IRC :90-1985

GUIDELINES FOR SELECTION,

OPERATION
AND
MAINTENANCE OF BITUMINOUS
HOT MIX PLANT

THE INDIAN ROADS CONGRESS

1985

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 90- ~985

GUIDELINES FOR SELECTICN,

OPERATION
AND
MAIl TENANCE OF BITUMINOUS
HOT MIX PLANT

Published by
THE: INDIAN ROADS CONGRESS
Jammigar House, Shabjahan Road,
New DeUil~110 011
1985
Price Rs M!~4
(Pita packin~1and postage)
<<
 I

IRC:IS.MSS
First publibsd : Sepipaber 1985

:f.~ •o• ‘.~:•

(RIgIita qnM~unaid 7),MiIs at naad)

PrkIsd:st PRWr*ID, Nn DiN-lb 0$

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<<
 IRC:90.1985

CONTENTS

Page
I. Introduction ... 1
2. Classification ... 2
3. General Description ... 6
4. Selection of Plant ... 21
5. Layout, Erection and Trial Run ... 22
6. Starting, Shutting Down and Storage ... 28
7. OperatIng Techniques ... 31
8. MaIntenance and Upkeep ... 41
9. Requirement of Materials and Tools ... 51
10. Safety ... 53
it. Modem Trends in Technology ... 55

LiST OF APPENDICES
Appendix I: Information Recommended to be 57
Supplied by the Purchaser with an
Enquiry or an Order
Appendix 2: Information Recommended to be 58
Supplied by the Manufacturer
AppendIx 3: Method ofCalculating Rate of 59
Hire Charges
Appendix 4: Output Analysis ot a Hot Mix Plant 61
Appendix 5: Sample Calculations to Workout 62
Requirement of Hot Mix Plants
Appendix 6: Staff Requirement ,.. 63.
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P C 90 :1985
LIST OF FIGURES
Fig. 1: Bitumen Batch Mix Plant 7
Fig, 2 Bitu men Continuous Mix Plant S
Fi~g. 3 Cold Aggregate Feeder ii
/1g. 4 Cold, Elevator 12
Fig. 5 Dryer Unit 13
Fig, 6 Dust Collector 14
Jig, 7 Hot Elevator and (li-ad flon Unit - - 19
Hg. 8 Ni ixer Unit - -- 20
Fig. 9 Typical Continuous Plant and Piping - - - :23
Arrangement
to Pert Chart for Erection and com mission
of 20/30 TP}-E Plant

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 901985

GUIDELINES F’O.R SELECTION, OPERATION AND

MAINTENANCE or BITu:MINm’S HOT MIX PLANT

INTRODUCTION

Flexible pavements of mode rn highways are constructed by

Laying hot mrx of stone aggregate and bitumen of the desired
compos~t1onin pre determined thickness. For achieving the
designed strength of pavement~, the hot mix has to conform to
aid dost n spc t. if ahons in rcSpcL I @1 ci tding and q uantities
of difierent sizes of stone material, quantity of bitumen, tempera-
ture of the mix, etc. Such hot mix with ngid quality control can
only be produced by the machine cal led Asphalt Hot Mix
Nan I:

Hot ni ix plant can achieve:

(1) Uniform drying of aggregate to desired moisture content,
(2) F’re4eating of aggregate to the required temperature.~
(:it Accurzste control on the grading and quantity of aggregate.
(4) Accurate control on the tluantity n~d tempera lure of bitumen and
mix
(5) Urtiform coating of stone particles with bitumen.

The above factors are very vital for bituminous road cons—
it w lion ot h1h st in d tt ds intl signify thu importance o~hot nux
~ tnt I h~ u t. of hot ii t s p1 ml is also n~tesstry lot more
efflt.:icnt and economic~ utilisation of available resources such
!as bitumen, the cost of winch has increased ma,ntfolds in the
recent past

For the above purpose, the Highway Construction and

Mechanisation (citit ru ittee constitute ci a Working Ci roup consisting
of S/Sh ri 0, Viswanathan, 1.K Dugad, 3$, it. Moses, V.8. Pandit,
A representative, each of C PWD, Mfs Marshall & Sons, .M ‘s
Say ill lion & Fntnnmu in ( ii tnd PcI s Mtllais

<<
I RC 90-1985

This Working Grou p firm Used the draft Guidelines: in their

meeting he Id on 16th August, 984 and these we re. later considered
by the Highway Construction and Me.ch anisation Committee in
their meeting held on 241h Scptem her, 1984 (personnel given on
the inside of the front cover) -

‘Fhe Executive Comm ittee in theèr meeting held on 14th

Janua ry, 1985 approved thi.rse Guidelines which were conside red
by the Co unclE in their 112th and 113th meeting held at Luckno~s
on 3rd and 7th February, 1985. At this meeting, the Council
constituted a. Subcorn ni ittee. consisting of’ D,G. (R+D~), Sh ri CL
V iswanathan and Sb r I A. P. Paracer and a,uthorisecl them to
finalise the docu inent in Eight oF the corn ments of the members
mdc i.l u ring the meeting and received in writing, This Soh~otn-
rnittee in its meeting on 2nd August, 1985 finalised the Guidelines
For Selecticn, Operation and Maintenance of Bituminous Hot Mix
Plant br publication,

An attempt has, therefore, been made in this book to pres:ent

important aspects of operatin n and upkeep of Hot Ni ix Plants so
as to get best out of them,

2. CLASSIFICATION

F-lot mix plants are mainly classified on the following basis

(I) CapacOy
(2) MobiLity
(3) Prime Mover
(4) Measuring system

(I) Capacity Plants are classified on the basis of per

hour out put capacity~ Plants of the following capacities are gene-
rally avail able in the country:

(i) 6 tonnes to 10 tonnes hr

Iii) 10 tonnes to 20 onnes
1lhr
(iii) 20 lonnes to 30 ionnesihr
(iv) 30 to 45 tonnesflir and above, upto 120 ~onne~hi

The lower output is at 6 per cent moisture content and higher

one at 2 per cent moisture content (by weight) of aggregate.
I

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 iiu: : 90.l9t1~E

The following are the limitations for use of mini hot—mix

plant 6-10 tonnes/hour capacity,
Hot mix plant of 6—10 T. P.H. capacity does not ha~e
era dation control unit. Hence such plants can he used for patch
repairs and premix carpet work only and is not suitable for
bituminous macadia ni or asphaltic concrete. This work is inten —

(led to cover big size hot mix plants. Only generally conforming
to iS : 3066-1965,
(2) Mobility: The plants are generally classified as: static,
portable and mobile,
I) Static phml: A plant designed to be erected on a site permanently,
with no special arrangement to facilnate its removal and shilling.
(iii Porlable plant: A plant so designed thai it may he easily dis-
assembled into sections, to be transported by road or rail.
(iii) Mobile plant: A plant so designed that it may he easily separated
into sections, and each section equipped with pneumatic tyres, for
eiisy movenieat, The length, width and height ol any section
of the plant, ahen prepared for moving, should prefer ably not
exceed it) m, 3 m, and 4,5 m respectively, to meet traffic megula—
a)n -
Generally, plants upto 10 tonn es capacity are. fully mobile
and used for patch repairs or premix work, Plants above 30
tonnes capacity are portable or stationary.
(3) Prime Mover: Plants are also classified on the basis of
the type’ of prime-mover, viz. (a) Diesel Engine or (h) Electric
Motor,
Comparative advantages and disadvantages of diesel engine
plants:

Advantages:
(a) The unit is self—contained, and therefore, the plant can
he installed and used at proposed site without m uch delay as it
is not dependent upon any external sostrce of power viz, electri-
city.
(bE it can be used at any site far away from cities and
towns where there is no power line passing nearby.
(c) The operators and mechanics are generally more con—
versent with the upkeep of mechanical components.
(d) The Department need not pay the fixed minimum
charges to the Electricity Board, whether the plant runs or not.
3
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tRt’ 90- 19ft5

