

Developed with customers in mind, 

PMIII is Astec’s newest plant 

control system. 

Controls have looked at how plants 

use their various control systems 

and developed answers based on 

real-world demands. Their latest 

design, called the PMIII, has just 

been introduced and is earning 

praise from customers as a responsive 

and intuitive system for today’s 

hot-mix production. 

LAYING THE FOUNDATION 

Of Astec’s legacy systems, the 

PM96—commemorating the year 

of its release, 1996—was an 

early version of a single-bore or 

multi-bore control system. It provided 

reliable service for hot-mix 

plants throughout America for 

years. However, with new technology 

came changing expectations. 

Operators were pleased 

with the PM96’s ability but as 

more demands were put on the 

system, newer controls would 

need to be integrated as well. 

NEW EXPECTATIONS 

The next generation release, the 

PMII, was designed to be its 

replacement. It maintained the 

same level of control but replaced 

the PM96’s specialized user-interface 

with a standard PC terminal, 

which relied on a so-called soft 

PLC and ran in Windows. The benefits 

to the plant’s machinery were 

the same, but the benefits to operators 

were exponentially improved: 

necessary training time decreased, 

plant control increased. 

Just before the release of the 

PMII, Astec released the TCII, a 

highly automated and exceedingly 

detailed plant control system. “This 

is the Cadillac of control systems,” 

said Al Williams, one of Astec’s 

PM96 system overview 

PMII system overview 


senior control engineers and 

head of the Industrial Control 

Group. Williams has over three 

decades’ experience with 

Astec’s asphalt control systems 

and has seen many of them 

put to the test—and pass with 

flying colors. “With a system 

like the TCII, for example,” he 

explained, “it can do whatever a 

plant operator needs. It’s almost 

as if, if something has an on/off 

switch, the TCII can automate 

it.” 

LEARNING BY DOING 

The TCII’s chief advantage over 

earlier systems is its capacity 

to learn and communicate 

with smart motors, variable 

frequency drives (VFDs), and 

other equipment. In addition to 

allowing operators easy manual 

control options and automated 

operations within preset limits, 

the TCII records and reports 

information about the plant’s 

efficiency from various points 

within the hot-mix production 

process. Thus, the TCII allows 

operators to use that information 

in realtime, establishing a more 

responsive and productive control 

system. 

However, not every plant 

requires that level of intricate 

data-management. Also, for 

some plants, a system like the 

TCII might be their ideal model, 

but perhaps management has 

not allocated enough resources 

to afford a “Cadillac” control 

system. With those customers’ 

needs in mind, Astec Controls 

developed their latest version 

of plant control systems—the 

streamlined PMIII. 

MADE WITH CUSTOMERS 

IN MIND 

Developed by Astec’s in-house 

controls engineers, the PMIII 

is a PLC-based control system 

comprised of separate modules 

for burners, silos, motor controls, 

and blending and loadout. With 

these features, the PMIII can 

be as robust or as simplified as 

plant operators desire. Williams 

noted, “Customers can purchase 

CPUs for each part of the plant 

or just one for the motor or the 

PMIII system overview 

PMIII burner controls 

PMIII silo controls 

burner. If someone out there 

still wants to use the old PM96 

push-button control panel 

for one part of the plant, that 

customer can still install PMIII 

modules everywhere else.” 

The PMIII’s modules can be 

installed individually to specify 

the options to a unique asphalt 

facility or they can be installed 

together as a package, similar 

to the TCII. 

Some plant operators complain 

of “information overload” in 

competing control systems. 

With that in mind Astec updated 

the PMIII user interface to 

rely on minimal graphics on 

each screen, reducing distraction 

and increasing an operator’s 

ability to find information 

with speed and clarity. Also, 

even though each individual 

screen may appear simple, the 

PMIII retains the ability to drill 

down for more information. 

This layered approach to data 

management allows the PMIII 

to provide abundant information 

that an operator may need 

without overwhelming users. 

Lastly, the PMIII’s built-in diagnostics 

reduce plant downtime, 

helping operators probe for the 

source of any problems along 

the production line. Also, the 

system’s improved reporting 

makes a greater variety of data 

available, which will assist 

management in long-term 

plant decisions. 

“Instead of just sending a signal 

to start or stop, the PMIII 

can read current on motors,” 

Williams added. “This is normally 

a feature you would only 

find on a larger, more expansive 

control system. Now that 

a more streamlined system 

can provide this level of data, 

more and more plants will have 

a level of control they never 

thought possible.” 



423.867.4210 



The Shape of Things to Come 

3D printing capability brings 

ideas into reality for Astec, Inc. 

Innovation, by its nature, tends 

to outpace resources. In custom 

manufacturing, ingenious solutions 

and next-generation ideas are 

sometimes put on hold because the 

cost of the equipment and materials 

to make them a reality are cost 

prohibitive or too rare to produce 

them in a widely accessible manner. 

Even building a prototype of 

a new machine part can require 

dedicated hours and expense with 

no guarantee of success. However, 

by using state-of-the-art 3D printing 

technology to create prototype burners, 

Astec, Inc. has narrowed the gap 

between what can be imagined and 

what is possible. 

THOROUGH PROCESS, 

PRECISION EQUIPMENT 

Working both with outside partners 

and engineers inside Astec, the 

3D printing process is overseen by 

Michael Swanson, P.E., manager of 

the Astec Burner Group. First, the 

engineer presents a problem and 

the idea for a new part, and it is 

designed and drawn as a 3D CAD 

model. Depending on the part, virtual 

tests are performed to assess 

the design’s performance using 

computational fluid dynamics (CFD), 

discrete element method (DEM), 

and other analysis software. Then, a 

physical prototype is built in the 3D 

printer and testing of the prototype 

determines if a new iteration is 

needed. 

The Astec Burner Group relies on a 

3DSystems ProJet 5000, a largescale, 

precision 3D printer that the 

team operates on an almost daily 

basis. The ability to create prototypes 

in precise detail meeting the design’s 

The 3DSystems ProJet 5000 professional 3D printer provides detailed 

prototypes for Astec.

The prototype printed nozzle part before test firing. 

needs is key to Astec’s successful 

use of 3D printing. “Every part is different,” 

said Michael Swanson, “and 

when building a prototype, even the 

smallest change in a design can 

yield different results. The more 

exact we can build a test part, the 

more accurate the tests will be.” 

OUT WITH THE OLD 

Historically, Astec outsourced such 

quick turnaround prototype manufacturing 

to third-party suppliers, 

a process that limited the amount 

of testing that could be performed 

and the number of prototypes that 

could be produced. “The old method 

of drawing a part and individually 

machining it took two weeks,” 

Swanson added. “The current technology 

has cut that time down to, on 

average, two days.” 

