Asphalt Recycling Plant (RAP)

Turning old pavement into new mix

Reclaimed asphalt pavement (RAP) still contains aggregate and bitumen. A hot recycling plant adds a second, dedicated drum that warms RAP at a controlled temperature. The heated RAP is weighed and added to the mixer with new aggregate, bitumen and, where specified, a rejuvenating agent.

When it pays off

The case is strongest where milling is routine — resurfacing programmes, city maintenance and highway rehabilitation — and where new bitumen and quarry aggregate are expensive or far away.

What to plan

RAP must be managed: crush and screen it to consistent sizes, keep stockpiles covered, and test it regularly. We help size the RAP line to the tonnage you can reliably supply.

The RAP line, unit by unit

Unit	Function
RAP feed bins	Meter crushed RAP by belt feeder, separately from new aggregate
RAP drying drum	Warm RAP at controlled temperature without direct flame contact
Heated RAP surge bin and scale	Hold and weigh hot RAP for each batch
Main plant (batch)	Dries and screens new aggregate, weighs bitumen and filler, mixes the batch
Additive dosing (option)	Adds rejuvenator or other additives per batch

When an RMX-R makes sense

Condition	Why it matters
Regular milling work nearby	You need a steady RAP supply — at least several thousand tons a year
Expensive new bitumen or aggregate	Savings scale with the material RAP replaces
Specifications allow RAP	Many agencies set limits by layer; check yours
Space for RAP processing	Crushing, screening and covered storage need room

If you only have occasional millings, a cold RAP feed collar on a standard batch plant may be enough.

RAP content in practice

Hot recycling plants commonly run 30–50% RAP in the mix; the exact figure depends on the specification, RAP quality and the layer being produced. Higher percentages need good RAP management and a mix design that accounts for the aged binder.

RAP processing and stockpiles

• Separate millings from different roads where the binder or aggregate differs
• Crush and screen to two fractions (for example fine and coarse) for better control
• Keep RAP covered — wet RAP limits output and raises fuel use
• Sample and test binder content and gradation for each stockpile

Price range

Indicative FOB prices for RMX-R plants run from about $245,000 to $450,000 across 80–160 t/h. See the model-by-model price page and the price guide for details.