(e) the. supply ot’ diesel oil is noss —a—days moore regular that:
elec:tric ixrtve’r which is affected by power cttts and erratic supply.

l)isadvantages
(a) Engine t epairs are treq tie tit ci tie to d ttsty and hot atmos-
pheric conditions prevailing at hot mix plant sites,
(b) Down time is more. as repairs of engines take thrte,
(c) In smaller engines upto 5 HP, the starting operation is
by handles, Hence it causes fatigue. to the operatmg staff.
(d) Overall performartce is’ not so good and outturn per
ann tim is less resulting in higher unit cost of prod ttction
-

Comparati~e advantages/disadvantages of electrical motor driven

plants

Advantages
(i) the inttial capital cost of electrical motor driven plant is
less than the diesel engine driven one,
(ii) Starting and control of various motors is quicker and
‘tnooth Ope ration by pttsh button in easy reach of dl river means
,

less fatigue.
(,tii ) Electrical motors located at dlitierent places can be
started and stopped from one. control panel by a sin gie operator
thereby red tteing o1:.erating expenditure,

(is) Maintenartce and re patt ot electrical rrtotors and switch

g~cars is negligible compared to the diesel engines.
(v) Electrical operation is smooth and con venient.

flisachantages
(I) Plants cartnot be straight away used if electric supply is
not available within reasonable reach,
(1)) if power tratisrnissiort lines are to he specially extended
to the stork area, located far e.way from the main high tension
lines, the cosl involved will be very high and uneconomical.
(iii) In case of restrictions on use of electric power short
5t1 pp~)~’olta Il,et
fluctuations, gene rators a.re procured at an extra
cost sshe rc’by the cost of operation irtc-reases appreciably.

<< 4
 9O~]9~15

(4) Measuring System There are two types of plants,

namely, Batch Type and Contin anus Type. Quality and cons~s~
tency of the mix will not be affccled due to break down of the
plant, interruplion in supply of aggregate or slight variation in
specification ol stone chips supplied by ditlerent quarries.

Buick Type (Fig. 1) In hatch plant each batch of aggre~

gate and asphalt is accurately weighed by means of weigh hopper
scales.

Advuntages
(a) Every hatch can be checked accurately and quabty con~
trok will he better as such consistent and accurate mixes can be
obtained

(h) The specification can he easily changed at any moment

batch type plant, say from B.M. to A.C., whereas in the conti~
nuous plant adjustments at various places, recaliheration of feeders,
gradation control, unit filler feeder and bitumen system a~e
necessary and may take 4 to 5 hours. Hence if the specification
of work involves frequent change, it may he preferable to go in
for batch type plant.
(c) Even if the temperature of hitum en is not coni rolled
accurately and the viscosity is Ion’ (volume only s’a ries on this
account), the mix will not he affected since bitumen supply is
regulated by weight of each batch.

E)isndvantages

(a) Initial cost is higher.

(b) The erection and dismantling is more difficult as height of
hatch plant is generally more.
(c) Output is relatively low as each batch is to he weighed.

(d) As the weighment is done manually by the operator,

personal factor is involved in weighing each batch and this may
cause some mistakes. Also there may be parallax or zero error
~nreading dial scale.
Continuous Type : (Fig. 2) ln continuous plant the quanti~
ties of aggregate and asphalt are measured by volume i.e. the flow
through the gates~
<< 5
 :90 1983

Advantages
(I) More output, since! each hatch is rtrtt weighed befdtre
mrt ix ing.
(!2) Initial cost is less than the batch type piartt.

(1) It a large quantum ot work of the sank spe elite tttdtn is tn

vol ved, this type of plant can cater to the requirement fairly well,
and economically, as once the gates/valves are adjusted, no
personal facto r is! involved~so far as operator is conc!erned,

Disadvantages
(I) If the cold feed is not strictly c:orttrolic d or if the operator
is careless in not waiching th!e smooth flow of aggregates the!!
results cottldl be! bad.
2 Btn Its L I indicators ai net essa iy ts the flow ol m aterials
depends- on the’ depth o!f aggregate in the bin o’ver the! feed
con v eyor,
(3) The vol time of chips differs with the moisture content a!n!d
hence! will not be the same at the feed end and after drying!!.
Hence acctt rate mnixes ate not possible. Also the moisture content
may s’a my with each stack and each part dtf the clay to a certain
extent,
(4) Bitumnen is suppi ied v olu metrically, and sprayed conti~
n uously irtto the mixer by a! pump geared with apron feeder, If
te mupe ratu re o l~hitu men is not controlle dl, depending upon viscosity,
the volume will S’it ry and bitumen content !wiIi not he uniform,
5) We igh ht idpe tS t eq one ci to know the tctual qnantit3
(tonnage) of mix produced by the plant,
3, GENERAL DESCRIPTION
flot mix plants shou!l ci have the following main components
(1) Cotd Aggregate Ft
(2) Dryer Unit
(3) Dust Collector
(4) Hot Elevator
(5) S’econdary Ci radatien Unit
(6) Mineral Fitter SLipply Unit
(7) Bitumen U 1
(81 Mixer Unit

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 Rc: : 90~t955
(I) Cold Aggregate Feeder (Fig.3) This can be portable on
pneumatic tyres or stationary, This has two or snore bins or cornS
partnlents, each provided with mechanical means for feeding
aggregate at a uniform and predetermined rate, to the cold eie’vator
or directly into the dryer. The!feeder provides for the adjttstment
of total and proportionate feed anti is! capable of being locked in
any setting. Sitice this is a critical control point in the production
of asphalt mix, its capacity shnuld be realistically fixed, Accord-
ing, to iSI, the capacity of the feeder, with the gates half’ dosed,
shall not be less than the capacity of the dryer.

The design should be such as to minimise clogging or arching

of aggregate in the bins, For this purpose, it may be preferably
to have sonic of the bins with itidividually reciprocating/vibratory
feeders, A grill is provided over the bins to! prevent large pieces
of stone, stick or root, clogging the gates. One of the hins feeds
finer material like sand or grit, as the case may he, whereas othe,r
two bins feed the aggregate of different sizes, The gradation of
the composite aggregate is controlled by adjustable gate opening
befbre discharg,e on the belt conveyor for being fed to the! dryer
by the cold elevator,
he t’eerling height of tIle bins should be about lj to 2 metre
for loading manually. Feed ing platfor rtt is otherss ise essential,
Alternatively, when front—end—loader is used maximum dumping
clearance of loader will limit the loading height i .e, the height rtf
the bins,

(2) Doer Unit : It consists of cold aggregate elevator, dryer

elm u in, burner an el blower,

(a) Cold aggregate elevator (Fig.4) ‘‘he’ aggregate (cold metal)

l’eed obtained from feeder or shaker feeder is raised to a ss!tfficicnt
height with the help of cold elevator, and discharged into the
feeding chute of dryer drum. The drive for cold elevator is gi; en
at the upper shaft sprocket, and is obtained ft om the shaft and
sprocket driven by dryer drum. The cold elevator is not mally
a bucket conveyor, but can also be other types like belt conveyor,
The links are made or malleable iron castings. The betckets are
made of M~S,sheets with hard edge.