When Astec brought 3D printing inhouse, 

Swanson’s group now had 

the technology to machine more 

prototypes, quicker and at greater 

savings. With the lag time between 

iterations reduced to a mere couple 

of days, engineers can now finetune 

their tests and see immediate 

results. Today, Astec can build a prototype, 

assess it, and manufacture a 

Testing of the burner with its 3D prototype is successful. 

new version for testing in a fraction 

of the time it would have taken to 

machine just one prototype using 

the old method. 

COMPUTATIONAL FLUID 

DYNAMICS 

Accurate implementation of CFD 

is key to a 3D-printed prototype’s 

success, but it is also the starting 

point for innovative and cutting-edge 

designs. “In the past, some of the 

parts we’ve tested for burners would 

not have been possible to prototype. 

The complexity and intricacy of the 

design would have made it nearly 

impossible to find a shop with the 

equipment capable of machining 

them,” said Swanson. 

As Astec’s ability to prototype ever 

more intricate parts increases, so 

too is their opportunity to solve problems. 

Swanson noted that requests 

to build prototypes continue to 

increase and he sees no ceiling on 

3D printing’s potential. “If it can be 

drawn,” he noted, “it can be built.” 

NEW IDEAS, NEW OPTIONS 

Astec, Inc.’s use of 3D printing for 

prototype parts and sales and marketing 

display models benefits the 

entire company. Testing is now possible 

for more parts with increased 

complexity, leading Astec engineers 

to implement more concepts that 

would once be deemed too farfetched 

or prohibitively expensive 

for the real world. In the future of 3D 

printing, however, the real world is 

what you make it. 



423.867.4210 

dhunt@astecinc.com

Mobility 

The 

Down Under 

Astec portable asphalt plant allowed Fulton Hogan 

to meet the requirements for working on Barrow Island. 

Astec Australia delivers asphalt 

portability to major civil 

contracting company. 

In 2012, Fulton Hogan 

Industries transported its new 

highly portable Astec asphalt 

plant to Barrow Island, a remote 

island off the western coast of 

Australia. Fulton Hogan Industries 

is a very prominent business 

“down under,” which specializes in 

building and maintaining transport 

and civil infrastructure in Australia, 

New Zealand, and the South 

Pacific so that communities can 

operate safely and efficiently. 

The plant was custom-designed 

and built for Fulton Hogan’s 

Asphalt Surfacing Operations to 

provide them with a highly portable 

asphalt plant which could be 

moved easily from state to state 

and offshore. 

Kellog Joint Venture Gorgon 

The Kellog Joint Venture Gorgon, an unincorporated joint venture 

between KBR, JGC, Hatch, and Clough, is the Gorgon’s Project’s 

downstream engineering, procurement, and construction management 

contractor. The scope of work includes three LNG trains, 

LNG storage, and load-out facilities, including a jetty, domestic 

gas plant, utilities, materials offloading facility, and a construction 

village. 

The first and biggest test for 

the plant’s “ease of portability” 

came when Fulton Hogan won 

the supply of hot-mix asphalt for 

the Gorgon Project on Barrow 

Island. To undertake the project, 

Fulton Hogan would need to move 

its new highly portable asphalt 

plant through four of Australia’s 

six states over 4,345 km (2,699 

mi) by road across the breadth 

of Australia and then by sea to 

get to the remote Barrow Island. 

The plant was moved along the 

project route using ten trailers to 

transport the plant components. 

Each trailer customized to meet 

strict Australian standards for 

safety and registration. Thanks to 

innovative engineering by Astec, 

Inc. engineers, the trailers met the 

transport solution required to keep 

Fulton Hogan’s Gorgon Project 

moving forward. 

THE PLANT’S ARRIVAL 

Fulton Hogan’s portable asphalt 

plant was originally bound for 

Brisbane, Queensland (Eastern 

Coast of Australia), which is the 

Port of Arrival of the portable 

asphalt plant. It was stored at 

Astec Australia’s head office facility 

for pre-commissioning work 

and registration with Queensland’s 

Department of Transport, something 

difficult to achieve if the 

plant does not comply with ADR 

regulations and Australian standards. 

Thanks to the efforts of 

Astec’s engineering team and 

liaising with Astec Australia, this 

was a successful task. 

After the arrival of the plant into 

Brisbane, Fulton Hogan was then 

awarded the Barrow Island project 

in partnership with the Kellog Joint 

Venture Gorgon. The portability 

of the plant was showcased as it 

was transported from Brisbane, 

Queensland, through New South 

Wales, South Australia, and all the 

way through to Perth in Western 

Australia. 

TRANSPORT PREP 

In Perth, the asphalt plant was 

shrink-wrapped and quarantined 

in order to comply with Barrow 

Island’s stringent environmental 

quarantine regulations, which 

applies to all buildings, materials, 

and equipment introduced to 

Barrow Island. The requirements 


Barrow Island 

Home to Australia’s largest operating onshore oilfield, Barrow Island 

is a Class “A” Nature Reserve. This brings the highest level of protection 

under State legislation for the island’s plant and animal life. 

Approvals for work on the island underwent an intense assessment 

before being granted. State and Federal Governments put measures 

in place to protect the area throughout the life of the project. 

The Gorgon 

Project 

The Gorgon Project is a 

$43 billion joint venture 

developing the Greater 

Gorgon Area gas fields. 

Touted as the largest 

resources project in 

Australian history, it will 

also be the single largest 

investment of its 

kind in the world. The 

Greater Gorgon Area 

gas fields contain about 

40 trillion cubic feet of 

gas. This is the nation’s 

largest undeveloped gas 

resource. The Gorgon 

Project is owned by the 

Gorgon Joint Venture, 

which includes the 

Australian subsidiaries 

of Chevron, ExxonMobile, 

Shell, Osaka Gas, Tokyo 

Gas, and Chubu Electric. 

The venture will process 

15 million tonnes (16.5 

million tons) per year 

of liquefied natural gas 

(LNG) and 300 terajoules 

per day of domestic gas 

on Barrow Island, 70 

km (43 mi) off Western 

Australia’s Pilbara Coast. 

The gas processing portion 

of the project will be 

located on Barrow Island, 

limited is size to 300 

hectares (741 acres), or 

1.3 percent of the island. 

Fulton Hogan acquired the portable 180 MTPH (198 TPH) Astec 6 ft x 33 ft 

(1.83 m x 10.06 m) Double Barrel ® plant in 2012 and features the following: 

portable 8 ft x 11 ft (2.44 m x 3.35 m) three-compartment cold feed system; 

portable 24 in x 50 ft (61 cm x 15.24 m) conveyor/static scalping grizzly; 

Whisper Jet ® burner; portable Pulse Jet baghouse for 30,384 ACFM draft 

system; portable compact self-erecting 40 ton (36 tonne) surge bin; PM 

Continuous Mix Blending Controls; Heatec 15,000-gal (56,781 l) portable 

tank; and a Heatec 500-gal (1,893 l) horizontal calibration tank all tailored for 

transport on ten trailers through Barrow Island. All the components and trailers 

met the stringent compliance measures for doing work on the Gorgon Project. 


