Aggregate · AVL-WMM
Wet Mix Macadam Plant
Precision granular base layers — engineered for highway scale.
100–400 TPH
Output capacity
5
Model variants
18
Spare parts
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Overview
Wet Mix Macadam (WMM) is a mechanised road pavement base course in which precisely graded crushed stone aggregate fractions are proportioned, blended with a controlled quantity of water in a forced-action pug mill, and compacted in layers to form the dense, stable foundation beneath bituminous or concrete surfacing. The Avelta AVL-WMM series is purpose-built for civil contractors and road-construction agencies executing national highway, expressway, airport, and urban arterial projects where the base specification demands consistent aggregate gradation, uniform moisture distribution throughout every truckload, and full production traceability — requirements that manual water-bound methods cannot satisfy at commercial throughput rates or on tight paving-train schedules.
At the core of every AVL-WMM plant is a robust twin-shaft counter-rotating pug mill. Aggregate fractions spanning 0–40 mm or 0–53 mm to the approved gradation are drawn from individual hopper bins by variable-frequency-controlled belt feeders and metered continuously onto a collection conveyor. An in-line belt weigher measures the combined mass flow rate and feeds this signal back to the PLC, which trims individual feeder speeds in real time to hold recipe proportions within tolerance. Water is introduced through calibrated spray nozzles positioned across the mixer inlet, governed by an electromagnetic flow meter and metering pump, so that mix moisture is maintained within ±0.5% of target regardless of output rate or variation in incoming aggregate moisture. The forced-action mixing action ensures uniform coating and moisture distribution before the mix is discharged directly into haulage trucks for immediate transport and compaction.
Avelta engineers the AVL-WMM range for the sustained demands of long-haul infrastructure contracts — high ambient temperatures, remote project sites, multi-shift operation, and the throughput discipline imposed by rolling compaction crews. The plant structure is fabricated from structural steel section with heavy-duty corrosion-protective coating. All primary wear components — paddle tips, trough liner plates, and conveyor belting — are designed as fast-change, bolt-on items replaceable without shaft removal or specialist tooling, keeping planned maintenance windows short. The PLC supervisory control system supports multi-recipe storage, shift-based production logging for QA handover documentation, and optional remote monitoring so that the contractor's technical office and the Avelta field service team can track plant health and intervene before an unscheduled stoppage disrupts the paving programme.
Typical applications
- National highway base course construction to WMM specification (IRC SP:19 and equivalent international standards)
- Expressway and freeway sub-base and WMM base layer production for high-axle-load pavement structures
- Airport runway, taxiway, and apron pavement base courses requiring tight gradation and moisture uniformity
- Urban arterial road reconstruction and ring-road rehabilitation projects with high daily output demands
- Industrial estate internal haul roads, hardstandings, and manufacturing plant yard paving
- Port, logistics terminal, and container yard pavement base construction
- Heavy vehicle parking areas, freight depot yards, and bus depot aprons
- Rural all-weather road improvement programmes where mechanised WMM replaces traditional water-bound macadam
| Output Capacity | 100–400 TPH (model-dependent; stepless rate adjustment via VFD) |
|---|---|
| Mixer Type | Twin-shaft counter-rotating pug mill with replaceable Mn-steel paddle tips |
| Mixer Trough Length | 2,500 mm (AVL-WMM100) to 4,800 mm (AVL-WMM400) |
| Aggregate Feed Bins | 3 compartments standard; 4-compartment option; 15–25 m³ per bin |
| Feed Bin Total Capacity | 60–100 m³ (dependent on bin count and model) |
| Maximum Aggregate Feed Size | 0–53 mm; nominal WMM gradation 0–40 mm |
| Weighing System | In-line belt weigher, load-cell based, accuracy ±0.5% of reading |
| Water Dosing Range | 0–450 L/min; electromagnetic flow meter with PLC closed-loop control |
| Mixing Residence Time | 30–45 seconds (adjustable via discharge gate timing and shaft speed) |
| Installed Power | 55 kW (AVL-WMM100) to 160 kW (AVL-WMM400); 415 V / 50 Hz / 3-phase standard |
| Control System | PLC with 10-inch colour HMI touchscreen; ≥50 recipe storage; shift logging; USB data export |
| Paddle Arm Tips | 12–14% manganese steel, bolt-on; replaceable without shaft disassembly |
| Dust Suppression | Integrated water-spray dust suppression on hopper discharge and conveyor transfer points |
| Chassis Configuration | Bolted skid sections standard; road-towable trailer chassis available on AVL-WMM100/150 |
Working Principle
How the Wet Mix Macadam works
- 01
Aggregate Loading and Bin Feed
Crushed stone aggregate fractions — typically 0–10 mm, 10–20 mm, and 20–40 mm or equivalent site-specified splits — are loaded into the multi-compartment feed hoppers by wheel loader or conveyor. Variable-speed belt feeders mounted beneath each bin draw material at independently set rates, depositing the fractions onto a common collection conveyor below.
- 02
Proportioning and Belt Weigher Control
The combined aggregate stream passes over an in-line belt weigher that continuously measures total mass flow rate and individual feeder outputs. The PLC compares live readings against the stored recipe and trims feeder VFD speeds in closed loop to maintain correct aggregate proportions and target total output rate throughout the shift.