(b) Dryer drum (Fig.5) The dryer druni is a revolving cylin-

drical drum of M.S. Plate about 12 mm thick and of size ito 2 m
dia a nd 3 to 12 m long, depending on the capacity of the! plant,
in this, aggregate is dried (final moisture content should net he
more titan 0,5 per cent by weight) and he’ated to proper tempera-
9
<<
lttC 001985
tare. Tile dryer should have capacity to heat the aggregate upto
180”C. The drum generally rotates at about 10 to 20 r,p,ni.
!!!I~he burner is located at the discharge end, so that the
aggregate get less heat initially, and maximum before discharge,
the hot gases and aggregate moving in opposite directions, A
t’uel pump linked with the drum drive’ (to prevent the use of the
ho rite r with a stationa my die in) supplies fuel to the burner,
!ihe flow of the aggregate through the drum is achieved by
L’tthem inclining the drum away from the feeding end (in which
case the flights are straight) or having horizontal drum (in which
case the flights are inclined), The series of longitudinal cups or
channels called ‘Lifting flights’ pick up the aggregate, and
cause them to cascade through the burner flame, d!ur ing
its travel f’rom feeding end to discharge end, A pyrometer is
fitted at the discharge end to measure the temperature of hot
aggregate, ‘The slope of the dryer, the arrangement of the flights,
the speed of’ revolution, the length of the dryer drum determine
the time required for the aggregate to pass through the dryer
drum, and hence they can be varied to a certain extent, !]~he
controls are, no doubt, available for varying aggregate feed and
heat from the burner,
(ci Blower and burner: The low air pressure oil burner
‘,vhich uses light diesel oil or furnace oil, as fuel, is used to heat
the aggregate in dryer drum, it is mounted at the front end of
dryer drum, and refractory brick and clay lining is provided
to prevent burning of mouth of the dryer drum. It should he
ensured that the flame of burner is directed centrally in the
dryer drum. The burner should be of adequate capacity and
should ensure complete combustion, without leaving a film of
carbon on the aggregates, which would prevent the asphalt from
sticking. Incomplete combution also results in excess eomsump-
tiort of hid,
1 he consumption of fuel of’ the burner for 20—30 TPH plant
may vary from 100 to 250 lit/hr or from 3.75 to 7 litres per ton
of mix produced depending upon the moisture content ofthe
aggregates, ambient temperature, type of mix etc. The consump~
tiot!t of fuel oil in the bttrner being large, the economy of the
plant operation would be affected, etniess the jets in the burners
are! of the right type, size and well maintained, Air is supplied
by high speed low pressure blower to ensure complete combustion.
(3) Dust Collector: (Fig~ 6) The! exhaust fan which pro-
ides the draught to draw the flame and hot gases through the

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dlryer also dmaws out a portion of the fines and dust from the
aggregate as it passes throetgh the dryer and screens. in order
to red uce the (Just nuisance and to recover usable fines, a dust
collector is used as an integral part of the dryer draft system~
Generally, the collector is of the cyclone type in which the
lines are separated by centrifugal force, i’he air and hot gases
laden with dust and fines enter the cyclone tangentially at the
sidle near top, and exhaust tht’oi!tgh the outlet pipe which extends
part way down into the cyclone front the top at its centre, The
collected fines are drawn from the bottom by means of sere n’
conveyor. If the fines! are suitable for use in the mix, they are
then Rd in correct measured quantities into the mixer by the
tnineral feeder, Sonic mixes require more fines than are recovered
by the dust collector, In this case, additional fines or min~
e ral filler are added through the filler feeder ~ir an auxilIary fines
fee dr.
(4) Hot Elevator: (Fig. 7) Hot elevator is a bucket
and chain conveyor sinular to cold elevator, hut totally enclosed,
which lifts the dry aggregates to the scTeens. The bucket size
is almost double that of the cold elevator buckets, The hot
elevator can be a single chain with centrally fitted buckets, ot
double chain, in which case bttcket is bolted at the end to each
third Iink of the chain,
However, the double chain elevator is not recomntended,
since the pitch of’ chain sprocket gets disturbed dite to differential
expansion during working,
(5) Secondary Gradation Unit: (Fig. 7) This consists of
screens and! storage bins for proportioning the aggregates.
(ii Screens: Normally four deck screens are provided,
s%hich are fiat, vibrating type, inclined downwards and vibrating
at high speed. The amplitude of the vibration is adjustable.
The screens have a normal capacity slightly in excess of the
full capacity of thr mixer or dryer, and operate on the ~reject
system’, wherein the Red is first c!lelivered to the largest aperture
size screen through which material passes to the next smaller
size, a rtd so on, the over—size or ‘reject’ material from each going
to the appropriate storage bin,
(ii) Storage bins : There are four aggregate storage coni part-
meats, with discharge gatiis in each, !Each hot bin is provided with
an overflow pipe of st!t!fiieient size and location, to prevent any had:-
Icing up of material into the bin, or against the screens, Adequate!
tell—tale devices sitot!tldl he provided fru’ indieating~the levels

<< 15
1RC : 90-1985
of aggregates in the bins, to warn the operator when aggregates
level gets very low in any bin and regulate the cold feed suitahIy~
(iii) Aggregate proportioning twit
Batch type plant In hatch type plant, means for accurately
weighing, each size of aggregate and mineral filler, in a weigh box
or a hopper, suspended on scahis, are provided to hold a full
batch, Norntally, the weigh hopper is suspended on a balance
lever system, with knife edges. The weights are recorded on
a large diameter springless dial scale. i’hus the weights indicated
in the dial are the cutn ulative weights of various types of
aggregates discharged from the! bins to the weigh hopper. The
radial discharge gates of the various storage bins are operated by
hand, or ~osver operated.
~fl p~~p~u)flfi~g itnit for tneasuring liar the asphalt is similar
te the aggregate, except that the dial scales for weighing the bitu-
men usttally read to the nearest 2 kg.
If the right amount of~asphalt and aggregate are not mea-
sured out, a good mix cannot he had, Not enough asphalt
give!s a mix that does not have all the aggregate coated, and
therefore!, it will not hold together on the road as well, Too
much asphalt will give a soupy mix, with little stability and blec’—
dIing~wil I result,
in recent years, there is t.t trend towards fully auton’atie
operation, Such plants handle the entire measuring and mixing
phase a!otornat~cally a ad include safeg,urads to ensure accuracy,
batch after hatch, This frees the operator to co’ordinate other
plant operations, sttch as proper bitt balancing through remote
feed control and reg ulatian of aggregate temperature through
remote burner control.
Ctntint,ous type unit : While in hatch plant, the aggre-
gates’ and asphalt are generally measured by tveight, the same
are measetred by votttme in contin onus plants It is, therefore,
neeL::ssary that convenient and accurate scales atid facilities
shall have to he provided separately for cross checking the neces-
sary devices by weight.
itt continuous p1 artts, each bitt or compartment li as an acert—
nt tely controlled individ ual ciate to form an orifice, f’or vol ott etni—
cal ly measuring: the mate rial discharged t!~rorneach comnpartnient.
The orifice is rectangular with its width constant, and height
variable hy means of niechanica I ly operated gate, w hich can be
locked in any position. Indicators are provided to show gate

<< 16
 n c: so 985

opemngs in ccntRneters, Plate a pron feeders convey the materiel

tro iii the bins, The plate apron feede rsar e equipped with a dust
prool revolution counter to corn pute the da~sproduction The
a~rgregatefrom apron feeders is dumped into a siagle discharhe
chute, which feeds the rrnxer.

A metering pump supplies bitumen in metered flow to the

spray bar placed above the pug milL A specific arno alit of
bitumen is disehaiged 1) orn the pu m~iat every revolution of the
pump shaft, Hc~ncethe ci ischa rpe can be varied by varying the
RPM of the pump shaft. For this purpose, a set of sprockets
are provided. The metemin p pump is positively interlocked with
plate apron feeder to ensure synchronisaUon of aggregate and
bitumen teed.
(6) Mineral Filler Supply Unit Sonic mixes require more
fines than are received by (lust collector. Hence” means are
provided for conveying, proportioning, and charging mineral
filler, directly into the mixer to the extent of 6 per cent by wcight
of the hot mix plant output.