10 Trailers 

Trailer One: 

1 PCF-811-3E-A portable 

8 ft x 11 ft (2.44 m x 3.35 m) 

three-compartment 

cold feed system 

1 x spare wheels and racks 

to each trailer 

Trailer Two: 

1 PCF-811-3E-B portable 

8 ft x 11 ft (2.44 m x 3.35 m) 

three-compartment cold feed system 

1 x spare wheels and racks to 

each trailer 

Trailer Three: 

1 PIC-2450E-SG portable 

24 in x 50 ft (61 cm x 15.24 m) 

conveyor/static scalping grizzly 



Trailer Four: 

1 PDB-633E portable 6 ft x 33 ft 

(1.83 m x 10.06 m) Astec Double 

Barrel ® drum 

1 DB-GRN001 Astec warm mix system 

Trailer Five: 

1 PBH-30E portable Pulse Jet 

baghouse for 30,384 ACFM draft 

system 



Trailer Six: 

1 DA-275 275 BBL Dry Additive 

System (10 ft, 6 in wide) 

(3.05 m, 15.24 cm wide) 



Trailer Seven: 

1 SEB-4024C portable compact 

self-erecting 40 ton (36 tonne) 

surge bin/24 in (61 cm) drag 

(10 ft, 6 in wide) 

(3.05 m, 15.24 cm wide) 



Trailer Eight: 

1 PMII-B Continuous Mix Blending 

Controls with 30 in (76 cm) console 

1 WM2000PB Profibus loadcell 

truck management system 

1 PCH-27.SP Pilot control center, 

9 ft, 8 in x 30 ft, 6 in (2 rooms) 

(2.74 m, 20.32 cm x 9.14 m, 

15.24 cm) 

1 ELIF-PM PMII electrical 

interface (MCC panels, main 

breaker, etc.) 

1 DNSWITCH day night switch 

1 TES-20 power and control 

cables with plugs and receptacles 

1 SPCL-ELEC special voltage 

electrical system 380/50/3 



Trailer Nine: 

1 TA-15PD.SP special design 

15,000-gal (56,781 l) portable 

tank (9 ft, 6 in diameter) 

(2.74 m, 15.24 cm diameter) 

1 MACC-2024 2.5 in (6.35 cm) 

twin pump asphalt metering 

system (10 hp pump) 

1 HACC-1437 3 in (7.62 cm) piping 

tank to asphalt metering package 

1 HACC-1440A Australia - 

3 in (7.62 cm) jacketed piping 

from metering package outlet 

1 HACC-1446 3 in (7.62 cm) 

piping - second compartment to 

metering package 

1 HACC-1451 3 in (7.62 cm) 

piping - AC unloading pump to 

second compartment 

1 SPEC-PPG special ball joint 

piping from trailer to TA-15PD 



Trailer Ten: 

1 HC-120 1,200,000 BTU/hr (output) 

gas/oil heater with manifold 

1 SPEC-TRLR portable trailer for 

transport of Heatec and Astec 

components 

1 CAL-1HE 500-gal (1,893 l) 

horizontal calibration tank 

(mounted on trailer) 

1 Astec Australia fibre feeder 




include thorough cleaning and 

disinfection treatment of all items 

prior to transportation. After treatment, 

small items are placed in 

shipping containers and larger 

items, such as building modules 

and plant components, are shrinkwrapped 

to prevent contamination 

during transport. Shipping to 

Barrow Island is carried out by 

barges departing from both Perth 

and Dampier. 

In order to commission the plant, 

every employee and subcontractor 

to Astec Australia had to be 

approved and participate in an 

extensive induction program. 

The program consisted of an 

initial thirteen-page application 

to be inducted onto the project. 

Documentation included all licenses 

and tickets relevant to the person 

and the work to be completed. 

All inductees were flown to Perth, 

Western Australia, to attend inductions 

for Kellogs Joint Venture, 

Fulton Hogan, and Ertech. Each 

person had an extensive medical 

exam and an elevated work 

platform ticket check and competency 

demonstration. Upon arrival 

onto Barrow Island, the induction 

included a campsite and environmental 

inspection. The plant was 

commissioned on Barrow Island in 

October 2012. 

Fulton Hogan acquired two Roadtec pavers (RP170 and RP190) for night-paving projects 

on Barrow Island. 

“ 

endeavor … 

” 

TRAILER-MOUNTED MOBILITY 

The Astec, Inc. portable asphalt 

plant for Fulton Hogan is comprised 

of various components 

that are all trailer-mounted on ten 

trailers for complete compliance 

with the strict ADR compliance 

rules in Australia. If the plant does 

not comply with ADR standards, 

the plant will not be allowed to be 

transported and would make the 

Astec stands by its equipment 

and provides unwavering 

support no matter the 

portability null and void. The main 

challenge was to ensure that no 

trailer was wider than 3.2 m (10 ft, 

5 63 / 64 in). 

Fulton Hogan also acquired two 

Roadtec Pavers (RP170 and 

RP190) for paving on Barrow 

Island. Both pavers also endured 

the stringent shipping, quarantine, 

and commissioning requirements. 

Astec Australia is devoted to continuously 

meeting the needs of its 

customer—and by working hand 

in hand with Fulton Hogan’s people 

were able to design, build, deliver, 

install, and commission this highly 

portable asphalt plant even under 

the extreme logistical challenges 

presented by the Gorgon Project 

on Barrow Island. 

Michael Thompson, who is Fulton 

Hogan’s national operations manager, 

airports, enjoys the challenge 

of tackling these logistically difficult 

projects. Michael said that 

the old saying “the devil is in the 

details” is very true, especially 

when it comes to the amount 

of planning, preparation, and 

management that is required to 

be successful on these types of 

projects. Michael also said that the 

key ingredients for success are 

safe, dedicated, reliable, and persistent 

people supported by highquality 

reliable equipment. Michael 

continued that with Fulton Hogan’s 

Astec plant and equipment, he felt 

extremely confident that Fulton 

Hogan was working with a company 

that listened intently to its 

needs, and had designed and built 

a plant accordingly. 

Fulton Hogan’s portable asphalt plant featured a burner and drum equipped for the Astec 

warm mix system. 

“Not only that, I know that Astec 

stands by its plant and equipment, 

and that they will always be 

there to support us wherever and 

whatever we do. Sure, there will 

be the odd occasions when things 

don’t go quite as you expect, but 

with Astec we know that they have 

a very good understanding of our 

business, and we know that we 

are dealing with very honest and 

reliable people that will always 

respond and support us,” said 

Michael. 

To further test the portability and 

reliability of its new highly portable 

Astec Double Barrel ® asphalt 

plant, following the completion of 

its Barrow Island project, Fulton 

Hogan plans to transport back to 

Australia’s east coast to tackle the 

refurbishment of the runway on 

Brisbane’s International Airport. 

