0 5 . 2 016
Customers offer t ips on… Retrofits, Expanding with Ready-Mix,
Extending Plant Life, Hitting Deadlines, Building a Business
AmmAnn inCre A se sinve stment in indiANew Plant, New Products
page 18
reCyCling reCordHRT Plant Hits 99 % Mark page 4
t h e A m m A n n g r o u p m A g A z i n e
Strong PreSence at BaumaAutonomous Plate, Plants and More
page 20
C o n t e n t s
How can we do more for you?
pg 4 remArKABle reCyCling
Mix made from consumer goods
pg 6 shAft-seAl retrofit
Easy repairs, longer life
pg 8 dAtA drives profit
Compaction passes eliminated
pg 10 A neW niChe
Silos help broaden concrete product line
pg 11 limited disruptions
How to complete a retrofit – quickly
pg 12 no dAy At the BeACh
Maintenance on the English Channel
pg 14 AlWAys on time
How did toll road stay on schedule?
pg 16
AlWAys reAdy to groW
New plants build business
pg 18 A perfeCt fit
Ammann’s capabilities match India’s needs
pg 20 innovAtion on displAy
New products unveiled at BaumaHans-Christian Schneider CEO, Ammann Group
Look through these pages and you’LL
see how ammann customers Like you are
succeeding aLL over the worLd.
There is the use of 99 per cent recyclables at an Australian asphalt plant, a cost-effective retrofit in Germany, a long-lasting plant in the UK, tight deadlines met in Indonesia and a growing business in Kazakhstan. Each of these customers faced a challenge – and met it. Each also has a smart business sense and a commitment to excellence that drive their companies forward. We would never take credit for their successes, but we are glad to be associated with these businesses
and are pleased that such a prosperous group chooses to partner with us. Their confidence drives us to do even more – to always strive to make the next generation of plants and machines even better. As you read further through the magazine, you’ll see that several pages are devoted to new and improved products that will be introduced at Bauma. These products feature durable components for long life and, ultimately, reduced cost of ownership. Efforts to provide efficiencies that benefit your bottom line go into all products big and small, and the new launches are no exception. Time-saving technology, too, is in each and every plant and machine. Also present in all Ammann products are improvements customers like you have suggested. We do listen, and meeting your needs is our business. We hope to see you at Bauma. Please stop by the Ammann booth and tell us how we can do more for your business.
We have a good thing going. Let’s keep it up.
ammann-group.com 3
holz nAmed president of CeCe
Bernd Holz, managing director of Ammann Verdichtung and Ammann sales director Europe (North), has taken up the presidency of CECE (the Committee for European Construction Equipment) on behalf of the Czech association SVSS.
Holz succeeded Eric Lepine of Caterpillar. “The CECE priorities for the next term include the completion of the new engine exhaust emissions legislation in all its technical detail, as well as activities in the fields of outdoor noise regulation and machine safety standards, including the drafting of a new standard for machine visibility,” Holz said. Another area of particular attention will be the issue of skills development and the availability of future engineers, Holz said. CECE consists of dedicated experts collecting and sharing their knowledge to produce technical insights and contribute to an informed decision-making process at EU level.
newS & noteS
neW distriBution Agreement
A distribution agreement has been made between SBMTP, a subsidiary of the PGA TP Group, and Ammann France. The launch of this strategic alliance provides an opportunity for the SBMTP sales force to have first-hand access to the cutting-edge technology of Ammann compactors. The agreement was signed at Nové Město in the Czech Republic, the location of Ammann's compactor factory. Through PGA TP, Ammann gains coverage in large parts of France, including three major regions: Grand-Ouest, Atlantique Limousin and Aquitaine Occitanie.
For more information on how to find a cost-effective compaction tool for your jobsite, visit www.ammann - group.comMMP-1193-00-EN | © Ammann Group
The Ammann light compaction product line comes in all shapes and sizes, just like the jobsites you work on. The product diversity ensures you have a perfect fit for virtually any application, creating efficiencies that impact your bottom line.
FROM RAMMERS TO ROLLERS, THE LIGHT COMPACTION TOOL YOU NEED.
4 ammann group magazine
It was the first time a mix has been manufactured with such a large amount of recycled consumer goods, said Dante Cremasco from Downer, the Australian company that manufactured the asphalt.
“The higher than normal recycle content percentage was achieved using post- consumable waste materials that would typically be stockpiled or sent to landfills,” he said. The end product is also worth noting.
“The mix itself actually performs better than a straight mix,” Cremasco said.Ammann worked closely with the Downer team to help make the mix a reality.