(7) Ilitunmen Unit Tanks for storage of bitumen shall be

eq uippe cI fbr heating the material, unc:i e r effiective an ci postive
control at all times, to the temperature requirements set forth in
the specifications for the paving mixt ure. Fl eating is accomplished
by steam or oil coils, electricity or low flame tempe.rat err oil
burners. If oil burners are used, lire brick, cast iron or other
suitable liners shall Lie provided so that the flame cannot impinge
directly on the tank plates or flue tubes, A circulating sys:tern ibm
the bitumen is’ provide ml for proper and continuous circulation
between storage tank. and proportioning units during the entire.
operating period~ Suitable, arrang..e ment is providerl tbr recording
the tern perature at the tanks and in the circulating syste in. All
pipelines and fittings are steam or oil jacketed and properly insula’
ted to prevent loss of heat, Storage tank capacity should be
sufficient for at least one day’s run~ if so required, means are
provideml for the hUm g of the storage tanks with packed bitumen
by means that will ensure. the complete emptying of bitumen drums
at a rate not less than the maximum demand of the plant.
Satisfactory means, by weighing, metering or volu metric
measurements, are provided to obtain the required percentage of
hitu men in the mix within a tolerance of 2 pr. r cent of the qs:iantity
required. Where the quantity of bitumen is controlled by rneteN
ing or by s olurne, provision is made whereby the amount of hitu~
men delivered th rough the meter or the bitumen bucket may he

<<
11< t ~ I

cattily checked by weight S citable insulation Von ntaintatttittg,

the temperature of the hittt men itt the tank, pipe I irtes, meters,
weigh bttckels, spray bans, flew lines or othcr containers is
provide ±
Att anrnoured therrrrometec ncadittg from 90°—200°Cis fIxed
in the bit ttrnen feed line at a st.titable lctcation rtear the discharge.
valve at the mixer utiit

in case anti stripping agents are to be used suitable stirring

arrangement i a the bitumen tank would he necessary.

(8) Mixer Unit: (Fig. 8)

Batch type The hot aggregate from the gradation contrrtl
unit via hoppers and hot bitunten are fed into the pugmill. Pug—
ntili or mixer box is a semi-circular box macic of cast steel plates
with renewable linings~ it has two shafts, on ~sbich paddle arms
and tips are fttted~ The tips are adjustable to take care of the
wear and also to ensure that the clearance between the liner plates
attd paddle tips is less than 2 cm, Mixer liner plates and paddle
tips are of high manganese steel or equally wear resisting. material
and are replaceable~
1 he capacity of the mixing unit on prtgroiil should he speci—
:1k d tnt ensure. the mix output of say :io TPU at 2 per cent mnrristttne
content of the aggregate in case of 20-30 ‘[PH plant. Ass itming
I ~ otiruttes of” mixing titne Ion mixing each hatch thoroitghty a
p ogmill capacity or 1,000 kg wou I d be sufficient. Most plant
mart alitetu e is at La cli a p1 ate showing their capacUy rating fin the
tnixe. TIus rating should never be exceeded.
[he arrange meat of” the paddle tips of the mixer imparts a
secondary sideways ntovc rnent to the material in addition tn the
primany motion of’ material taking itlace along planes parallel to
the planes traced by the paddles. For this purpose, the paddle
tips in both the shafts are slightly inclitied to the direction of
travel. Sin cc the turo shafts of the pug mu I rotate in opposite
ci Lrectiun~this a rrantgetnerrt results in one shaft movni g. the material
to the night itnd the other shaft moving it to the lefi_ The side
thrust created by this systeni is taken care of by thrust bearings
tilted itt the shall.

I he rnizitlg period is uttlised by the operetto r in weigh batch

hopper, atid of weighing the mineral filler and tire hinder to liet
tort xittioitt output.

is
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 lFtC’ gcLl9gS
(:ontinunus plant in eotiti a tint its plant, the aggregate fec cl-
ing, the asphalt flow, the mixing, and the discharge of the mix go
on continuously. The paddles are set to mix and crowd the mix
from the slightly elevated in feed a ad, over an adjustable ram at
the lower end, They are also of a type adjustable for angular
positioti on the shalt and reve rsihle to retard the flow of mix
in this case, it’ the pugrttill is under-filled, or over—filled it can be
corrected by decreasing,fincreasing the mixing time, by lowering
raising the ram, by reversing sonic of the paddles, or by increas-
ing/decreasing the amount of material being (ccl into the pugmill.
ih e mix from mixer box is discharged into the waiting
Lorries,
4. SELECt’ION OF PLANT

General
(1) The hot mix plartt should generally conform to the India it
Standard Specifications : IS : 5890 for mini hot mix plant and
IS : 3066 for bigger capacity hot mix plant.
(2) The information to be furnished tnt supplier1? manufacturer
on each component, as specified in the last page of 1.5.5, (extracts
at Appendix 1) should be ilnalised keeping in view the advantagesj
disadvantages of that component enumerated in the previous
chapters.
(3) Furnishing of the foliov~iog information will help the
supplier/manufacturer to offer a plant most suitable to meet the
specific requirements
Ii) Output capacity Total qwsntutmt of vwotk, length of road, ante
pet iod of completion, phasing of work and availability of resoutci’s,
namely, atan material and money will help in determining per hour
output capacity of the ptant.
(it) Ntttaber of separations of material Mix design and gradation of
available aggregates will determine the number of stockpiles or bins
rectuired as well as the methods of reclaiming.
(til) Type of material to be handled “the characteristics of’ the aggregate
to be handled will affect the selection of system components. For
example, extrentely abrasive aggregates such as trap rock, or sticky
materaial may tend to bridge over bin openings or adhere to the
feeder,
(iv) Flexibtlity required: Necessary degree ot’ nttx ñexibility [or instance
where a variety of mixes will he needed over a short period ci’ time
witl need a feed and other system that will permit quick and econo-
micat switching of mixes,
(v) Portability : Whether the plant opetatioo is to be portable semi-
portable or stationary will help detettriine its configuration,

21
<<
I tn C.’ no. I 085

ci Altitude For altitttde ci’ ~ ork faboul ltWO in) loss of HI’ or
engines due to deration trill treed lo he taken care of’,

14) [he following aspects may be kept in view while evalua-

ting, the various oilers
lit With eqttipment like hot mix plant ittttial purchase price is usuatly
a small part of the total cost of ownership during its life span.
Excessive PC) 1. consumption, frequent repairs and down time,
often associated with low bid machines, quickly eat up savings,
But for assessing the “[oral cost of owning and operating the equip-
ment’ over its entire life, accurate cost records of similar machines
components are essential.
iii Standard plants,assemblies manufactured in large quantities, keep-
ing in view the makes and models already available may be prefert’ed
as ‘stttndardisation’ has ii numbet of advantager.
I it) the responsibility for ensuring completeness of the plant at destination
site should rest with the supplier.
i’~ ‘I’lme supplier should ettsure quick ereciton and sat isfactot 3’ t i’ta 1 7 Ut)
tipto specified work tng hours.
(v) After stile service and supply ol spare parts should he guaranteed.
(xtl training facilities both at work site and at the manufacturers work-
shop should be available,
(\ iii Literat ore 111cc operators manual, service manuals, spare pitt’ ts cat it-
logue and lay out drawings should be supplied.
(~iii) Warranty guarantee: for satisfactory performance should be available,

