Bitumen Spray Bar and Nozzles

Trace-heated bitumen spray bar and stainless steel atomising nozzles delivering a metered, uniform bitumen spray across the aggregate charge in the pugmill.

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At a glance

Bar material	Carbon steel pipe, Schedule 40 or 80, 25 – 50 mm NB
Trace heating	Electric MI cable 15 – 30 W/m or steam-jacket (per plant spec)
Operating bitumen temperature	150 – 170 °C
Nozzle material	Stainless steel 316 body, hardened orifice insert
Nozzle spray pattern	Flat-fan or full-cone, 25° – 60° included angle
Nozzle orifice diameter	3 – 8 mm (flow-rate matched)
Number of nozzles per bar	6 – 20 (mixer width dependent)
Bitumen supply pressure	0.3 – 1.5 bar at bar inlet

Overview

The bitumen spray bar is a heated pipe manifold mounted above or within the pugmill mixing chamber on the AVL-ABP batch plant. It carries a row of spray nozzles spaced uniformly across the full mixer width. When the aggregate and mineral filler charge has been weighed into the mixer and is in motion, the plant control system opens the bitumen weigh-scale discharge valve and the spray bar delivers the metered bitumen dose simultaneously as a fine, distributed spray across the full width of the tumbling aggregate mass. The spray phase typically lasts 4–10 seconds, and the quality of that distribution determines the subsequent mixing time required to achieve full coating.

The spray bar must maintain bitumen at 150–170 °C right to the nozzle tip to prevent viscosity increase that would degrade atomisation and spray pattern. Trace heating (electric mineral-insulated elements or steam jacket, depending on plant specification) is therefore an integral and critical part of the assembly.

Function

Non-uniform bitumen distribution from blocked, worn, or cold nozzles creates dry aggregate zones and over-rich bitumen accumulations within the same batch. This grading cannot be corrected by additional mixing time alone — aggregate particles already coated in excess bitumen will agglomerate rather than separate under paddle action. The result is variable coating quality that may produce asphalt with localised voids or flushed areas on the road surface. Each nozzle must deliver the same flow rate and spray angle; partial blockage in even one nozzle shifts the transverse distribution pattern and increases the mixing time needed to compensate.

Construction & quality

Spray bar body: Schedule 40 or Schedule 80 carbon steel pipe, nominal diameter 25–50 mm, fabricated with end flanges for connection to the plant bitumen supply line, and a thermocouple or PT100 temperature port for monitoring actual bar temperature at the control panel. Trace heating: electric mineral-insulated cable elements, rated 15–30 W/m, factory-wound along the bar body and terminated in a junction box; or steam-jacket where plant uses thermal oil heating. Insulated with mineral-wool blanket and aluminium-foil vapour jacket. Nozzles: stainless steel 316 body with hardened orifice insert, flat-fan or full-cone spray pattern (±25°–60° included angle), threaded BSP or NPT into the bar at equal pitch across the mixer width. Orifice diameter 3–8 mm matched to the plant's bitumen pump pressure and required flow rate.

When to replace

Individual nozzles delivering reduced or zero flow, visible as dry aggregate patches on the mix surface immediately after the spray phase
Worn nozzle orifice producing a wider, unfocused spray pattern with larger droplets and poor atomisation
Bitumen dripping from the bar between spray cycles, indicating valve seat wear or nozzle check-valve deterioration
Bar body temperature below the set-point despite heating power being on — indicating trace-heating element failure
Inconsistent aggregate coating results across batches using the same recipe, bitumen grade, and aggregate temperature

Compatibility & fitment

Avelta spray bars are fabricated to the mixer width, nozzle pitch, and supply-flange standard of the AVL-ABP pugmill for 0.5 t to 3.0 t batch capacity; nozzle count, spray pattern angle, bar heating type, and connection flanges are matched to the plant's bitumen metering and heating system.

Why buy from Avelta

Avelta spray bars are fabricated with trace-heating elements factory-wired and thermocouple ports installed, supplied with a full nozzle set pre-fitted and flow-checked, so the replacement bar can be installed and operational within a single maintenance window without nozzle pre-assembly or electrical re-termination on site.

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