“Our relationship with Downer is one of partnership where we work together collaboratively to further improve the way
we design and manufacture our plants to continuously deliver more effective, efficient and sustainable products,” said Paul Vandersluis, Managing Director, Ammann Australia. “This close relationship has enabled us to continually set industry benchmarks.” Downer created and laid the mix, which also included recycled asphalt (RA), during a demonstration at its flagship Bayswater facility in Victoria. The Bayswater facility features an Ammann Universal High Recycling Technology plant that manufactured the mix. Downer partnered with their customer, the City of Boroondara, on the demonstration. “If we can show that producing a 99 per cent high quality renewable asphalt is
universAl hrt > 240 t/h > Dual fuel Burners > RAH60 with 3 feeders > RAC with 2 feeders > 7 feeders for virgin materials > 5 t mixer > as1 control with ecoview > 400 t asphalt storage
an ammann asphaLt pLant has produced a
mix consisting of 99 per cent recycLed
materiaLs, incLuding toner from print car-
tridges, tyres and gLass.
ammann aSPHalt Plant HitS recycling mileStone
99 % of Product Made from Recycled Mater ials
ammann-group.com 5
Research conducted by Downer shows the use of the recyclables improved the asphalt quality. Downer reported:
> A 30 per cent improvement in deformation resistance, increasing product ability to resist damage from heavy traffic.
> A 16 per cent increase in stiffness, which improves bearing capacity to carry heavy traffic. This also means a thinner surface can be placed, further reducing emissions.
> Improved durability and resistance to fatigue cracking due to innovative product design.“the mix itself ACtuAlly
performs Better thAn
A strAight mix.”
possible, then we should be able to routinely market 75 to 80 per cent to our customers,” Cremasco said. The company is hopeful that higher recycling targets are written into future project specifications. Current best practices in Australia include 30 to 40 per cent renewable materials, with some limited facilities achieving higher production levels.Downer produced 25 tonnes of the mix during the demonstration, attended by a host of governmental officials. The mix was used on a two-way access road for a City of Boroondara sporting facility.
Mixes that are almost exclusively RAP have been manufactured previously, Cremasco said. What made this particular mix unique
That will be significant given Downer’s size. The company manufactures about 2.5 million tonnes of asphalt per year at its approximately 30 plants. “These days there are spending restraints from government authorities while consumer expectations are always rising,” Cremasco said. “This mix improves performance, reduces costs and preserves raw materials. It meets the needs of the government and the public.”
was the use of recycled consumer goods. They included crumbed tyres and printing toner, which acted as a polymer; and crushed glass, which essentially replaced sand. RAP accounted for about 75 per cent of the mix. The only non-renewable material in the mix was 1 per cent binder. Cremasco said the paving crew that worked with the mix found it to be trouble-free, and no extra measures were needed. “It’s easy for crews to place,” he said. “The mix itself had a good matrix about it.” While the company describes its Bayswater facility as one of the most
advanced of its kind in the world, no special adjustments were made to the Ammann Universal HRT. Keys to the process are the plant’s RA silos, located above the pugmill, and the twin-drum, parallel RA drive. The plant also is built to introduce recyclables beyond RA, Cremasco said.
Downer purchased the Ammann Universal HRT about two years ago because of its fuel efficiency and ability to use 80 per cent RA.
The impact goes beyond environmental benefits, Cremasco said. “Cost is another driver,” he said.
“We have an internal target to reduce cost. When we eventually get into full production mode, those savings will be passed onto the consumer.”
6 ammann group magazine
Concrete producers have long known a retrofit results in a plant with modern capabilities at a fraction of the cost of a new purchase. But a German company has seen significant benefits from a secondary retrofit undertaking: the revamp of the shaft seal system so that it’s compatible with the Ammann Elba mixer. Essen, Germany-based Heidelberger Beton Rhein-Ruhr found itself in need of a new mixer when the existing component wore out. Heidelberger Beton had purchased its Elba plant in Dortmund in the late 1990s. The plant had proven extremely reliable and productive, but it was time to take action to keep the mixer in good condition and productive.
anotHer Benefit of a retrofit
New Shaf t Seal System Wil l Provide Signif icant Cost Savings
separating the shaft-seaL system enabLes more cost-effective
maintenance and prevents damage to bearings.
ammann-group.com 7
Service experts from Ammann Elba visited the Heidelberger plant, and a retrofit program was introduced that included implementation of a new mixer axis with Elba Wear Protection (EWP). Many components, such as the feeder system or the plant control system, did not change as they were still in good shape. The project also included installation of the bearing and shaft sealing system that included the patented Elba holeless tiling, which makes for extremely quick replacement.
Advantageous Reconfiguration Key to the success of the project was the shaft-seal system. The retrofit separated the shaft bearing and shaft seal to create a new configuration that brings substantial benefits.
> Concrete fluid that can leak through a worn sealing cannot damage the bearings anymore.
> The shaft seal now can be repaired from inside the mixer, requiring much less time than before.
> The life of the new shaft seal is much longer than before.
The reconstruction project took only a week to complete, and was undertaken during the winter break in January when the plant wasn’t operating.
eLba wear protection
Elba Wear Protection (EWP) is a complete wearing package with an excellent price/performance ratio. EWP protects parts and components and ultimately extends the life of your plant.
