Project ‘Croydon Asphalt’ When Croydon Asphalt came to Horrod’s to refurbish and remove a 4 ton mastic mixer from its chassis and purpose build a lorry chassis on which to  mount it, Horrod’s documented the process from start to finish.

The Project:  

Croydon Asphalt presented Horrod’s with the challenge of taking an old 4 Ton Oil-fired mastic asphalt mixer that had been converted to a gas-fired heating system from a road towable air-braking chassis, refurbishing and placing it on the back of their vehicle making what was commonly called back-in-the-day a ‘showboat’.

The Process:  

The Mastic Mixer preparation:

Horrod’s started by removing the engine cover, mixer body, engine and gearbox from the existing chassis. Once this necessary task was performed, the refurbishment could begin.

4 stirrers and stirrer caps were removed, the U/Pan was cleaned and a small section replaced to put the pan back to a useable condition – the existing stirrers were cleaned and built up to allow for the correct pan clearance and 2 loading lids were replaced.

The next step was to close off the existing burner aperture under the front end of the mixer and re-site them at the rear of the machine for the new heating array a 3-burner Propane gas-fired unit complete with pilot protected flame failure system making them easier to access and maintain.

The outer case, 2.5 mm mild steel sheet was removed along with the lagging – new 3 mm outer case sheets and lagging were fitted to the offside and nearside of the machine body.

The next challenge was to compact the front end of the machine since its road towable length was 5½ metres, with the new vehicle only providing 5 metres total length, the engine, engine extension shaft and jockey pulley assembly were moved which allowed us to shorten to the exact length required.

The asphalt outlet commonly called a ‘banjo’ was dismantled, cleaned and repaired before being refitted.

The engine and gearbox were checked and run to ensure working order was maintained.

The Vehicle Preparation:

The tipper lorry had to be stripped right back, leaving us with a cab and chassis - removing the tipper body, tipping ram, hoses & P.T.O.

Building from the chassis fitting larger chassis rails to accommodate the mixer sub-frame; the construction of the sub-frame was designed to allow manual loading of block materials from the nearside which provided a higher working platform in order to load the machine with the asphalt but with proper safety level to prevent an operative from falling inside. This design allowed Horrod’s to construct 4 storage cabinets on the underside of the loading platform providing maximum space efficiency.

The off-side working platform was constructed to be lower. Guard rails were designed and fitted so as to allow them to be ‘dropped down’ which in turn allowed the men to lower these guard rails in order to load and store signs and plastic barriers without the need of traversing the rear steps of the platform.

Now Horrod’s could mount the mixer body to the sub-frame, they went together like hand in glove.  4 x 47 kg bottle carriers were fitted behind the cab with side-steps fitted both offside and nearside for safe access and easy loading of propane cylinders and entry to the engine compartment of the machine.

A rear fold-down platform below the ‘banjo’ was fitted and tested to the correct working height necessary for decanting the asphalt safely, the platform can be used with buckets and with wheelbarrows, for which a dedicated ramp gives access to the platform.

Once all engineering, fitting and building were complete the mixer body was dismantled from the vehicle and both units were sprayed. Once the paint was dry the unit was reassembled and ready for Croydon Asphalt to collect.

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