Fulton Hogan knows that when 

they do, Astec will be there to support 

them. 


Contact David Smale 

General Manager Australia 

+61 7 3714 8800 

+61 419 969 335 

dsmale@astecaustralia.com.au 

or Robert Messner 

Regional Sales Manager 

+61 419 965 202 

rmessner@astecaustralia.com.au 


On 

Your 

Side 

The lead-up to Independence 

Day weekend is a quiet one 

for Travis Sneed, Astec’s 

regional sales manager for the 

Southeast. While people throughout 

his territory—from Florida up 

through Alabama, from Mississippi 

east to Georgia—will be buying 

fireworks and setting up backyard 

barbeques, Travis and the ten other 

regional sales managers are completing 

a safety training course at 

Astec headquarters. “On holiday 

weeks like this, a lot of our customers 

are off work,” Travis explained, 

“so that makes it a good time for 

us to come in and take care of 

in-house business like I’m doing 

today.” Before the week is out, 

Travis will not only complete more 

training courses but also familiarize 

himself with Astec’s newest 

product catalog and equipment 

changes, as well as deliver news 

on how products in the field are 

meeting expectations and where 

they can improve. Then he’s back 

on the road, because customers are 

expecting him. 

A NEW LEVEL OF SERVICE 

Travis Sneed has been with Astec 

in one position or another for over 

two decades, but back in February 

of 2001 his unofficial position was 

guinea pig. He was named the 

Earning a customer’s trust 

is job #1 for Astec’s Travis Sneed 

first regional sales manager for 

parts, meaning that he was now 

responsible for maintaining Astec’s 

customer relationships for a large 

section of the country, not just a 

few clients here or there. 

“I remember having a few weeks to 

see if we could get it off the ground 

before we wanted to commit everyone’s 

effort to it,” Travis recalled. 

Since then, the regional sales support 

system did not just get off the 

ground, but took flight. Today, Astec 

divides all of the United States and 

sections of Canada into eleven 

parts regions—each one with its 

own support person like Travis. 

SUPPORT FOR CUSTOMERS 

“I consider myself a liaison 

between Astec and the customer. 

I understand that this is a sales 

job,” Travis noted, “but I’m on the 

customer’s side. That is my most 

important job.” 

Other than three or four weeks a 

year for training, being on the customer’s 

side could be taken literally. 

“We serve as a support team for 

the customers,” Travis added. He 

travels his territory constantly, 

meeting with customers across 

the Southeast to answer their 

questions, provide solutions, 

and generally make their parts 

experience as easy as possible. 

Over time, customers know they 

can trust Travis to advocate their 

needs. 

“Without that level of trust,” Travis 

continued, “believe me, there is 

no sale.” 

RELATIONSHIPS WORK 

BOTH WAYS 

Through Travis Sneed and the ten 

other regional sales managers, the 

relationship between Astec and 

its parts customers is mutually 

beneficial. “We spend three or four 

days of each work week with our 

customers,” Travis added, “and they 

are the real-life test labs for our 

products.” With access to that raw 

amount of hands-on experience, 

Travis and his colleagues can report 

back to Astec’s engineers on the 

latest needs from the field—which 

is sometimes the easiest way to 

communicate. “Many times I’m 

the messenger of a great idea, one 

our customers brings to the table,” 

Travis said. 

“When our customers have information 

our engineers need, I 

want them to know that I’m there 

for them,” Travis continued. “My 

number one goal is to build that 

relationship.” Building relationships 

and building trust, improving 

service and improving products, the 

Astec Parts Regional Sales team 

is a major reason Astec customers 

expect and receive superior 

service. 


In the Heart 

of Texas 

According to Corey Clark, 

director of asphalt and 

fleet operations with Clark 

Construction of Texas, Inc., the 

family-owned and operated road 

construction’s bread and butter is 

“mill and lay.” 

In operation since 1978, Clark 

Construction specializes in seal 

coat and hot-mix asphalt projects 

across Texas. With innovative 

approaches to the chip seal 

industry and asphalt paving, the 

company has excelled in areas of 

safety, quality, and performance. 

What has been a contributing factor 

to its success? A fleet of equipment 

manufactured and supported by 

Roadtec. 

“We purchased the Roadtec 

RX-700 Cold Planer in June 2011, 

Company excels at mill and lay 

projects with Roadtec equipment. 

and we also have the SP-200 Spray 

Paver, SB-2500c Shuttle Buggy, 

RP-190 Paver, RX-60c Cold Planer, 

and the RX-600e Cold Planer,” said 

Corey Clark. “On a recent job, we 

rented the Roadtec RX-600e and 

liked the milling machine so much 

that we purchased it for future 

projects.” 

The project Clark referred to was 

the Marble Falls job northwest of 

Austin, Texas. 

BLANCO COUNTY HWY 281 

Marble Falls in centrally located in 

Texas on Highway 281 in Blanco 

County. Clark Construction of Texas, 

Inc. was awarded the road repair 

project in January 2013. Work 

began in May on Highway 281 

from the Burnet County Line to 

US 290 West in Johnson City. The 

15.051 miles (24.22 km) were set 

to be repaired using the traditional 

method of putting down the oil 

application (tack coat) ahead of 

putting down mix and sealing with 

a top coat. Clark Construction was 

able to have the application method 

changed to use a membrane 

underseal and a Roadtec SP-200 

Spray Paver. The SP-200 puts down 

the tack coat just seconds before 

putting down mix. 

This method, according to Clark, is 

more efficient. “Using the SP-200 

is cleaner, faster, and requires a 

smaller crew.” The spray paver 

used on Hwy 281 was the second 

machine Clark Construction had 

purchased from Roadtec. According 

to Roadtec’s Texas service technician 

James “JW” Whittington, Clark 

Construction was instrumental in 

helping Roadtec develop the first 

spray paver and purchased the unit 

in March 2005. Clark Construction 

traded this older machine for the 

SP-200 Spray Paver in its current 

fleet. 

MILL AND LAY 

The top 1.75 in (4.44 cm) of the 

highway was milled and replaced 


Roadtec SP-200 Spray Paver 

The SP-200 Spray Paver sprays tack and 

applies hot-mix asphalt seconds later. 

Combining spraying and laydown produces 

a high-quality mat with a strong bond 

between layers. A spray bar just in front 

of the paver’s auger distributes the liquid 

through computer-controlled, self-cleaning 

valves. An onboard microprocessor precisely 

controls the rate of flow. Valves can 

also be controlled manually. Valves are 

arranged in sets of three, providing plenty 

of spray capacity so you can move fast. 