Benefits include: > Reduced component costs because of extended life
> Reduced labor costs because of fewer replacements and repairs
> Quick and simple installation > Less caking with mixer, discharge hopper and skip
> Easy cleaning
8 ammann group magazine
Compaction technology provides considerable savings Many contractors take steps to squeeze every bit of power from every drop of petrol. Yet compaction technology, one of the most substantial road construction efficiencies of late, has gone unnoticed by many. The savings that result from compaction technology can be significant. In fact, technologies including Ammann Compaction Expert (ACE) are helping contractors improve compaction measurements to the point where multiple passes are eliminated. “What provides bigger fuel savings than reducing the
number of passes the compactor makes?” asked Kuno Kaufmann, Head of Compaction Technologies at Ammann Group. “With ACE technology, contractors can do exactly that. There is improved
information as to when compaction is achieved, and the operator and machine can more quickly
move to the uncompacted areas of the jobsite.”
Fewer passes also translates to more efficient use of labor and reduced wear on machines. ACE technology, offered on many Ammann soil compactors and tandem rollers associated with road construction, provides benefits beyond eliminating passes including:
• Enabling use of smaller, more efficient machines to deliver compaction force typically associated with larger models.
• Automatic adjustments that quickly adapt to changing conditions and boost productivity in the process.
• The avoidance of costly re-work, particularly when compacting multiple layers.
The Ammann technology is an automatic measurement, control and documentation system. ACE systems can be supported with GPS mapping to provide data regarding the areas the compactor has covered. All measured values can be displayed and evaluated, including the load-bearing capacity of the material, the
number of passes, and the frequency and amplitude values. There are several system variations. ACEpro measures and evaluates the characteristics of the ground and automatically adjusts the amplitude and frequency accordingly, while ACEforce measures the absolute value of the bearing capacity of the compacted material. “We are able to offer these technologies to contractors at all phases of the construction process,” Kaufmann said. “Variations of the ACE system are available for soil compaction, including cohesive soils. Asphalt compactors also benefit, as do vibratory plate compactors.”
tecHnological toolS to fuel your BuSineSS
El iminate passes , access manuals , research products
compaction system turns data into productivity.
new website and app provide essentiaL
information in the office or on the jobsite.
1
ammann-group.com 9
3
Customers benefit from Ammann app Ammann’s Service App continues to impress customers who are taking advantage of the cost-free after-sales management tool. The intuitive app is particularly helpful when customers are in the field and unable to navigate through multiple layers to reach essential information on a hand-held device. The app enables access for both Android and iOS devices. In addition, manuals and service videos have been updated. The app, for Ammann machine users and owners, provides an abundance of information. All Ammann machines are represented on the comprehensive app.
The app is available in English, French, Spanish and German. It provides gigabytes of machine data to customers whether they’re in the office or on a jobsite. There are many benefits to the cost-free app. To find out for yourself, visit the app store on your phone and search Ammann.
New and improved website Ammann has unveiled a new customer-focused website. The site is built to make it easy for customers to find the information they need, including product descriptions, specifications and stories about their peers. Language versions continue to be developed. In addition, fresh content will regularly be posted to help ensure customers are up-to-date on Ammann products and industry trends.
You can visit the new site at Ammann-group.com.
Categories in the app include:
> Service contracts > Manuals > Parts books > Service videos > Dealer locator > A link to the Ammann website home page
> A link to Ammann used equipment
2
“WhAt provides
Bigger fuel sAvings
thAn reduCing
the numBer of
pAsses the
CompACtor mAKes?”
10 ammann group magazine
BKG Transport Beton GmbH & Co KG develops concrete
for projects that include road building, but a year ago
the company found itself at a crossroads of its own.
The business, near Karlsruhe, Germany, had found success with its
Ammann Elba ESM 110 Concrete-Mixing Plant and its 4 80-tonne storage silos. The
mobile plant had performed well since being purchased about 5 years ago and already had been moved successfully once. Yet the market increasingly demanded more varied concretes. The ESM plant was able to meet those requests because of its built-in ability to create special products such as steel-fibre concrete, self-compacting concrete and paving concrete.
SiloS give Plant exPanded life
Plant Adds Capacit y, Maintains Mobil i t y
While the plant could handle the variety, the 4 storage units were not enough. Mr. Dieter Sülflow, Managing Director of BKG Transport Beton, saw a way to reach additional customers who needed the specialised concrete at a fraction of the cost of investing in a new plant. BKG Transport Beton investigated the addition of 3 silos, each with a storage capacity of 80 tonnes. The solution was tricky because the plant was on a small site with little room for new equipment, let alone the addition of 3 silos. “The biggest challenge was to integrate the new mobile silos into the existing plant configuration,” Sülflow said. The new silos also had to fit into the plant’s overall concept of mobility.
fitting new siLos onto
a smaLL pLant site was
essentiaL to bkg’s abiLity
to expand its concrete
product Line.
a 7-day re trofit How to Minimise Disruptions While Upgrading Your Plant
Concrete plants need to be updated and modernized to remain productive and, ultimately, competitive. Yet the best results occur when improvements are made with limited disruptions to ongoing operations. Dyckerhoff Beton GmbH & Co. KG based in Wiesbaden, Germany, needed upgrades in aggregate storage/dosage and weighing at their concrete mixing plant in Karlsruhe. However, other key plant components remained productive and were not part of the improvement plan. That meant the company needed the new bins and weighing belt to be seamlessly integrated into the existing plant operations. How did Dyckerhoff Beton GmbH & Co. KG ensure disruptions to its existing operations were limited?
