An asphalt mixing plant capable of producing up to 300 tonnes per hour
After one year of works, the new asphalt mixing plant in Bastogne went into operation this summer. The first trials started in July, ahead of the start of production in August to supply construction sites in Belgium and Luxembourg. During its first month of operation, the plant produced 14,500 tonnes of asphalt mix, intended for the development of the site itself and for the Socogetra and Karp-Kneip construction sites.
The plant can produce 240 tonnes per hour for abrasion layers. Its capacity is 260 tonnes per hour for foundations integrating 60% of old asphalt, and up to 300 tonnes per hour when that proportion rises to 80%. Since it went into operation, its energy consumption has decreased by 20% compared with the previous facility, while maintaining a continuous output of 240 tonnes per hour.
The site is equipped with covered storage areas capable of storing 8,000 tonnes of old asphalt and 10,000 tonnes of sandstone and limestone. The materials are transported to the plant via an underground conveyor belt. A team of six people is responsible for running the plant.
Geert Aelbrecht, General Manager of BESIX Affiliates: “With this new plant, we are strengthening our ability to supply construction sites as close as possible to their needs, both in Belgium and in Luxembourg. It is a strategic investment: it secures our supply chain while enabling us to produce more with recycled materials while using less energy.”
More recycled materials to reduce reliance on virgin resources
The plant was designed to comply with current standards on emissions of dust and pollutants. It also makes it possible to incorporate a high proportion of old asphalt mix into production. During the trials, asphalt mixes containing 50% recycled materials were produced for use on construction sites. For the development of the site itself, this proportion reached 90%.
These materials come from milling off road surfaces during refurbishment works. After crushing and screening, they are reintroduced into new asphalt mixes. Their reuse reduces the need for new granulates and allows some of the bitumen contained in the old roadway to be recovered. Combined with the plant’s reduced energy consumption, this process helps to reduce carbon emissions associated with the production of asphalt mix. Its precise effect will have to be determined on the basis of a clearly defined calculation method and reference scope.
Local supply to construction sites in Belgium and Luxembourg
Owned jointly by Socogetra, a subsidiary of BESIX Group, and Karp-Kneip, Bastogne Enrobés is strategically located to serve the province of Luxembourg in Belgium and the north of the Grand Duchy of Luxembourg. This proximity reduces supply distances and meets a need in an area which, until now, has lacked an asphalt mixing plant in the vicinity.
The plant is expected to produce around 160,000 tonnes of asphalt mix per year for BESIX and Karp-Kneip construction sites, to which between 10,000 and 20,000 tonnes could be added for third-party clients. In this way it strengthens the capacity of both partners to secure their supplies, serve their markets more locally and offer asphalt mixes integrating a high proportion of recycled materials.