To cut down on refill stops, the SP-200 is 

equipped with a 2,100-gal (7,949 l) tack 

tank. The spray bars extend as needed 

with the screed and each nozzle can be 

manually shut off for partial passes. For 

paving at any time, a material transfer 

vehicle (MTV), such as the Roadtec 

SB-2500c Shuttle Buggy, delivers mix to 

the spray paver’s gravity-fed hopper, which 

has a capacity of 11 tons (9 tonnes). The 

spreading augers deliver the mix to the 

hydraulically extendable, vibrating screed. 

with 2 in (5.08 cm) of special 

specification 3224 dense-graded 

hot-mix asphalt. The road repair 

was approximately 15 mi (24.14 

km) long and consisted of four lanes 

(two north and two south). The 

Texas Department of Transportation 

(TxDOT) approved SS 3224 for use 

in May 2011. 

Once the milling was finished, the 

Roadtec SB-2500c Shuttle Buggy 

fed the Roadtec SP-200 Spray 

Paver as 2 in (5.08 cm) of hot-mix 

asphalt was put down. This process 

of pavement preservation is one of 

the most cost effective, efficient, 

and versatile options available on 

the market. The benefits include 

reduced noise levels, enhanced 

skid resistance, and improved ride, 

drainage, and aesthetics. Overlays 

can be placed in varying thicknesses, 

allowing flexibility to design 

according to the needs of the 

highway. Future maintenance of the 

roadway exists through the recycling 

of materials. Hot-mix asphalt (HMA) 

consists of well-blended aggregate 

and asphalt cement—a 100-percent 

recyclable product. 

The road work took Clark 

Construction through the small 

town of Round Mountain, population 

of 182 (according to the 2011 

census). A few weather-related 

delays hampered progress, but 

with the Roadtec equipment, Clark 

Construction kept pace and completed 

the project on time. 

“The project took about two 

months,” said Clark. “We experienced 

some rain delays and were 

pushed on the schedule, but with 

the Roadtec equipment, we finished 

the project on time near the end of 

July.” 

Clark continued, “We put down 

approximately 60,000 tons (54 

tonnes) of asphalt on the project. 

The Roadtec machinery held up well 

and we experienced fast production. 

The support we receive from 

Roadtec is essential to our success, 

and having a Roadtec fleet of equipment 

provides the right tools for 

what we love to do best ... mill and 

lay.” 


Contact Roadtec Sales 

800.272.7100 

sales@roadtec.com 


Every Day is 

Recycle Day 

Upgrade to new 

asphalt plant 

brings Astec’s 

warm mix system 

to the forefront 


Callanan Industries’ Dillman 

UniDrum plant features a 600 

ton (544 tonne) New Generation 

Storage System. 

“With the counterflow design, we run recycle every day … 

and with the service we receive from Astec and Dillman, 

we are happy operators in the asphalt industry.” 

Callanan Industries, Inc. is a 

leading supplier of paving 

materials and construction 

services in New York. Founded in 

1883 by Peter Callanan in South 

Bethlehem, the company focused on 

aggregate mining. In 1895, Callanan 

won the first road building contract 

let by New York State. A forwardthinking 

man, Callanan pioneered the 

concept of a state highway system. 

Callanan Industries was acquired by 

Oldcastle, Inc. in 1985 and continues 

its mission to be cost competitive 

while providing high-quality materials 

today. 

FRESH START 

When it comes to asphalt, look no 

further than Callanan Industries’ 

purchase of a Dillman UniDrum plant 

in 2012. Although the 1994 Astec 

Double Barrel ® plant had served 

them well, the company decided it 

was time to trade it in and upgrade 

to a newer model. 

“It made sense to upgrade and put 

in a new plant with the upcoming 

move to a new location,” said Jeff 

Frani, general manager of asphalt 

operations with Callanan Industries. 

“We were new to Dillman and were 


Callanan Industries’ new Dillman UniDrum plant features a Pulse Jet baghouse, TCII controls, a low-profile truck scale, and a seven-compartment cold feed system. 

impressed with the counterflow 

design of the UniDrum.” 

BRAND NEW PLANT 

Callanan purchased a stationary 

400 TPH (362 MTPH) 9 ft x 54 ft 

(2.74 m x 16.46 m) Dillman Unified 

counterflow drum plant for the 

South Bethlehem, New York, location. 

The plant features the following: 

• 10 ft x 14 ft (3.05 m x 4.27 m) 

seven-compartment cold feed 

system 

• 5 ft x 12 ft (1.52 m x 3.65 m) 

dual deck scalping screen 

• 68,194 CFM Pulse Jet baghouse 

• 600 ton (544 tonne) New 

Generation Storage System 

• 11 ft x 100 ft (3.35 m x 30.48 

m) low-profile truck scale 

• Dual 10 ft x 14 ft (3.05 m x 

4.26 m) recycle feed bins 

• Pilot control center with TCII 

control system 

• Astec warm mix system 

COUNTERFLOW DESIGN 

What separates the Dillman 

UniDrum from other plants? It’s the 

unique nature of producing quality 

hot-mix asphalt at a high production 

rate with a high percentage 

of recycle. The extra-long drum 

length maximizes mixing and drying 

times to reduce fuel usage and 

provide optimal mixing. The system 

eliminates the time-consuming 

process of trunnion alignment and 

ensures the equipment operates 

correctly. Centered around a large 

20 in (50.8 cm) trunnion, fitted with 

adjustable double-row Timken 

bearings and ring fitters, this 

system is an industry exclusive, 

according to Dillman. The key is 

its unique pivot pin system, which 

allows the asphalt operator to easily 

dial in the dryer in a matter of 

minutes without the need of any 

special equipment. In the end, 

the dryer rotates properly without 

excess wear to the tires, trunnions, 

and thrust roller assemblies. 

Frani is a fan of the patented 

flighting design on the Dilman 

UniDrum. The flights are adjustable 

to better control the baghouse 

temperature and moisture 

removal from the aggregate. Its 

unique recycle entry is also a plus. 

The inlet into the drum allows 

immediate mixing of recycle 

with the hot aggregate, bringing 

the recycle up to temperature 

and removing moisture quickly. 

Maintenance is made easy with 

the clean-outs in the collar around 

the drum. 

“The Dillman UniDrum is operating 

well for us; we’re using 20-percent 

recycle on state surface mix and 

30-percent recycle on base mix,” 

said Frani. “We have several entities 

that we are supplying mix to 

for various projects around our 

area; we range anywhere from 

2,500 tons to 3,000 tons a day 

(2,267 tonnes to 2,721 tonnes) 

depending on the job.” 

Frani continued: “The combination 

of quality equipment with 

top-notch service from Astec 

and Dillman makes our partnership 

worth its weight in 

asphalt.” 



423.867.4210 



The 

Power of 

Portability 

HOT-MIX MAGAZINE 30 VOLUME 18 NUMBER 2 

Tennessee contractor 

welcomes efficiency with 

portable Astec plant

Hoover, Inc.’s 7 ft 

(2.13 m) Astec 

Double Barrel ® 

plant uses the 

PMIII controls 

and features a 

portable 10 ft x 

14 ft (3.05 m x 

4.27 m) five-bin 

cold feed system. 