Turn to experts. With nine bins to replace, the company turned to Ammann Elba because they had successfully completed other modernization projects. They selected Ammann Elba’s largest mass-produced bin: the type RD 52-468/9. The storage capacities are significant, with each bin holding volumes of 52 m3.
Find the right design. The bin’s design enabled the restoration without a need for more space or additional foundations while also providing the total volume capacity of 468 m3. This was accomplished in part because of the compact design of the bins, compared with the previously rounded structures. Using the original space was essential because it meant no modifications had to be made to the existing bridge crane for changing the bins or the connection to the belt that feeds the mixing plant.
Consider other changes, too. Dyckerhoff Beton GmbH & Co. KG made other updates, including connection and the distribution to an aggregate heated air heating system and installation of cameras that monitor aggregate levels. An option for loading and storing special products also was part of the improvement plan. Individual portion controlling will now be more closely monitored at the plant, as will coarse-fine ratios per chamber on the 1000 mm weighting belt. The on-site work went quickly, with only seven days between the start of installation and the commissioning. This reduced downtime to a minimum and instituted more efficient systems in the shortest amount of time possible.
rd 52 lineAr storAge Bins > 2 to 6 chambers > Up to 21 m long > Capacity of 104 m3 to 312 m3 > Options include rear side coverings, scale testing equipment and calibrating aids
ammann-group.com 11
The company turned to Ammann Elba, which had proven to be a helpful partner during earlier work installing and relocating the plant. After-sales support also created confidence in Ammann Elba. “Specifically, the service staff of Ammann Elba left a positive impression,” Sülflow said. Together a team from BKG and Ammann Elba determined the best locations and process to fully integrate the new silos into the production process. The result is a company that can develop more varied products while also improving production and availability of all concretes.
supermoBil esm 105-110 > Single-shaft compulsory mixer > Output ranges from 2 m3 to 2.66 m3 of compacted fresh concrete per batch > Spacious mixing platforms > One-day plant assembly
12 ammann group magazine
the coLas team has many methods for making
their pLant Last. chief among them: invest in
quaLity and then be reLentLess in the pursuit of
earLy signs of troubLe.
1 Demand quality when purchasing the plant. Hudson works for UK-based Colas Ltd., which is part of Colas SA, a major international group with headquarters in France. He and others at the local site encouraged the purchase of an Ammann Uniglobe 200 Batch Plant when the decision was being made a decade ago.
“Ammann came up with a design that perfectly matched our needs,” Hudson said. “The plants have durability, and the pieces fit together to limit wear.” Hudson’s bottom line: Choose a superior product, because all the maintenance in the world can’t make a poorly manufactured plant last.
2 Buy quality replacement parts.
“You don’t save money when you use cheap replacements,” Hudson said. “That’s why we buy parts directly from the manufacturer (Ammann). Parts that fit perfectly reduce wear, last longer and therefore reduce cost.”
Despite challenging conditions, an asphalt plant owned by Colas Ltd. has continued to achieve a 98 per cent availability rate despite operating in an extremely tough environment. “There is a view of the English Channel from the top of the plant tower – that’s how close we are to the water,” said John Hudson, an engineer and site foreman at the plant in Carnsew Quarry, Cornwall, England. “We have a lot of moisture in the air.” The conditions can get a bit raw, but they aren’t the only challenge facing Hudson and his colleagues, who operate and maintain the asphalt plant. “Plants are an investment, and you have to maximise the return,” he said. “By ensuring the plant lasts, you can get the most out of that investment.”
hoW do huds on A nd his C ol l e Ague s m A K e t he pl A n t l A s t ?
3 Walk around – a lot. Hudson and his team have their regular inspections of dryers, the baghouse and other commonsense locations. Yet they also look for wear in less obvious places. Have abrasive aggregates worn down various components of the elevator? Do materials routinely spill in a specific location, which can take a toll over time? “If you can’t find something, you’re not looking hard enough,” Hudson said.
4 Watch what’s moving.
“There are a lot of moving parts to an asphalt plant,” Hudson said. “There are rollers for conveyors and gearboxes that drive the conveyors. Pay special attention to those moving parts. Moving causes wear and, if one of the moving parts breaks down, it can often damage others.”
7 StePS to making your aSPHalt Plant laSt
98 Per Cent Uptime for Colas’ Ammann Facil i t y
ammann-group.com 13
“there is A vieW of the
english ChAnnel from the
top of the plAnt toWer —
thAt’s hoW Close We Are
to the WAter.”
5 Schedule a regular maintenance day. “The reason the plant doesn’t look 10 years old is because we maintain it every weekend,” Hudson said. “I think the saving grace of any asphalt plant is preventive maintenance.” Saturday is the maintenance day for Hudson and his colleagues. Tasks include maintenance and repairs, as well as inspections that often uncover work for the following weekend. “If a problem is found, it’s not ignored,” Hudson said.
