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Viscocel Bitumen Modifier Pellets Ease Handling for Hanson Aggregates
Date: 22 September 2003

Excel Fibre Technology’s Viscocel 500 binder-free fibre bitumen modifier pellets have been used by Hanson Aggregates’ Craig yr Hesg quarry, near Pontypridd, to manufacture SMA for the resurfacing of major trunk roads in Swansea and Newport.

The Viscocel 500 pellets are being used with Excel’s SMART refibreising system, which ensures the pellets are fully converted into loose, open fibre before being added to the SMA mix in a single, continuous process.  The SMART system used by Hanson features a gravimetric feed primary module, with a 500Kg hopper capable of supplying fibre for 160 tonnes of SMA.

In the first two weeks of operation of the SMART system at the Craig yr Hesg quarry, Hanson Aggregates have manufactured over 1,000 tonnes of SMA wearing course, using 6mm, 10mm and 14mm aggregate.

Having formerly used Excel’s Viscocel loose fibre bitumen modifier, Hanson Aggregates are benefiting from reduced manual handling with the new pellet modifier, while maintaining the performance associated with loose fibre.  

In addition, because the pellets are themselves bitumen-free, they offer cleaner and easier handling than bitumen coated pellets, along with greater reliability and consistency of dispersion in the SMA mix.  They also require a lower addition rate than coated pellets and shorter mixing times for full dispersion.

Developed to deliver the benefits of Excel’s industry-leading and HAPAS-approved loose fibre bitumen modifier in an easy-to-handle pellet format, Viscocel 500 pellets are designed to be used in conjunction with the company’s patented SMART range of bespoke refibreising systems to maintain the performance characteristics of loose fibre, including fast and even dispersion, and high levels of consistency for optimum bitumen performance.

Once dispersed in the SMA, Viscocel 500 fibres hold the bitumen in place by creating a lattice, which binds the material together, enhancing the bitumen’s ability to adhere to the stone aggregate.

Viscocel 500’s performance results from the closely controlled manufacturing process that ensures correctly engineered fibres are produced batch after batch and that these fibres are precisely pelletised so that they hold firmly together during handling and transportation, but break up and disperse readily prior to being added to  the SMA mix.  This results in superb consistency across the laid road surface and, consequently, a repeatable high level of performance.

The patented SMART range of pellet refibreising systems is based on three ‘primary module’ refibreising options, together with a range of standardised pellet hopper configurations to create a dedicated handling and refibreising unit that takes into account throughput rates, storage capabilities, working practices and existing plant equipment and infrastructure.

Pre-commissioned and fully factory-tested, SMART systems are designed to be quickly and easily installed onto a pre-prepared site, minimising assembly time and operational disruption.