You can’t miss the Omaha 

Orange blazing the skyline 

in Lebanon, Tennessee. The 

brilliant orange hue is the signature 

color of Hoover, Inc., and adorns 

all of the components of its new 

hot-mix asphalt plant. 

THE EARLY DAYS 

The Omaha Orange paint color 

stems from Tom Hoover, Jr.’s great 

grandfather Ephriam Hoover, Sr. 

Ephriam ran a motor freight company 

and the orange color was on 

all the trucks. Ephriam continued 

With a portable plant, Hoover, Inc. 

is able to bid on projects otherwise 

passed over; portability is an 

added benefit. 

the use of the color when he 

started his crushed stone business. 

He expanded into ready-mix concrete, 

hot-mix asphalt, and grading 

(construction in general). Even after 

the passing of Ephriam in 1979, the 

company remains family-owned 

and operated. Through the years, 

the company has delivered on 

its dedication to provide quality 

product. With devoted employees 

(some spanning employment over 

decades), the operations still focus 

on crushed stone and asphalt. 

NEW AND EFFICIENT 

The 7 ft (2.13 m) portable Astec 

Double Barrel ® plant has been in 

operation since December 2012. It’s 

not the only Astec plant that Hoover, 

Inc. has in operation. 

“We’ve been impressed with Astec 

since our introduction in the early 

2000’s,” said Tom Hoover, Jr., assistant 

construction manager with 


Hoover, Inc. has a 400 ton (362 tonne) New Generation Storage System with two 200-ton (181 tonne) silos, and an Astec warm mix system with a Phoenix ® Talon burner. 

Hoover, Inc. has three asphalt 

plants located within quarry sites 

in Tennessee, which are able to 

provide competitive prices on 

quality hot-mix asphalt. 

Hoover, Inc. “Astec’s reliable service 

and top-quality product led us to 

purchase a new plant; it’s a relationship 

that has served us well.” 

Set up of the plant was smooth. 

Calibrating and troubleshooting the 

plant with PMIII controls took a bit 

longer. An Astec technician stayed 

over a period of three months to 

ensure operations were functioning 

at peak performance and the crew 

overcame the learning curve of the 

new plant. The Hoover, Inc. plant 

was one of the first plants to have 

the PMIII controls in use. 

“Once the guys had the controls 

figured out, they loved the functionality 

and ease of use for plant 

operations,” said Hoover. “Having 

on-site Astec training was a plus.” 

PERKS OF PORTABILITY 

The Hoover, Inc. plant is outfitted 

with an Astec warm mix system. 

According to the Tennessee 

Department of Transportation 

(TDPT), 10 to 35 percent of fractionated 

recycle is allowed in mixes. 

Producing 250 to 300 TPH (226 

to 272 MTPH), Hoover, Inc. is supplying 

material for I-40 in Wilson 

County and a TDOT job (State Route 

141). 

“Having the portable plant gives 

us the flexibility to bid on more 

projects,” said Hoover. “The ability 

to move when we need to 

and the added efficiency of the 

Double Barrel ® drum and the 

Phoenix ® Talon burner set us up for 

success.” 



423.867.4210 



Wake Up 

the Echoes 

At Walsh and Kelly’s 

South Bend plant, the past 

prepares for the future. 

The Dillman UniDrum allows Walsh and Kelly’s South Bend 

plant to run a higher percentage of recycle than before. 

For most people, South Bend, 

Indiana, is best known as 

the home of the University of 

Notre Dame and its famed Fighting 

Irish football team. The Irish fans 

always hope the season ends with 

a chance to play for a national 

championship, but the operators 

at Walsh and Kelly’s South Bend 

plant were watching a different 

type of season come to its close. 

Just as Notre Dame’s fans cherish 

their program’s storied history, the 

team at Walsh and Kelly would 

also rely on their past to build a 

successful future. 

TIME FOR A CHANGE 

Walsh and Kelly noticed a growing 

problem—one that would 

require a careful decision and 

serious investment. The South 

Bend plant’s CMI triple drum was 

approaching the end of its lifecycle. 

Compounding the issue, the 

stainless steel ring between the 

recycle and the burner was wearing 

away. That component alone 

could cost the plant’s budget 

upwards of $50,000. Needing a 

new drum, in addition to a significant 

repair, the time was right to 

consider a major retrofit for the 

plant. 

Walsh and Kelly decided to 

replace their CMI triple drum 

with a Dillman unified drum. The 

Dillman UniDrum is often used for 

new plant packages but can also 

be used for retrofit jobs, making 

it a perfect choice for the South 

Bend replacement. Furthermore, 

with a capacity ranging from 

from 200 to 600 TPH (181 to 

544 MTPH), the Dillman UniDrum 

would be an improvement over 

the plant’s old drum. 

BIGGER AND BETTER 

Another consideration was that 

triple drums are notorious for 

filling up with reclaimed asphalt 

pavement (RAP) in the outer 

chamber. This had been an ongoing 

problem for the South Bend 

plant, one they could eliminate 

with the right replacement. The 

Dillman unified drum presents a 

high quality counterflow design. 

The inlet into the drum allows 

immediate mixing of recycle with 

the hot aggregate, bringing the 

recycle up to temperature and 

removing any residual moisture. 

This creates a natural moisture 

barrier for the recycled material 

and prevents deposits. Using this 

new drum, the South Bend plant 


The Dillman unified drum is a high 

quality counterflow design offered 

in both portable and stationary 

arrangements. 

could expect to expand its use of 

RAP to between 40 and 45 percent 

without any problems. 

Walsh and Kelly was also able to 

make use of the existing frame 

by extending it to fit the Dillman 

UniDrum’s extra-long drum. The 

drive chain assembly, motor, 

and reducer were built the same 

as existing double drum plants, 

which greatly reduced the downtime 

and allowed for the drum to 

be fitted into place within a brief 

window. In addition to accommodating 

a high percentage of recycle, 

the extra-long drum length 

cut back on the amount of fuel the 

plant requires because it maximized 

mixing and drying times. 

A GOOD SWAP 

Another advantage presented by 

the Dillman unified drum is its 

reduced maintenance costs over 

its expected lifecycle. Dillman 

introduced the UniDrum as an 

option for both portable and stationary 

arrangements, making it 

one of the sturdier mixers found in 

today’s plants. Whereas the plant’s 

old CMI triple drum was increasing 

its operational costs in both 

routine maintenance and energy 

consumption, as it approached 

the end of its lifecycle, the Dillman 

UniDrum is expected to remain a 

consistent and efficient ingredient 

to the South Bend plant’s future 

success. 