~ LA k-OUr, Ern’iC:TION Ar’,D TRIAL RUN

5. I . Plant La\ —ottt
5. I. I. Orientation : Orientation of the hot mix plant itt rela—
tiNt to the clirttct ion ot’ wind is very’ itnpomtant, since during workimtg
of the p1ant. a Jot of metal d tist and fumes are generated and
given away into the atrrtosphere. A It hottgh cycionic dust collec-
tor a ‘rests the usabttt fines ol aggregate, still a lot of dttst escapes
into the atinosphe re, It becomes a hazardous problem for the
health of stat!’ as well at, ‘,:ntrin”:’s, bea rings, and all working parts.
It is essential that this’ cltist, as well its chimney exhaust, is carried
by the atmosphe rtc’ witt d , away from the plant. Hence the direc-
tion ol’ [lie wind blowing fur most part of the year in a partictrlar
area shottld be kept in view as far as practicable while deciding
the orientation of the plant
5, 1.2. site : Many laeiors are important in selecting a
satisl’aetctmy plant site. The size of plant site should lad tide sufli—
eicrtt mark spaLe. ~ ~ic~’tayoat reference drawing. An area
approximately 4 27 metres is req ttired lbr machine alone.
Adeclttate space for site office, storage ol’ oil and I trbricants, tools

22
<<
 lRc: 90.1985
and tackles, aggregates, bitumen space for parking of tippers, front
end loader and such other matching equipments etc., is required
for continuous opet ation, This greatly affects the output and
hence economical working. Proximity to job and preferably
nearer to city (but away from residential area), traffic considera~
tions, location of availability of drinking water, noise abatement
and dust nuisance regulations, availability of electric supply are
also points worthy of note,
Once the site has been selected, the plant should be located
with prime consideration given to truck traffic patterns and pre~
vailing winds, Tanks and heaters should be so located to mini~
misc piping, and to facilitate the delivery or aspalt and fuel,
without interfering with plant operations. Representative arrange~
ments are shown Fig. 9.
DUST
GRADATION COLLECTOR
UNIT
COLD FEED

HOT OIL

—~ HOTOIL LINES
FUELOLLLIP4ES
..a JACKETED
ASPHALT LINES
S THREE WAY VALVES
‘fAN K G~~
‘~“ VALVES
~ T(MP
MOTORCONTROLLED
VALVES

Fig, 9, Typical cont uiuous pktn~and piping a rrangeinenl

5.1.3 i..~ocationof component units: Foundation drawings

of the plant should be well studied so as to take care of functional
layout of various assemblies. The storage and input of aggregate,
the location of the asphalt storage tanks, and approach road to the
Plant for tippers having been planned, a layout should he drawn
on the plant site, and proper foundation[excavntion should be done.
5.1,4 Site drainage and foundation The site should he so
selected that contour of the ground will drain the water, away
from the plant area. In case this can not be conveniently achieved,
then suitable drains should be dug with sufficient slope, so that
23
<<
I tiLt.. 1985

water does not aecumtmlate at plant l’btttidations and nearby area

of the plant.
Rock formation near the. sttrface is also tindeskahle, since a
pit tmtust be excavated for elevators, etc.
The fotmndation will he requ red for ( L) Cold feeder and col cI
elevator and (2) Dryer drum and hot elevator, (3) Mixer unit,
(4) Asphalt tanks, (5) .LD,C), tank, etc.
The foundation concrete mix shottld he pro~~e rly designed, to
give sufficient strength, Proper care should be taken to install
foundation bolts. it is advisable to prepare. the wooden fdmmat,
so that relnttive centre distance of all foundation bolts will be
accurately maintained he lore the concretiti ~ is done, The wooden
c i’oss sleepers of size 0.3m width hy 0. i 5m depth should he pro-
vided ott the concrete fottmt elation, so as to ni inimise vibrations,

5.2. Erection
While erecting the ntachine, ensure the following:
1) Power supply of about 95 KW, if it is an electrically
driven plant, 20-30 TPH capacity.
2) One Mobile crane of 10 ton aes capacity, mtr two mobile
cranes of 5 tonnes capacity, in which ease erection can he c.omnp—
Icled in abottt S clay’s even. When gantry is used, it will take
a ho ut 19 days.
(3) E:t’ectioa can he in the following seqctence
a) I”liict” ‘he vihia mr screen over the’ gradation
i

contt ol unit
(h) Position the gt’aciation control units and other
units
(c) [reel tni,’cer unit including ttte secondary hot
des a tor
(d) Erect primary vertkal hot elecator
(e) F:irecl 1 ryer unit , cyclone d Lsi ccii lect or assembly,
and cold elevatcir
If) Erect bituminous lartk imtcl tiding bitu macn pipe
lines, and tag the, bitumen pipe lines suitably
tg) Erect 3-bin feeders
iiI Assemnhtc’ fuel oil a mid hot oil pipe lines,
(41 A “PERT’’ chart, simmtilar to the one given in Fig. lO
for crc ctinn may he prepare ci and followed, Detntils of’ calculation
l~rthe chart are given in Tables I and 2 re.spective.ly.
24
<<
 1 P C 90’. 1985

H
U 1Ii’~ LI’
0j ~ II ‘i’~~ IL’ \5) I, itl~
TL~”~ I 1~kd~
H~t~’
111/
I IL I~ I ~ lit I II U ~ I~II yr in, ,t,~ ,.,

Il ‘~4(’~~~ ‘‘1,111, IL IL. Li ‘IL, fl iL Li ‘!LI’I IL L~C~V$

It’ I
IL It

I ig. Ill i’eL I cloi LI [II’ ned lii ztnd cofinntissifln cit 20 30 1’ 1t”t plani

iaiqctm I An ts’i’i’s Otn’m’rT—SL,’scK :mi,ARI’

Predecessor Successor Average 1. atest l:iarliesm Slack

t.::sent Event lime alIenable possihie ‘Ft..’T’t:::
(P. F’) (S. E) in clays Time Time
] (I) (IL) (“i’tE,t

0 0 0
a i :~ 2 2 a
1 2 I 3 3 0
:: :~ 3L 3L 0
I, ,~ ‘I’ 4 II
1 5 I 5 5 0
1 7 I 51 5 H
S i’~ 7 7 0
IL 7 1 S ii 0
9 12 I 8.3 81 0
IS 13 I 1I 9i1 I)
7 S I 7~ 6 II
1’, lI’l .1 it 6) It
lii 11 . Hi 7 t~
II IS I t~l3 511,’ 0
13 15 ,‘, III 10 0
4 14 ~‘ H 7 1
14 15 10 10 ci
H 16 :1 tI 13 Ii
II, 17 7. .5 1.5 Ii
“ i 2 I’7 17 0
It 19 1 19 151 0

C’ritical paIt’i l,I,t_2_3.4_5,,9,ti,l:’i.l5,ltL,i7.tH_ldl

“1

<<
EtC : 90-1985
Tssut 2, AcTjvrTmas INvOLvED IN TIlE ERSCT10N AND
C.oMMsssmoN o~linT Mete PLaNT

5?. Acti- Desceiption Normal time

No, vity in days

I. A Gantry erection 2
2. 13 Fixing vibration unit
3, C: Fixing ‘secondary hot elevator
4. [) Positioning of all units
5. Fl. Lifting the gradation unit t.o required height
‘I, F Erection of vertical hot elevator 2
7’. ci Lifting mixer unit to required height
H, H Lifting dryer unit to required height
9. 1 Erection of cyclone assembly
10, J Erection of cold elevator
Ii. ‘K t..ifting the bitumen tank to required height
12. I Lifting three bin feeder to required height
13. M Fising loose parts of bitumen unit and
gradation unit
14. N Fixing loose parts of mixer and dryer unit
15, C) Electrical wiring of the plant 3
16. P Final check up of various units 4
17. Q Final check up of electrical units
18. it Individual unit testing on the toad 3

(5) Position different units as per the erection drawings,

on the ground, so that no further change will be required later on,
Once the machine is jacked up, it is~ c’Iifficult to change the
position.
(6) Jack up untts, arid p~ovicle ttnihei packines ttndt, r the
frame to form a. uniform contact between ground and frame,
When last tier is placed, lower the unit slowly, so that frame
rests on the sleepers evenly and firmly,
(7) While erecting different assemblies, care should he
taken lo maintain accuracy in horizontal and verticat levels, as
well as’ inter aiigrtn’tent of different units, This ‘will ensure that
no i.t’ndne strains are developed, and all shafts and driv.es shall
‘work’ smoothly. If such care is not taken, there can be frequent
and costly ‘failures, due to misalignment.

