With recycled materials becoming increasingly important in the construction materials sector, manufacturers are meeting this need through new machines and innovations.
Recycled material usage in infrastructure projects is only set to increase due to an expanded push from outside and within the construction materials sector to become more environmentally friendly.
BP Mitchell is an established name in London’s construction materials space. From its headquarters in Hertfordshire, north of London, the producer processes mixed construction and asphalt waste for various uses.
Construction and demolition waste, or asphalt waste, can present a unique challenge for a construction materials provider and differ in its production cycle from virgin rock.
BP Mitchell operates a large wash plant where recycled materials can be cleaned for further processing and a Ciber asphalt plant for its asphalt-related products.
When it comes to crushing and screening equipment, the Hatfield-based company turns to one name: Kleemann.
“Our goal is to produce recycled material of the highest quality possible. To achieve this, we invest in high-quality, cutting-edge machinery,” BP Mitchell managing director Brendan Mitchell said.
“What impresses us time and again about the Kleemann plants is their innovative features and outstanding ease of use. Our people find the machines very easy to handle. Everything can be adjusted and operated intuitively and conveniently.”
BP Mitchell recently purchased a new MOBIREX MR 100i NEO mobile impact crusher for its operations.
This recent addition expands the company’s existing Kleemann fleet, which includes four MOBICAT jaw crushers, two MOBISCREEN coarse material screening plants, and a MOBIBELT mobile stacker.
BP Mitchell’s plant in Hatfield produces material for road substructures (Type 1, less than 40mm grain size) and provides further processing for the washed plant. It also recycles asphalt grains smaller than 20mm for the Ciber asphalt plant.
The MOBIREX MR 100i NEO was selected because it can handle sticky materials and mixed feed materials.
The crusher’s features, including the automatic crushing cap adjustment, enable it to handle this varied load of materials with ease.
This means the MR 100i NEO can easily switch between washing plant feeding and processing recycled asphalt (RAP).
“The crushing gap adjustment can be operated at the push of a button – definitely a highlight in this machine class,” Mitchell said.
Kleemann designed the MOBIREX MR 100i NEO to handle a high production load while also requiring low-fuel consumption. The balance can be tricky to strike, but BP Mitchell has noticed the new Kleemann machine only consumes 11L of fuel per hour while producing up to 60 tonnes per hour of 0–20mm grain size.
“The advice and service we receive are first-class,” Mitchell said. “We know that we can rely on the on-site technicians, and that gives us real peace of mind.”
Screencore’s success
Due to the significant demand for recycled construction materials, some manufacturers are beginning to specialise in equipment for the sector.
Screencore’s international distributor network has supported a growing list of producers of recycled construction materials. This group of dealers and distributors has provided Screencore equipment to the US, French, UK, Australian, and South African markets.
Screencore offers a range of solutions, including tracked jaw crushers, Trident scalper-screens, Orbiter trommels and radial stockpilers to customers working in the sector.
The company can also develop a bespoke selection of stationary recycling plants based around its Orbiter trommel range, which works alongside Screencore’s stockpilers and scalpers.
“The Screencore product range was developed to meet the needs of the modern contractor and materials handling operation. We have set out to build the highest standards of equipment that helps people in the field be more profitable, efficient and effective in what they do,” Screencore director Ciarán Ryan said.
“We have also incorporated environmental efficiency into our processes to minimise customers’ carbon footprint. All this has meant that working with our distributors has seen Screencore equipment adopted on numerous projects, turning construction waste into reusable and/or resaleable products.”
The Screencore XJ is a machine crusher with a dual-power 1000x650mm jaw crusher. The crusher is fed demolished or excavated materials by an excavator or loading shovel before crushing to -100mm.
Any ferrous metals, such as rebar or wire, are easily removed for resale or recycling by the overband magnet on the XJ crusher’s discharge conveyor before being fed into the Trident 124 scalper/screener.
The Screencore XJ Dual-Power Crusher is easily transportable due to its lightweight, allowing contractors and rental fleets to move it with ease. The combination of the Screencore XJ Dual-Power Crusher and Trident 124 scalper/screener can be set up in less than 30 minutes.
“Screencore will custom-design conveyors, stockpilers and feeders to meet application requirements,” Ryan said.
“Our designs are renowned for their quality and ease of assembly, arriving in neatly packed containers and specified to over-deliver on throughput expectations.
“We also supply a range of air separation systems for stationary and mobile plants.
“Screencore has gained much experience using electric power from various sources. Main electricity has proved to be an ideal power source, delivering a cost-effective and environmentally efficient solution.
“Through this power source, or the dual-power solution, precision processing of materials is accomplished without producing the emissions that would be of concern, and at the same time, at a low [operating] cost.” AB
