Several trails prove that zipper has been consistent in churning the additives, new aggregates and fines at desired pace and variable depths
Asphalt Zipper which is manufactured in state-of-the-art facility with the latest laser welding and robotics at the only plant in Utah (USA) making it a fully American machine. The first Asphalt Zipper model was launched in India at the EXCON 2011 show in Bengaluru. Since then, the equipment has proved over at least at four successful operations and trials over a period of 6 months. A simple, portable rugged and highly reliable equipment capable of performing multiple tasks as that of pothole patch repairs, milling off bituminous layers for RAP recycling. Pavement dismantling for full depth reclamation (FDR) as  well as soil stabilisation for asphalt pavement projects are effectively done at 300 mm depths in a single pass.
The Zipper is available in covering 0.2 metres to 2.4 metres so that the host vehicle can be as compact as a skid steer, while there are models to suit the commonly available like JCB 3DX (backhoe loaders) for such works. The Zipper not only offers a very high return on investments as a milling machine, but also the application of FDR and Soil Stabilisation makes it a sure winner when compared to conventional and even higher-end machines.
The results from the Zipper have been    consistent in churning the additives, new aggregates, fines etc. at desired pace and variable depths up to 300 mm in single pass with full control by the host-vehicle operator or the wireless remote, making the job more easier. The result is a thoroughly mixed (homogenous), best suited for easy       grading and roller compacted later.
Application of the zipper is not restricted to these but reach more avenues of mining being launched shortly for coal and limestone. The major advantage is the easy mobilisation, which happens in a matter of minutes without any cranes or trailers. The controls are simple and easy. Minimal crew requirement also makes the operations cost effective. Cummins powered diesel engine is offered on models with customisation of cutting drums and varieties available to suit Standard, Fine Milling and Z-Mag for stubborn asphalt ensure that most applications are accommodated. Field trials at least two locations in Bengaluru have resulted in excellent stability of the newly constructed pavement with reduced thickness of BC layers while withstanding traffic abuse without any signs of distress over the past several months.
In September 2012, the Zipper was put to a rigorous test by the MES at the Leh airport runway asphalt milling at Ladakh. This happened when attempts to mobilise conventional milling machines failed to meet the limited requirements of the project. At an altitude where the hardships compound exponentially, the Zipper was an absolute success. The MES who are in charge of the airport required the milling of the runway and an overlay. Once the Zipper was selected by the MES, the BRDC team left no reason to excite the team with the Zipper’s pace and accuracy of the work. With recent trials with a local contractor near Mahape (near Mumbai) with NMMC excellent results were obtained when milled depths varying from 75 mm to 250 mm.
The Zipper has also performed soil stabilisation with renowned admixture manufacturers and for trials and work execution too. This was the second application that the Zipper proved its mantle and worth every paise.
Recently at the 2012 Australian Mining Exhibit, the Zip-Miner was launched and saw the most rapid sales of 4 units in less than a month. The order book has never stopped. In India what remains to be done is the demonstration of application on limestone surface mining and coal mining and similar applications of gypsum, laterite, salt etc. BRDC welcomes requests to conduct such trials for aspiring enterprise house.
More applications in the near future for national highway are in the pipeline which would ensure that the zipper is recognised as vital equipment for Indian contractors. As for consultants, they would look more closely as options best suited for their clients’ projects, covering mobilisation, internal site travel and ease of operation with ownership costs at a fraction, which is spent on larger machines with almost similar output.
Authored by -Chetan Kanakia, Director, Bharat Road Development Combines Pvt. Ltd.