‘26
<<
 IRC:,O.19$5

5.3. Trial Run

5.3.1. With a new plant, or one that has been Inoperative
for a few weeks, it Is always advisable to run a short mechanical
test without feeding materiel, or circulating bitumen. This affords
an opportunity to check visually the drive tensions In kits and
chslns. alignment and pneumatic pressure, etc.
5.3.2. Safety preeaatleas: The Chief operator should take
precautions to ensure that all personnel engaged In “preliminaries”
are now clesr of moving oarts. See also that tools, etc. are not
left where they might vibrate and ftli into moving parts. Also
ensure that all guards are properly fitted and thatInspection doors
and covers are closed. Mike sun that the plant can be started
with no possible risk of injury to personnel.
5.3.3. Trial stardag up:
(1) Diesel eegiass: A copy ofthe manufacturers Instruction
manual, specially dealing with mel, lubrication, coolant, and star-
ting procedure should be studied and understood. Cheek whether
batteries are charged fblly. Start the engine with the power take-
off clutch disengaged, and allow to run light for about 5 mInutes,
~hilst the lubrIcating oil warms up. Dlsei~gagethe bitumen pump
clutch beibre engaging the poner take off clutcb with a firm and
steady movement.
(ii) Startlag up eleetrie motors (Diesel gsasralers): Start
the power pack, and when warm, engage clutch to start the
generator. The generator supplier may prefer starting the biggest
motors first check this in the manual.

(lii) Starling up eleelrie motors (Mel. sqply): Whoa wiring

up electrical motors at site, uncouple the drives to the unit, so that
direction of rotation can be checked. The uncoupling of drives is
particularly Important where back-slip devices and gear boxes are
fitted. When electric motors are not wired In starting sequence,
the rule tIn starting is “largest motors first”, whilst much of the
overload power is “In hand”. The remainder may be started In
any order, though it is good practice to work from screen to feed,
excluding the Bitumen Pump, which should be started only when
bitumen is hot and ready for circulation. The motor manufic-
turers’ Instruction manual and plsnt wiring diagram are the best
guide.
Note: Sine. bitumen Iv not to be cueulat.d In the trial run, do not lint the
pump motor (or mpg. Its clutch) the pump should not be run “dry”.
27
<<
LRC 90-1985

(iv) Lubrication Application of correct grades and quanti-

ties of oils and greases is very important, speciaUy in gear boxes
and oil baths as they are usually drained before shipment. Nor-
mally a gear box is fitted with 3 plugs—filler, level and drain
pigs In all cases, upper most is filler, middle one is level, and
bottom plug is the drain. To fill a gear box, add recommended
oil until flow commences at the level of middle plug hole.
Replace both the plugs.

Drip feed lubricators should be fil’ed with oil.

Grease all bearings fitted in belt conveyor rollers, cold eleva-

tor shafts, apron feeder rollers, dryer drum supporting roller, hot
clevator shaft and all driving chains.

The plant is now’ in full mechanical operation and can be

switched to regular production.

n STARTING, SHUTTING DOWN AND STORAGE

6.1. Cbeck List Before Starting

ta) Have you carried out daily mathtenance as per instructions
Ib) Have you topped up all oil tanks and gear hoses with proper
grade of oil and fuels ?
*(c) Have you checked the oil level in the air cleaner and topped up ?
(ii) Have you checked the tightness of the ‘V’ belts, flat belts,
chains?
(e) l”lave you checked all the grease points?
(1,1 Have you checked that all gttards and covers are fitted
(gi Have you heated the bitumen pipe line to achieve free 110%

~çh~Have you disengaged the clutches before starting the engine ?

(I) lEave you cleared the accumulated stones before starting the
bucket elevator
(j~Have you checked the conveyor belts for any damage or wear?
(k) Have you checked the conveyor rollers for free turning 7
(1) Have you checked that too much fuel is not spi ayed into the
combustion chamber of the dryer 7
let) Have you checked that there is no water in the bitumen tank
before pouring bitumen 7
*frr Engine Drit’en Plant onlt

28

<<
 [EtC.’904985

6.2. Stopping and Shutllng Down

(1) Aboitt ten mint.ttes before prodttction for the day is to be,
ceased, or two or three batches short of the desired number of’
batches, Ihe ft eder unit shottlel he stopped.

(2) As the last aggregate lcave,s the dryer, shut off the burner
by closing down the fuel oil supply, at ihe shut-off cock close to
the burner. Then shut off the dryer motor, (in engine drive it
plant disengage clutch and then stop the engine).
(3) When the final batch has been mixed and discharged,
clean with L.D.O. or H.S. D. at both ends of paddle shafts to
ensure that they are ft’ee to rotate at the time of starting the plant
next day.

(4) Do not stop the plant sshile material is in transit, When

the dryer, elevator, screen, bins and mixer are empty, the plant
may be stopped.

(5) Tttrn off all drip feed lubricators.

(6) Now, put off the bitumen tank burner by stopping fuc I
supply. Stop the bitumen pttnip, and immediately reverse its
drive, either by handwheel or reversing the motor rotation, Move
the lever on the pressure regulator (metering system only) to Ihe
“draining” position, Fix the discharge of weighfspray system
hopper in the open position. ‘The bitumen system must be drained
thoroughly, and care taken at this stage will pay dividends in easy
starting the next day. All bit’Ltmen piping should therefore slope
downwards to the kettles to assist drainage, and a tap should he
fitted in the~ delivery line immediately “after” the pump which
tnay be Left open overnight to prevent clogging of the pump.
U cleaning solvents are ure~l, these should he thoroughly drained off,
before re~circulatingthe bilumen,

(7) Fill up fuel tank.

(8) Report any defects or itnusttal sound to the Engineer—in—
charge,
(9) Check and rectify any leakage, specially in aslahalt and
hot oil system.
(10) Check all bolts and nuts for tiehtness, and checld chain
ens rt n

29
<<
~RC 90-1985
(11) inspect the blower of exhaust fan lhr balance and play
of heartng,,
(12) ‘Weld cracks in sheets, if noticed,
(13) Clean machine, specially dust/aggregate collected
underneath belt/chain conveyors, and lubricate all points.
(14) Cover motors, starter engine parts, exhaust pipes to
avoid rain or dew entering inside.
(15) Fill in the log book,

6,3. HInts on Storing the Plant

If the plant is to be left in the open for more than a month
or six weeks, certain precaulions should be taken, especially on
mobile. machine’s, and in extreme climatic conditions, These are
as follows:
(i) Completely cover diesel engines with tarpulin sheet, lea-
ving a free entry and exit of air to prevent condensation.
(ii) Remove batteries and store them in a dry place on a
“trickle” charge, or recharge before refitting,
(iii) In severe conditions, drain the radiator even if anti—freeze
has been added.
(iv) Isolate the mains supply to electrically driven plant to
prevent unauthorised starting,
(v) Cover exposed starter panels.
(vi) Wrap all vee belts (and their pulleys) with a strong, self
adhekive paper, and liberally grease exposed chain
drives.
(vii) Grease all adjusting screws to prevent rusting, e.g. dryer
cylinder swivel ring support rollers, motor slide rail ad-
justing screws, bottle jacks, etc.
(viii) Protect the dryer cylinder burner nozzle.
(ix) lt is advisable to re move the pneu niatic tyred wheels of
a mobile plant to storage, and protect the hubs ol’ the
a xle s.
(x) If’ a mobile plant is not erected, the weight should he
take.n off the running gear,

30

<<
 fltC 9G.19t~5

(xii If roller shutters are fitted on the mixer housing,, lower

the~eand lock up.
(xii) Close the windows of the control cabin and lock the
doors,.
(xiii) Cover the top of the exhaust ran to prevent ingress of
water.
(xiv) Cover the inlet of the burner air blower.
(xv) If the door is fitted in the dryer feed end box, pin in the
closed position.
(xvi) The whole plant may be preserved to some extent by
frequent attention to paint work, especially where chip-
ping and burning, etc. has occurred.