6 Utilise outside resources. Hudson’s team does most of the maintenance, but they also turn to the manufacturer for certain specialised services. “Right now we have Ammann here servicing the burners,” Hudson said. “We have them do that every six months.” The manufacturer has tools and experience that Hudson could obtain, but he realizes some efforts are best left to the specialists. “There is a lot that goes into that service and our time is better spent on the many other things that need to be done around here,” he said.
7 Think through the process in advance. When planning a repair for the upcoming weekend, Hudson takes a careful look at the tools that will be needed and the processes that are most likely to be successful. Depending on the repair, he sometimes designs tools that ultimately save considerable time. “You would be surprised how many frustrations you can avoid by looking and thinking through as many details as possible in advance.”
That approach – and the oth-ers – means more maintenance and repairs are completed in a timely manner. And that leaves time for…more maintenance and repairs, which in the end ensures the plant lasts longer.
14 ammann group magazine
CiKopo-pAlimAnAn proJeCt
stArt dAte: 5 July 2014 Completion dAte: June 2015 length of roAd: 110 km; is a segment of Trans-Java Toll Road estimAted Cost of ConstruCtion: About 8 trillion Rupiah for total reconstruction dAily vehiCle volume: About 30 000
4 keyS to meeting Project deadlineS
Ammann Plant Helps Ensure Indonesian Tol l Road Finished on T ime
Long-term efforts, such as the seLection of a pLant and staying
in good financiaL standing with suppLiers, heLp a company meet
tight daiLy production deadLines.
ammann-group.com 15
The Cipali Toll Road in Indonesia was an enormous undertaking. Yet its benefits were just as big. The Cipali Toll Road is part of a larger network, the Trans-Java Toll Road that connects key freeways in Jakarta and beyond. The Trans-Java Toll Road runs for 653 km and reduces the existing route by 40 km. What all observers witnessed was a project that finished on time and within budget. A key player in meeting both goals was asphalt producer PT. Dirgantara Yudha Artha, based in Bandung, Indonesia. The Cipali Toll Road covers 110 km and its development required around-the-clock asphalt production, with daily totals approaching 3000 tonnes. “We installed Ammann JustBlack 150 to finish this project,” said Jahja Tear Tjahjana, owner of the asphalt company. How, specifically, can an asphalt manufacturer meet its deadlines – and help others do the same – on such a demanding project?
Take care of your finances. This point is crucial yet often overlooked. “We are always on time in making payments to our suppliers,” Jahja said. “This makes them
happy to work with us. They then support us with good prices and make us their priority partner/customer.” When a need is sudden and urgent, the suppliers come through. Dirgantara Yudha Artha also has
an exceptional reputation with banks, which support the company decisively and quickly when needed.
3
Find a good plant manufacturer. The supplier and financial partnerships are crucial and contributed to meeting deadlines, but Dirgantara Yudha Artha also
realizes there is no substitution for a good plant. The Ammann JustBlack plant is reliable, helping Dirgantara Yudha Artha hit deadlines on the toll road and other projects. After-sales support is strong
to maximise availability—and ultimately capacity. The company’s use of the JustBlack plant has brought it bottom-line results that help perpetuate the timeliness on projects. “JustBlack saves about 20 per cent on fuel when compared with other plants,” Jahja said. That savings improves profit and also provides the company with more money to invest in improving its ongoing operations.
4
Consider capacity. Dirgantara Yudha Artha utilised an Ammann JustBlack asphalt batch plant with a capacity of 150 tonnes per hour. It typically produced about 120
tonnes per hour, but the extra capacity allowed for additional production when necessary. Capacity also involves reliability, as an idle plant produces nothing. Dirgantara Yudha Artha purchased its
plant in large part for its reliability. In particular, the company appreciated that all core components are manufactured in-house in Switzerland and fit together seamlessly to extend plant life and reduce interruptions. The result was outstanding production with the Ammann JustBlack plant producing 120 tonnes per hour for 20-hour shifts, providing 2400 tonnes per day.
2
Leverage your experience. Dirgantara Yudha Artha has been in business since 1990 and has manufactured asphalt for many different types of projects. “We have
worked on general construction and property/housing projects,” Jahja said.
“We also build roads, toll roads and airport runways.” The experience paid dividends in 2 ways on the toll road project. First, it
ensured the plant team was familiar with the required mixes. A second benefit was the team’s experience in switching mixes. Their history of making quick, frequent recipe adjustments made the minimal switches on the toll road project easy. Production continued without a hitch when a new mix was needed.
1
When the project was complete, Dirgantara Yudha Artha had produced enough mix to cover 55 km of the 110 km of multi-lane highway. Production had gone well and set the pace for the entire project. “We are proud of this project,” Jahja said. “We were a key, flexible pavement contractor in developing the road, which will have a significant impact on travelers and will improve our economic growth.”
16 ammann group magazine
Proven BuSineSS-Building PracticeS
More to ADSK Grow th than Just the Economy
adsk has grown
by being fLexibLe,
on time, committed
to technoLogy and
foLLowing a unique
method for knowing
when it’s time to expand.