- 03
Water Metering and Pre-Wetting
Metered water is delivered through a pressure-maintained spray bar fitted with calibrated nozzles positioned at the mixer inlet. An electromagnetic flow meter linked to the PLC modulates the metering pump to maintain the programmed water-to-aggregate ratio; the system automatically compensates for output rate changes and corrects for residual moisture in the incoming aggregate.
- 04
Forced Mixing in the Twin-Shaft Pug Mill
Aggregate and water enter the twin-shaft pug mill together, where counter-rotating shafts carry bolt-on manganese-steel paddle arms that continuously tumble, shear, and advance the material through the full length of the mixing trough. The defined residence time of 30–45 seconds produces a uniformly moistened mix with consistent gradation, ready for immediate compaction.
- 05
Discharge into Haulage Trucks
Mixed WMM exits through a hydraulically actuated discharge gate into dump trucks positioned beneath the elevated discharge chute. The high-clearance chute geometry accommodates standard rear-tipping trucks and articulated dump trucks without ramp construction, and the controlled gate opening minimises segregation during loading.
- 06
Control Monitoring and Production Logging
The operator monitors aggregate proportions, water dosing rate, belt weigher cumulative totals, and active alarms from the climate-controlled control cabin via the HMI touchscreen. The PLC logs every shift's production record — quantities, recipe parameters, deviation events, and timestamps — to USB-exportable files for QA documentation and payment certification submission.
Engineered Advantages
Why buyers specify the Avelta WMM.
Closed-Loop Moisture Control
An electromagnetic flow meter and PLC-controlled metering pump maintain mix water content within ±0.5% of target across changing output rates and shifts. The system compensates automatically for measured variation in incoming aggregate moisture, eliminating over-wet loads that delay compaction and under-wet loads that fail density tests.
Heavy-Duty Twin-Shaft Pug Mill
The counter-rotating shaft assembly is dimensioned for continuous-duty multi-shift operation. Shaft journals run in sealed, grease-purged bearings with extended re-lubrication intervals, and the trough shell is lined with abrasion-resistant plate to protect the structural fabrication from gradual erosion by hard crushed stone.
Fast-Change Mn-Steel Wear Parts
Paddle tips, trough liner plates, and conveyor skirting are fabricated from 12–14% manganese steel and designed for bolt-on replacement without disturbing the shaft assembly or mixer drive. Standardised fastener patterns and pre-drilled liners reduce planned maintenance time and lower the skill level required for in-field servicing.
Variable-Frequency Drives on All Feeders
Every aggregate belt feeder is driven through an independent VFD, giving the operator fine-resolution control of each fraction's contribution to the combined stream directly from the HMI. Output rate can be ramped up or down during production to match haulage fleet availability without stopping the plant or interrupting the weighing loop.
Modular Skid Construction for Rapid Mobilisation
The plant is supplied in bolt-assembled skid sections sized to load onto standard flatbed trailers or within 20-foot containers, enabling rapid transport between project sites. Skid assembly at site requires no crane-intensive foundation work; levelling pads and anchor bolts are the only civil preparation needed.
Full-Shift Production Data Logging
The PLC records aggregate proportions, water addition rate, belt weigher cumulative totals, recipe deviations, and alarm events every shift to USB-exportable production reports. These records support contractor QA submissions, quality-assurance audits by supervising engineers, and payment-certification documentation on specification-controlled contracts.
Export Packaging and Commissioning Support
Avelta supplies the AVL-WMM range with sea-freight-ready export packaging, a first-service spare parts kit, and comprehensive installation and operation manuals. Field commissioning by Avelta engineers and structured operator training are available as standard service options, with remote diagnostic access via cellular modem for ongoing technical support.
Model Range
Choose the capacity for your output.
| Model | Capacity | Notes | |
|---|---|---|---|
| AVL-WMM100 | 100 TPH | Compact skid-mounted unit suited to rural all-weather roads, district highways, and small urban rehabilitation contracts where site access restricts equipment size. | Enquire → |
| AVL-WMM150 | 150 TPH | Mid-entry model for state highway and medium-volume contracts; three-bin configuration standard, four-bin available; towable trailer chassis option for frequent relocation. | Enquire → |
| AVL-WMM200 | 200 TPH | The most widely specified model in the AVL-WMM range, balancing output rate, installed power, and mobilisation cost for national highway base course packages. | Enquire → |
| AVL-WMM300 | 300 TPH | High-output configuration for large national highway or expressway contracts; extended pug mill and wider collection conveyor; four-bin feed system standard. | Enquire → |
| AVL-WMM400 | 400 TPH | Maximum-capacity model for major expressway, airport runway base, and critical infrastructure projects demanding uninterrupted multi-shift production at volume. | Enquire → |
Spare Parts
Wet Mix Macadam Plant spare parts
Genuine, precisely-toleranced components for the Wet Mix Macadam Plant. Every part below has its own page with details and a direct enquiry — or message us the part you need.
Mixing Unit
5
Feed System
6
Machinery
3
Controls
3
Ready to specify your Wet Mix Macadam Plant?
Message us your target capacity and site details on WhatsApp, call +91 00000 00000, or request a detailed proposal.