7. OPERATThIG TECHNiQUES
7,1. The following are general operating tips in the sequence
of operation which Will help in better performance and optimum
utilisation of the plant,

7.1.1. Cold aggregate feeder:

(1) Segregation of aggregates as well as intermixing should
be prevented, when loading into hoppers.
(2) Hoppers should contain the correct sb~eaggregates, and
shou’d always be kept sufficiently full, to allow even flow
through the feed gate in a particular set position. Most
manufacturers give approximate tonage/hour tbr gate
openings in the form of calibration chart for each gate.
(3) Arching of fine aggregates is prevented by placing a
vibrator, preferably, under the fine aggregates hoppers.
(4) Moisture on fine aggregates should also be avoided, or
at least necessary allowance should he made.
(5) To avoid any aggregate damaging conveyor belt by get-
ting stuck between gate and belt,, it is better that
discharge gate openings of bins is at least 1,5 times max-
imum size of aggregate fed. A grizzly may he kept over
the bins to prevent large pieces of stone, stick root, etc.
clogging the gate.

31
<<
I RC 9O~•’L9SS
(6) Aft.:’ r days work, bins should be left with minimum of
material specially d urine rainy season. This will ensure
least strain on belts, and drives, when three bin feeder
is started next day.
(7) Check periodically fri material build up, preventing,
rollers front turning and remove the same.
(8) Do not close diseha rge gate, and run belts, to stop flow
of aggregates, but disengage clutch of auxiliary conveyor
and then stop prime mover,

‘7, 1 .2. (‘old aggregate bucket elevator

(I) In order to reduce the feeding height of three bin feeder,
a pit of approximately one metre depth should he dug,
to place the cold elevator mounting fr an1e.
(2) Ensure buckets receive material directly, eliminating
digging, although edges are hard faced to give long life,
(3) Ensure no cold mix (or aggregate) is accumulated in pit,
dug at bottom of cold elevator.
(4) in case of i’ain during previous night, ensure water logged
in pit o,t’ cold elevator is removed.
(5) Do not start the feedct unit until the dryer cylinder
burner has been incited.

7.1.3. Dner unit

(I) Daily before starting dryer, ensure feed box bottom door
is opened and cleaned to remove dust,
(21 Before starting tl’ie plant, the nozzle and burner sho iii ci
be cleaned with kerosene,
(3) Do not allow aggregate to ‘flow through the dryer drum,
when the vertical hot elevator bucket is not working.
(4) Before starting dryer d rum there should not he any
aggregate inside it, since a very high starting torque is
req uired to start dryer drum with aggregate.
(5) If furnace oil is used to fire burners, then it should be
preheated to bring clown viscosity before passing it
through burners.
(6) Do not permit open tire around fuel oil tanks,

<< 32
 kC : 90.1 95,5
(7) Always stand and hold torch at desired length to prevent
petting burnt in case burner puffs hack,.
(8) When lighting burner, never allow excessive fuel to be
sprayed into combustion chamber and drum.
(9) Do not keep burner lighted for a long time not more
than 5 ruin utes even without aggregate inaftle ci rye
drum, as it will damage the dryer itself. Operate on
low flame, when it is not loaded fully.
(10) Shape of flante is regulated by means of an air twirler.
Maximum swirl will produce a short wide flame and a
minimum swirl a long cigar shaped flame.
(‘Ii) lf fuel pump rielivery is irregular or negligible, pri rr: e
the pump and see that pump does not suck air through
joints on suction side.
(12) Watch exhaust smoke, if it is black, it would mean
excess fuel is being fed, and white smoke means excess
moisture.
(13) ~ that no holes are formed in cyclone unit, ‘I his
may add to excess dusty condition at site.
(14) The dryer should not he overloaded by passing snore
aggregate than it can handle. For this, check regularly
hot aggregate temperature to maintain at about 180°C
with the help of dial thermometer available, and the
ntoisture content should not exceed 0.5 per cent.
(15) Determine the desired temperature of aggregate dis~
charged from the dryer, by checking heat loss,
(a) Front dryer to mixer,
~b) From mixer to road, and
(c) From the temperature of mixing
for proper viscocity of asphalt
Keep flow of material through dryer uniform, and at a rate
dryer can handle, with its proper draught and rate of heat input.
(16) At the end of the day, put off the, dryer drum burner by
stopping fuel supply and then stop prime mover, In
case of engine driven plant, first disengage clutch and
then stop engine.

7.1.4. Burner:
(1) Ensure proper adjustment of burner fitted on dryer unit
to ensure uniform and desired aggregate temperature,

33
<<
iNC : ~0 955

Shorter and longer Ba rue length will affect proper heat.

ing of aggregates and dryer ends.
(2) When the burner works properly, the smoke eonsing,
out of exhaust will he light coloured. ‘~BJack smoke”
coming out indicates that oil is not ‘burnt completely,
necessitating inerr.asing the blower or draught air or
decreasing the flow of fuel oil. Excess moisture in
aggregates form steam and results in light colour,

7.1.5. Hot elevator:

(I) Daily before starting plant, any material at the foot of
elevntor should be removed through flap door,
(2) Do not allow aggregate to flow front dryer drum, when
vertical bucket elevator is not working.
(3) Hot elevator discharge chute is providled with liners and
is checked weekly to determine extent of wear.
(4) Fiot aggregates from dryer drum should be delivered to
vertical elevator, only after motor, or engine driving
elevator picks up speed and run at mated r.p.m.
(5) Care should he taken to see that buckets receive the
n’iatei ia I directly without having to ‘dig’.

7,1.6. Gradation unit

A. Screen unit
(i) The sere en must he of adequate area, rnust have,
cerrect size o,penings and properly arranged.
(ii) The screen must be set at the proper slope.
(iii) The screen should not have holes. The clogging of
screen will not allow the aggregates through. Freq~
eat inspection and cleaning of screen is, therefore,
a must,

B. Hopper unit:
(i) Ens crc that sutilicient material is stored always in
the four hopper bins.
(ii) Watch the automatic devices equipped, to ensure
that the plant is stopped when the aggregates level
gets low in any bin. Similarly, watch is to be kept
to ensure that overflow from any bin should also

34
<<
 iRc 90 1915
not occur. ‘l’hc col’d feed should be controlled
aecordm gI)’.
(iii) lake a sample~from each hot bin and cheek for the
proper grade.
(iv) Ensure proper gate openings, as the output and
proportioning depends upon the s’~me:.

Proportioning Material
(i) See,: that aggregate feeder gates are se,t as per cali-
bration chart for each gate.
‘(ii) Run g,ra’dation~ tests on each sample taken at
inte rv als.
(iii) Every day check up thefl scales fo’r zero error at no
load.
(iv) i’he aggregate~sshould he dise~harged from the hot
‘bins into the weigh hoppers, s’tarting with eoarses
and progressing dow ii to the finest, in the batch
plant.~
(v) The aggregate filler and bitumen weighing scales
should be correctly calibrated an ~ periodically
checked, say every week.