“i enJoy seeing
the groWth of the
CompAny And the numBer
of employees inCreAse every yeAr.”
ammann-group.com 17
As the economy grows in Kazakhstan, so does Almaty Road Construction Company. The company, also known as ADSK, purchased its first Ammann asphalt-mixing plant in 2001 and has bought 2 more since. ADSK needed the 2 newer plants because demand for its products has grown, in part because of its success on high-profile projects. Among the most notable are its production of mix for the region’s first high-speed highway, a 200 km road from ADSK’s hometown of Almaty to Bishkek. A more recent noteworthy project was producing mix for a high-speed road between Almaty and Ust-Kamengorsk. On those projects, both the general contractors and quality control laboratory were impressed by ADSK’s ability to produce a high volume of quality mix that met the required international standards. While there have been past successes, ADSK always looks for ways to improve its methods and operations.
1 Stay flexible for fuel. In 2015 the company’s 3 Ammann plants were modernised to accept the use of natural gas in addition to “mazut,” a heavy oil. The modifications have provided significant savings in fuel costs.
2 Utilise plants that can handle changing needs and maintain quality. ADSK has preferred Ammann products since the purchase of a Global 120 Asphalt Mixing Plant. That purchase was followed by a Global 160 in 2005 and, most recently, a JustBlack 200 plant in 2014. The first 2 plants are on a single site in Almaty, while the third plant is at a quarry in a nearby village. “We bought the Global 120 to produce quality asphalt for repair and replacement of roads in the city,” said Gagiyev Yunus, owner of ADSK. “At first production of the mix was just a small part of our business, but it grew enough that we created a separate operation.” The purchase of the second plant, in 2005, resulted from demand for quality mixes. ADSK added the JustBlack plant in 2014 because its high capacity can serve much of the region. “Generally we bought each plant when demand for good mixes was increasing,” said Konstantinov Victor, deputy to Yunus.
3 Always be on time. The quality mixes are just one way ADSK keeps its promises to customers. “Road construction is seasonal work, and our customers need us to help them be successful during those crucial times,” Yunus said. “The key to success for ADSK is high quality asphalt mixes and on-time delivery. We arrange everything according to the customer’s needs and work till the last truck is loaded. It doesn’t matter if it’s day or night.”
4 Customer service never goes out of style. The company believes in a tried-and-true motto: The customer is always right. How does ADSK know it will continue to meet the needs of customers – and ultimately keep the plants busy? “The first step is ensuring there is consistent delivery of the aggregates and bitumen,” Victor said. “The reliability of the Ammann plants then helps us deliver asphalt to our customers on time and keeps them happy.”
5 Keep up with technology. “Our asphalt mixes are and will always be the most modern and highest quality on the market,” Yunus said. “The next plant will use technology, science and the application of modern additives for the production of high-quality mixes.”
6 Don’t be afraid to grow. Yunus also has a simple but smart method for determining when it’s time to expand.
“When you see that you have closed all your credits, it probably means it’s time to extend your business,” he said. That has been the case several times over the years, with a staff that started at 40 and since has grown to 160. “I enjoy seeing the growth of the company and the number of employees increase every year,” Yunus said.
18 ammann group magazine
ammann’S PreSence in india growing
New Products and E xpanded Manufac tur ing Facil i t y
18 ammann group magazine
india’s economic potentiaL has Led ammann to expand both
its product offerings and manufacturing capabiLities
in the country.
ammann-group.com 19
“India, with more than 1 billion people and a growing need for road and other infrastructure, is an important market for Ammann,” said Hans-Christian Schneider, CEO of Ammann. “We are introducing a significant number of new products and solutions in plants, pavers and compactors. We are certain that we can continue to make our customers successful and the next generation of infrastructure in India of an even higher quality.” Ammann products displayed at EXCON 2015, the largest construction equipment exhibition in South Asia, showcased industry-leading technology and “green” attributes. The products included a range of asphalt plants, asphalt pavers and light and heavy compaction equipment. “Ammann’s strengths are a perfect fit for the direction the Indian market is moving,” said Asit Patel, Managing Director of Ammann India. “Customers increasingly want technology that provides efficiencies, environmentally friendly products and a high level of service. Ammann meets those needs.”
Compaction Products A significant announcement on the product front is the introduction of heavy compactors into the Indian market. “Ammann’s philosophy is to be a total solutions provider and the compaction product range will help in achieving that goal,” said Sunil Sapru, Regional Director of Sales and Marketing for Ammann India. A single manufacturer now can provide all the necessities for road construction including soil compactors, concrete and asphalt plants, pavers and finish compactors. “The compactors meet all the needs of the market,” Sapru said. That includes the new ARS 121 BS III Soil Compactor. “The technology is state-of-the-art with no rigid axle,” said Anand Patel, CEO Machines for Ammann India. Instead of a rear axle, the compactors are powered by independent hydraulic drive motors, which provide a number of benefits including optimal traction. “Better traction improves the compaction strength,” Anand Patel said. “While compacting on grades, Ammann compactors ensure far better performance when compared with conventional compactors with a rigid axle. Ammann compactors have best-in-class energy efficiency as well.”
