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Viscocel 500 Bitumen Modifier Pellets Pass Hanson Trials
Date:  24 June 2003

Excel Fibre Technology’s recently-launched Viscocel 500 binder-free fibre bitumen modifier pellets have successfully completed SMA trials undertaken by Hanson Aggregates at its Chipping Sodbury quarry.  The trials involved the manufacture and laying of 400 tonnes of SMA surfacing using two aggregate mixes.  The SMA was laid on roadways within the quarry itself and, for South Gloucestershire County Council, on the public highway approaching the quarry gates.

The Viscocel 500 pellets were trialled with Excel’s SMART system 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 featured a gravimetric feed primary module, with a one tonne hopper capable of supplying fibre for 300 tonnes of SMA.

Four aggregate SMA mixes were manufactured by Hanson using the refibreised pellets:  14mm and 10mm limestone course aggregates with limestone fine aggregate, and 14mm and 10mm gritstone course aggregates with limestone fine aggregate.

The SMA was laid by Hanson Construction Projects in the very high traffic areas in and around the quarry, which are used by a variety of vehicles up to 100 tonnes in weight, providing an extreme test of its strength and durability.

Commenting on the Viscocel pellets and the SMART refibreising system, Ian Bredbury, quarry manager of Hanson Aggregates’ Chipping Sodbury quarry, said:  "The SMA manufactured with the pellets was very high quality, which was essential to cope with the heavy traffic it will be subjected to.  The robust SMART system is well-suited to the harsh external quarry environment and performed well in refibreising the pellets into an easily-dispersed loose fibre."

Excel’s Viscocel 500 SMA fibre pellets provide improved performance over coated pellets, while requiring a lower addition rate 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.

Viscocel 500 does not rely on a binder to hold the fibre together in pellet form. This delivers cleaner handling along with greater reliability and consistency of dispersion in the SMA mix, since Viscocel 500 pellets do not rely on the binder melting before dispersion can take place.  This avoids ‘clumping’ in the mix and/or longer mixing times.

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.

Excel Fibre Technology, a division of Excel Industries Limited of Ebbw Vale, is the UK’s leading manufacturer of speciality fibres and fibre delivery systems.  In addition to Viscocel SMA fibre and pellets, Excel manufactures a range of products for use in varied industrial applications as well as the building and construction industry.