For all its new advantages, 

though, the Dillman UniDrum 

looks perfectly at home at the 

South Bend plant. The total retrofit 

and upgrade of the plant lasted 

until April, making the relative 

ease of the drum’s quick installation 

all the more impressive to 

Walsh and Kelly. With the plant 

upgrade complete, Walsh and 

Kelly plans to make full use of 

their new Dillman UniDrum, routinely 

running a high percentage 

of recycle at a higher capacity. 

Building on a strong foundation 

and taking advantage of new 

innovations, Walsh and Kelly’s 

South Bend plant is poised for 

continued success. 



423.867.4210 



The Dillman Service Department 

disassembles a fertilizer tower 

in preparation for a new 

tower to be erected. 

Branching 

Out 

Dillman 

reaches 

into new 

markets for 

industrial sales 

It’s been a busy year for Dillman, 

and it’s not over yet. The 

company known in the asphalt 

industry as a hot-mix asphalt (HMA) 

plant manufacturer is breaking new 

ground into the industrial and agricultural 

markets. 

“At Dillman, we are more than just 

a hot-mix asphalt plant manufacturer; 

we know our parts and expertise 

have crossover ability into other 

“ 

markets using components and 

services we know well. Whether 

it’s an electric motor, bearing, or 

belts, we have the expertise to 

source those parts for industrial, 

agricultural, and power generation 

industries,” said Tony Schwab, vice 

president and general manager with 

Dillman, a division of Astec, Inc. 

“Our knowledge of setting up new 

plants and handling retrofits can 

easily be applied to companies in 

other markets needing large, metal 

structures torn down or needing 

help with operational setup.” 

There will be groundwork 

needed to create brand awareness 

in new markets. 

” 

NEW MINDSET 

New to industrial sales, Dillman’s 

main focus is agricultural co-ops 

and industrial companies that use 

a preferred vendor list. Being on an 

approved vendor list enables the 

ability to bid on jobs closed to those 

not pre-approved. 

“To get on a true vendor list with 

companies that typically don’t 

think of a HMA manufacturer as a 

resource will be a step in the right 

direction as we branch out and 

apply our expertise, quality service, 

and quality parts to new markets,” 

said Schwab. 

As an example: Wisconsin is a 

strong agricultural state and the 

transition in farming over that last 

10 years has been bigger, bigger, 

and bigger. 

“Farming is big business; mom 

and pop farmers don’t really exist 

anymore; it’s a big enterprise with 

corporations and investors spending 

money,” said Schwab. “The booming 

business of farming opens the 

door for us to introduce ourselves 

and share what we have to offer, 

and it doesn’t stop there—our 

expertise and services make sense 

for power plants and those in the oil 

and gas industry.” 

BREAKING NEW GROUND 

Dillman is in the infancy stage of 

breaking into new markets. There 

will be obstacles, but Dillman is 

ready and willing to overcome the 

hurdles of expanding its reach. 

“There will be groundwork needed 

to create brand awareness for 

Dillman as more than just an 

asphalt company building HMA 

equipment,” said Schwab. “To create 

the mindset in the consumer 

‘I’m calling Dillman for an electric 

motor’ will take time and positive 

persistence. We know we can 

service those in other industries 

needing the same parts, wanting 

quality service, and needing 

comparable expertise with setup 

and tear down of machinery and 

operational equipment. “ 

In an effort to build an additional 

customer base, Dillman will be 

attending some farm shows and 

industrial trade shows to educate 

new markets on what Dillman has 

to offer. 

“We’ll do what is needed to be 

vetted as an approved vendor 

and we’ll continue doing the 

upfront work to be recognized,” 

said Schwab. “We want to be a 

business partner; we want to be 

the vendor that is called in an 

emergency; we want to be a ‘true’ 

dependable resource; we want 

to be an expert for industrial and 

agricultural markets.” 


Contact Tony Schwab 

608.326.4820 

tjschwab@dillmanequipment.com 


NEWS 

Astec Names 

Claude 

Executive Vice 

President 

Astec Inc. announces 

the year-end 

promotion of Steve 

Claude to the position 

of executive 

vice president. 

Steve Claude 

holds a Bachelor 

of Science degree 

in marketing from 

Steve Claude 

the University of 

Northern Iowa and has broad experience in global and 

domestic Fortune 500 sales. He joined Astec as vice 

president for sales, international, in 2007. In 2011, he 

was promoted to senior vice president, sales. 

As executive vice president of Astec, Inc., Steve Claude 

will work closely with incoming president Malcolm 

Swanson to ensure the successful operation of Astec, 

Inc. 

Astec Customer Unveils New Project 

In June 2013, Posillico Materials announced the unveiling of their new rail siding 

and materials transfer depot in Farmingdale, New York. A ribbon cutting ceremony 

took place to showcase this and other energy saving and carbon reduction measures 

in the completion of phase one of this major capital project in conjunction 

with the Town of Babylon Industrial Development Association. 

The project completion enables most of the materials that are required for asphalt 

production to be shipped via rail rather than truck. The new rail system and 

improved plant layout reduces fugitive dust and also eliminates 5,000 truck trips 

from local streets and highways annually. These changes result in reduced net fuel 

consumption and less CO 2 emissions. 

Astec Industries has been working with Posillico’s engineering and material experts 

since 1971 to help lead the region with asphalt recycling technologies and other 

beneficial reuses of materials that would otherwise require landfilling as waste. 

Astec’s vice president of national accounts Gail Mize said, “This recent expansion 

into receiving aggregates by rail will remove a considerable amount of traffic from 

the roads and goes far to demonstrate how good a neighbor Posillico is for the citizens 

of Babylon Township. Removing traffic count from the roads is always a good 

thing for the public, but is seldom possible.” 

Astec 

Promotes 

Pack 

Astec, Inc. announces 

the appointment 

of Steve Pack to the 

position of manager, 

inside sales, effective 

September 1, 

2013. He will be 

responsible for 

managing all inside 

sales activities, 

including pricing, 

quotes, product 

Steve Pack 

descriptions, and 

direct coordination between field sales, engineering, and 

manufacturing of all placed orders. 

Most recently, Steve Pack has held the position of sales 

coordinator as a member of the inside sales team. Steve 

Claude, Astec senior vice president, sales, said, “Steve’s 

extensive experience and understanding of the inside 

sales position and its role will greatly support his efforts in 

his new position.” 

The ribbon cutting was well attended by several elected officials. 

Rendition of the new rail siding and materials transfer depot. 


NEWS 

McClure Joins 

Astec Parts 

Astec, Inc. 

announces that Mike 

McClure is joining 

the Astec Parts team 

to cover California, 

Nevada, Arizona, 

New Mexico, and 

Hawaii. Prior to joining 

the Astec Parts 

team, Mike worked 

as a member of 

the Astec Service 

team. 