New UniBatch Asphalt Plant Also being offered in India is the all-new ABA 180 UniBatch Asphalt Plant. Ammann is the leading asphalt plant manufacturer in the world, and the ABA UniBatch series is its most popular offering. The ABA 180 UniBatch plant, like others in the series, is robust with proven high-end technology. It is “future-ready” and lends
itself to customisation as new technologies and efficiencies are developed. The plant also fits with the market’s desire for green products. Customers in India are picking up on green technologies such as asphalt recycling, the use of low-temperature asphalt and high-efficiency plants and machines. Ammann offers efficient machines and asphalt plants that are industry leaders when it comes to the use of RAP and recycling.
Service Commitment Improved service is increasingly important in the Indian market. Ammann is the leader in both the asphalt plant and paver markets, giving it the largest service footprint of any manufacturer in the country and putting it in a unique position to meet customers’ needs. “Service is of the highest importance,” Sapru said. “That has led us to increase the number of branches to help ensure parts and service are available when needed. It’s an expansion that will continue.” Also crucial is the training of the technicians at the locations. “We are committed to ensuring there is expertise at each and every branch,” Sapru said.
Manufacturing Growth Ammann also announced expanded manufacturing at its Ahmedabad facility. While details were not yet released, the company’s future manufacturing will include additional products as well as key parts and technologies for asphalt and concrete plants. Some key components will still be manufactured in Europe and assembled at Ammann’s Indian facilities. The entire range of asphalt plants, paver finishers, wet mix plants, bitumen distributors and curb pavers is currently manufactured – completely or in part – at the Ahmedabad facility. Joining the product line will be compaction equipment, concrete plants and additional asphalt plants, Sapru said. Ammann’s CEO sees the investment as a result of a prosperous relationship with the company’s customers. “Ammann has experienced a great deal of trust from our Indian customers,” Schneider said. “This motivates us to invest heavily in our facilities in Ahmedabad with one goal: to bring more products of the highest technology and quality at affordable prices to our customers. We are investing today into tomorrow’s productivity for our customers.”
“AmmAnn hAs
experienCed
A greAt deAl
of trust from
our indiAn
Customers.”
20 ammann group magazine
the ammann booth, its Largest ever at bauma, wiLL
showcase products and prototypes that prove the company’s
commitment to remain an industry Leader through both
outside acquisitions and internaL innovations.
ready for tHe SHow
Ammann Releases New, Innovative Products at Bauma
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The booth will feature 17 new products and several prototypes, including the innovative autonomous plate compactor. The compactor covers a jobsite without an operator, providing high compaction output at greatly reduced operating costs. It is the first autonomous plate compactor on the market. Also on display will be concrete plants and mixers developed by Ammann Elba, the company created when German-based Elba was acquired in 2014. Ammann Elba continues to be an industry leader, as proven by its new concrete-mixing plants on display at the booth.
Asphalt Pavers Both the wheeled and tracked versions of the Ammann 350 and 500 pavers have been updated. The pavers meet all emissions regulations worldwide and offer reliability, improved visibility and easy operation. The tracked versions – the AFT 350 and AFT 500 – provide improved traction in challenging underfoot conditions. The AFW 350 and AFW 500 are the best choices when mobility is essential. The next generation of Ammann’s unique mini paver, the AFW 150-2, has been released. The wheeled paver features a larger auger (120 mm diameter compared with the previous 100 mm) that ensures proper material distribution along the screed. A new material flow sensor is another consistency enhancement. A hydraulically extendible screed operates similar to those on larger pavers, enabling quick and effortless extension while the machine is operating.
Autonomous Vibratory Plate Unveiled at Bauma is a prototype of the first autonomous vibratory plate. The plate is easy to use, with the operator setting the boundaries by remotely navigating the plate around the jobsite perimeter. The number of vertices is not limited and the machine automatically detects the closed border. Next a working strategy is calculated and the field is compacted strip by strip. A highly accurate GPS system is supported by an electronic compass and collision detection.
Forward-Moving Vibratory Plates The APF 11/33, APF 14/40, APF 14/50 and APF 20/50 represent substantial new efforts to send compaction energy toward the materials and away from the operator. The compactors feature Ammann’s patent-pending Z-buffer, which isolates the guide hand from vibration and reduces operator fatigue. The Z-buffer is the key reason operator vibration levels for Ammann compactors are substantially below the regulations of the strictest countries.
Single-Drum Soil Compactors The ARS 200 T4f and ARS 220 T4f feature newly designed cabs and intuitive controls. The optional Ammann Compaction Expert (ACE) systems provide quality control, reduced machine wear and cost savings. The ARS compactors also incorporate popular existing features including a no-rear-axle concept with fully hydrostatic drive and the powerful Ammann dual vibratory and amplitude systems.
Pneumatic Roller The new Ammann ART 240 T4f Pneumatic- Tyred Roller provides productivity-improving operator comfort and an engine that meets Tier 4 Final emissions standards. Intuitive controls make operation easy. The spacious cabin features 2 working stations, while the multifunctional operator display provides instant feedback. The ART 240 utilises a front isostatic oscillating axle and a rear-drive propulsion system that provides the necessary power, regardless of tyre pressures or ballast weight.
22 ammann group magazine
other products that showcase
the depth and diversity
of the ammann Lineup
wiLL be on dispLay
at bauma.
Tandem Rollers with Oscillation The new ARX 90 T4f/T3 and ARX 110 T4f/T3 Tandem Rollers combine oscillation with the high compaction output seen on previous Ammann tandem rollers. The ARX machines are the first Ammann vibratory rollers to feature oscillation, a process that eliminates about 90 per cent of the stress to surroundings and materials caused by a traditional vibratory system. The new rollers combine the oscillating, back-and-forth-movement of the drum with a constant static load to reach compaction goals faster. For increased compaction output, the ARX utilises a combination of oscillation and the Ammann heavy-duty, 2-stage vibratory drum with easy adjustment of amplitude and frequency. The optional ACEforce system provides a host of benefits including measurement in absolute values, evaluation of material stiffness, an operator guidance function and documentation of the entire compaction process.
Trench Roller The new Ammann ARR 1575 Tier 4f Roller utilizes a Yanmar engine that meets the strictest emissions requirements in Europe and the U.S. The engine also provides excellent power and features reductions in noise and vibration. Productivity can be improved with easy-to-install extension kits that stretch drum widths from 640 mm to 850 mm. The ARR 1585 Tier 4f is the skid-steered version of Ammann trench roller and extends the portfolio to cover all customer needs and applications.
Asphalt-Mixing Plants New SolidBatch plants are built for flexibility, customisation and reliability. The SolidBatch 140 and SolidBatch 180, with capacities of 140 tonnes per hour and 180 tonnes per hour, are highly standardised and the base model features few “extras.” Instead, customers select the standard SolidBatch model and then choose from a variety of options. The new QuickBatch container plant is engineered for easy, cost-effective transportation and installation while still offering benefits typically associated with stationary facilities – including high-production capacity. QuickBatch was
designed for international transporting efficiencies and is built around the “container principle” logistics concept. Key core components, including dryer/filter units and mixing tower modules, utilize housings that also serve as certified transport containers. When it’s time to move, the components are simply loaded onto the transport vehicle. The Prime asphalt plant line has been expanded. The Prime 100 offers a capacity of 100 tonnes per hour and is a smaller, highly mobile version of the popular Prime 140. In addition to its exceptional mobility, Prime 100 is very compact when assembled. Despite its smaller size, the plant still utilises high-quality Ammann core components for optimal performance and output.
Concrete-Mixing Plants The new CBS Elba Concrete-Mixing Plant is designed for small- to medium-sized businesses seeking flexible concrete plant solutions. It features state-of-the-art design based on customers’ needs and offers output ranges from 105 m³/h to 160 m³/h. The basic unit can accommodate both EMS and EMDW single-shaft and twin-shaft mixers with a hardened concrete output volume ranging from 2 m³ to 3.5 m³. The CBS Elba offers easy, low-cost transportation for stationary and semi-mobile operation. A new line of mobile and compact concrete-mixing plants also has been launched. The first plant in the product family, the CBT 60 Elba Compact Concrete-Mixing Plant, has an hourly output rate of 58 m³/h. The entire compact lineup, available in the near future, will provide a performance range from 30 m³/h to 130 m³/h. The CBT 60 Elba is equipped with an Elba EMS 1000 single-shaft mixer and an integrated linear batcher for storing between 2 and 4 aggregate components. Fast installation times and trouble-free relocation result from the elaborate folding mechanisms. No foundation is required for plant installation.
MEET THE AMMANN
FAMILY OF PRODUCTS
For additional product information and services please visit : www.ammann - group.comGMP-1187-00-EN | © Ammann Group
MAXIMISING YOUR INVESTMENTWhat do the smallest Ammann plate compactor, the largest asphalt plant and every product in-between have in common ?
•Innovation that boosts productivity and efficiency, ultimately improving your bottom line
•Parts and components that ensure long life to maximise your investment
•The commitment of a family business that has thrived in the construction industry for nearly 150 years by keeping promises today – and knowing what customers will need tomorrow
ammann-group.com 23
MEET THE AMMANN
FAMILY OF PRODUCTS
For additional product information and services please visit : www.ammann - group.comGMP-1187-00-EN | © Ammann Group
MAXIMISING YOUR INVESTMENTWhat do the smallest Ammann plate compactor, the largest asphalt plant and every product in-between have in common ?
•Innovation that boosts productivity and efficiency, ultimately improving your bottom line
•Parts and components that ensure long life to maximise your investment
•The commitment of a family business that has thrived in the construction industry for nearly 150 years by keeping promises today – and knowing what customers will need tomorrow
AmmAnn-group.Com
Specifications are subject to change.GMC-1423-00-EN | © Ammann Group