Mike McClure 

Astec Welcomes Bush 

Astec, Inc. welcomes Ryan Bush as the 

regional sales manager for the New 

England states including: New York, Maine, 

Vermont, New Hampshire, Massachusetts, 

Connecticut, and Rhode Island. Ryan will 

be based in the Syracuse, New York, area. 

Tom Baugh, Astec vice president , North 

America sales, says of Bush, “His enthusiasm 

and knowledge of both the asphalt and 

aggregate sides of the business make him 

a valuable asset. I am confident that he will 

do well in his position as an Astec regional 

sales manager, servicing current customers 

and cultivating new ones.” 

Ryan Bush 

Williamson 

to Represent 

South Central 

Territory 

Astec, Inc. announces 

that Adrian 

Williamson will be 

representing Astec 

in Texas, Arkansas, 

and Louisiana. He 

will be based out of 

the Dallas, Texas, 

area. 

Adrian was previously 

the Astec 

Adrian Williamson 

Parts representative in California, Nevada, Arizona, 

New Mexico, and Hawaii. 

Brock Honored 

by Utah Asphalt 

Pavement 

Association 

Astec Industries, Inc. 

CEO and founder, Dr. 

J. Don Brock, was 

inducted into the UAPA 

Hall of Fame at the 

Dr. J. Don Brock 

2013 Utah Asphalt 

Conference. Each year, UAPA Hall of Fame plans to honor 

one individual who has made a major impact on the asphalt 

paving industry with the J. Don Brock Award. 

Brock Honored by Tennessee Road Builders Association 

Dr. Brock was honored by the Tennessee Road Builders Association with the 2013 

lifetime achievement award. The award was presented July 18 during a TRBA 

meeting held in Chattanooga, Tennessee. 

Given periodically, TRBA’s highest honor is given to individuals having demonstrated 

extraordinary support of the road building industry and association. This year’s 

recipient, Dr. J. Don Brock, only the 18th individual to receive the honor in TRBA’s 

85-year history, is more than deserving of the acknowledgement. 

An industry pioneer, Dr. J. Don Brock holds approximately 100 U.S. and foreign 

construction machinery and drying patents. His prowess goes way beyond 

Tennessee’s state lines and the 180 different products that Astec Industries and its 

subsidiaries provide, as Dr. Brock was recognized in 2012 by the American Road & 

Transportation Builders Association (ARTBA). Last September, ARTBA renamed its 

yearly Transovation Award, which recognizes innovative thinking in the transportation 

industry, after Dr. Brock. 

2013 TRBA President Tony Boals of Wright Bros. Construction presents award to Dr. J. Don Brock. 


NEWS 

Astec, Inc. Recap from bauma 2013 

Built for Skanska, an Astec 8 ft 

(2.44 m) Double Barrel ® drum 

mixer was on display at bauma 

2013 in Munich, Germany, 

showcasing the Astec warm mix 

system, Whisper Jet ® burner, 

and Shaggy Dog system. The 

drum service door was opened 

to allow viewers to see the key 

internal benefits of the features. 

This allowed the Astec, Inc. representatives 

to explain the Double 

Barrel’s ability to produce up to 

50-percent recycle with very low 

emissions. This is made possible 

by the patented design of heating 

the recycle (RAP) on the outside 

section of the drum, utilizing indirect 

heating. 

The Astec stationary plant model 

was displayed on the ground floor 

of the interior part of the booth 

with exceptional viewing from the 

main area, as well as the second 

floor above. The Astec, Inc. longterm 

storage silos displayed with 

the plant model were the center 

of many great discussions at the 

show, focusing on the ability to 

store multiple mixes produced 

from one plant for up to four 

days. 

During the show, these capabilities 

sparked a lot of interests in a 

region predominantly consisting 

of batch plants, which produce 

mix in a batch process that 

typically don’t utilize the many 

benefits of long-term storage. The 

booth was well attended by key 

industry leaders from around the 

globe. 

Left: The Astec 

booth at bauma 

2013 showcased 

an open design 

lending itself to 

great conversational 

opportunities. 

Bottom Left: The 

open door of the 

drum allowed 

visitors to see the 

internal components 

up close. 

Bottom Right: The 

Astec stationary 

plant model was 

displayed on the 

interior portion of 

the booth. 


NEWS 

Astec Promotes 

Renegar 

Astec, Inc. announces the promotion 

of Greg Renegar to the position 

of vice president, engineering. 

Greg Renegar brings a wealth of 

experience, knowledge, and skill 

with him to his new position. 

Renegar joined Astec in 

1985 after graduating from 

the University Tennessee at 

Chattanooga with a Bachelor of 

Science in mechanical engineering. 

Since joining Astec, Renegar 

has worked in the U.S., Canada, 

Greg Renegar 

and throughout Europe as a project 

engineer, field engineer, and design engineer. He was promoted 

to the director of thermal systems position in 1998 and became chief 

engineer in 2004. He will transition to vice president, engineering by 

the end of the year, and will be responsible for the overall performance 

of the Astec Engineering Department. 

Astec Names Swanson 

President 

Astec, Inc. announces the yearend 

promotion of Malcolm 

Swanson to the position of 

president of Astec, Inc. Swanson 

will fill the position vacated by 

Benjamin G. Brock who will 

transition to the position of chief 

executive officer and president 

for Astec Industries, Inc. at the 

end of the year. 

Malcolm Swanson holds a 

Bachelor of Science degree in 

Malcolm Swanson 

mechanical engineering from the 

Georgia Institute of Technology 

and has broad experience in both engineering and management and 

holds more than thirty patents. 

As president of Astec, Inc., Malcolm Swanson will be responsible for 

the overall performance of Astec, Inc. and Dillman. 

KPI-JCI Celebrates 3,000 th Screen Sold 

Johnson Crushers International, 

Inc. (KPI-JCI) celebrated the shipment 

of its 3,000th screen earlier 

this year, marking nearly $200 

million in revenue for the company 

from screen sales and providing 

47 high-quality, U.S.-based jobs to 

its skilled workforce. 

“We are very proud that our success 

as an American manufacturer 

has allowed us to create jobs in 

Oregon and beyond,” said JCI 

president Jeff Elliott. “We are also 

very proud of our employees, who 

have made this achievement possible 

through their commitment 

to continuous improvement and 

devotion to meeting the needs of 

the customer.” 

Today, as part of KPI-JCI and Astec 

Mobile Screens, JCI is the global 

technological and service provider 

of the foremost horizontal screening 

equipment on the market. JCI 

also specializes in roller-bearing 

cone crushers and portable, stationary, 

and track-mounted plants. 

“We are incredibly thankful to JCI’s 

founders for having the courage 

and vision to design this product,” 

Elliott said. “With the support of 

Johnson Crushers International, Inc. (KPI-JCI) celebrates its 3,000 th screen sold. 

Astec Industries, we have been 

able to create a state-of-the-art 

manufacturing facility to serve the 

needs of the market.” 

For more information about 

horizontal screens, visit 

www.kpijci.com.

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