7.1.7. Mixer unit

(i ) The pugmill does’ the job of p roper mixing, when the
tips of the paddle show clearly’’ above the mix. An
underfill e’rl ‘pugrnii I does not allow the paddies to work
pi opci ly iLl an ov~r hik ci pugmill, tht inatcrj il fib us
above the paddies and is not fully mixed.
(2) The mixing should, however, be done in the shortest
possible time necessary, to produce uniform mix. if the
mixIng~ tim~e is too short, the part~eies’sv’ouldnot have
a uniloi iii coatmg of asphalt II tht time too long thi.
asph tlt Loating will hardi n, bL enuse ol the long cxpo
sure to heat and air. An average time for dry mixing
could be a’bout 15 seconds followed by 30 to 45 seconds
of mixing, afier bitumen is added,
(3) Over size :gregittes entering mixer, cause mixer arms
to bend, as the clearance between the paddle tips and
insi’de lining of the mixer box is generally, not to be
snore t’ha,n 2 cm,

<< 35
I K (, : 90.1 ‘:155
(4) Cheek agyr ee,ate’; hopper gates and asphalt “ccci valve
to see that they close tightly and no leakage take place
into mixer aftrr the feed is stopped.
(5) Ensure sequencL’~eoarse aggregate enter first and pro~
gi”m.sstvely smaller sizes in the order of size.
(6) See tha’t the. peeldi les and tips are set to ensure proper
mnixing ection,
(7) See that the lining and tips are not worn. i’he life of
arms and tips is about 600 hours. The tips have a ten~
dency to wear faster in macadam work, corn pare il to
sealing, coat.
(8) Check uniform distribution of asphalt, covering all
parts of ntixer, over entire width,
(9) Cheek frequently the teniperatu re of mix as soon as
dumped into the tipper. Ensure that the. binder and
aggregate temperatures are within the specified
range.
(10) c:hec:k fit querL tly to see th:,i t the mix is arriving on the
road site at the proper temperature for laying and
rolling.
(11) Cheek as many represenlative sam pIes, for gradation
and asphalt content.

7.1.8. Bitumen unit

(1) Before filling the bitumen tank make certain that there
is no water in it. Even a small amount of water will
cause hot bitunie n to foa ru up several times its normal
volume, resulting in overflow of costly bitumen.
(2) Pill up bit u me a tank to about 80 per cent of its capacity
only, since vol time of bit utuen increases, when its ten’spe-
rature is raised. Besides the other nuisances of’ overflow,
the possibility of tire can be dangerous, where solid fuel
or oil fired hr. ate rs are in use.
(3) ‘The normal life of 10 mm ERW flue tube of bitu men
tank is about 600 hours on the burner side, and well
oser 1000 hours in the non burner side.
(4) ‘Phe boilers should be so positioned that the lead dis~
tancc front the boiler to the plant is minimum. This
would ensure safety, will not strain the punip, prevent

36
<<
 90.1985

ci oggirig of the line. i”he lead i:iipcs should be insulated

against risk to work mnan and to mn riintain the. tempera-
ture, it als:o should always be at an incline enahl tag
hot asphalt to run down to the boiler when riot in use.
ftc boiler also should be erected with siiy.ht downward
inclination towards the hottest firing end. Cold asphalt
under the flue tubes will then cI rain dow n the incline
towards the firing end, and can be di’aine,d without
chocking.
(5) it is better to kec p the top lids of’ the hitumnen tank
closed, as water, ii’ust etc are deterrants to good, clean
asphalt. Clean external sides of barrels before ehargin g.
to prevent’’forcign matter going into the boiler. The
dust and sand particles go down and settle down around
the flue tubes, which would result in poor heat transfer,
local heating of flue tubes, etc. and produce cracks in
the welding, resulting in leaks which can be dangerous.
(6) The life of the flue tubes is more, when lighter fuels,
such as light diesel oil, kerosene, etc. are used than fur-
nace oil, as furnace oil contains excessive sulphur and
other impurities. This takes their own toil.

(71 in case, excess fuel is fed mb the flue tubes, shut ofT the
fuel, and allow air to blow oil’ the furl, and once again
s:tart the proced ure. for lighting. the burner. It is always
safer to start the blower first before turning on the
fuel.
(8) Filtersar e not supplied as. standard, hut ii is’ essential
that one be fitted in pump suction as well as delivery’ line,
or preferably inside the kettle itself.
(9) Bitumen a’ mist be tnantairied at correct specified teni peru.
tu;re. Overheating may cause ~craeking’, i.e. 5e~:.srtration,
sirhile bitumen which is under temnperatu re h:: co ines
difficult to pump.
(10) Wht: never a certain type of bitumen was used, arid is
desired to change the same to a different type., the bitumen
tank should be drained scs thoroughly as possilbe, and
should be flushed out sv ith a solvent or original bitumen.
For instance, if asphalt has been used, tank should he
flushed out with kerosene before using tar. If tar has
been used, the tank should be flushed out ‘with a light
tar oil or ereasote before using asphalt.
37
<<
tRC” 90.1985
(11) Certain solvents ‘used for cleaning such as diesel oil
are. highly inflans triable, and therefore, must be thoro ugh—
ly drained away, before bitmen is circulated. if traces of
cleaning. fluid reach’s the. mixer, and contact the heated
aggregate, risk of fire cannot be ruled out.
(12,) Bitume a tank burner may be lighted, only when the
level of bitumen inside the tank is higher than that of
heating tubes.
(13) Adjust the swirl level of’ hs.trner to short flat pos~tion.
The burner should generally, have lean mixture, as
excess fuel results in incomplete combustion and pro-
duces various iwids, which in turn will corrode the
flue tube faster.
(14) Circulate hot oil for about 15 minutes, to melt bitumen
sticking to the surfaces.
(15) When introducing hot oil into a cold line, ope.n valve
very slowly, to allow piping and jackets to heat up grad-
ually. Rapid introd uction of hot oil into cold lines will
result in uneven expansion of lines, and mnay do damage
to connecting points in the line,
(16) Inspect frequently hot oil level in the hot oil tank. II’
level falls, cheek fbr any leakage in hot oil or jacketed
bitumen pipelines.
(17) Periodically check pipelines for any possible leakage
(bitu men, fuel oil and hot oil) and attend to it imme-
diately.
(IS) Ensure that dust does not enter meter relay boxes and
dial heads,

Care and Maintenance of Rotary Gear Bitumen Pump

(i) The bitumen do,es not pass between the rotors, as is
sotneti rnes wrongly thought, but carried round rotors in the
cavities between the teeth and outer wall or liner, Thus, when
working, a suction develops on the kettle side of the pinnp, and
a pressure develops on the delivery side. it is iniportant to bear
this in mind, when the pump and circuit are being drained as the
rotors must be reversed.
(2) The n’tost important feature of gear pumps is the need
for careful and thorough draining at the end of each operating
period. Failure to clean the pump, results in bitumen solidifying

38
<<
 tRC 90-1985

around the rotors, and can result in broken teeth or driving shafts,
etc., as the power is applied. i’he only means of relieving clogged
rritors is by heating the pump, which is troublesome.
(3) Do not run the pump in a ‘dry’ statefl
(4) When “weeping” becomes apparent at the bottom ptimp
gland, carefully tighten gland nuts, one flat at a time. l’f”we-
qiing” is allowed to persist, it soon becomes a leak and the gland
packing is to he. renewed, The gland should be sufficiently tight
to prevent leakage but shoul cI not he so tight as to cause undue
effort in turning the rotors by use of hand wheel.
(5) Always make it a practice to disengage the pump drive
at the end of operation. Otherwise, if the pla ntis started next
day, before the bit unien is sufficiently heated for circulation, the
~uinp drive, if still engaged, will place excessive strain on the
driving shaft, and might even cause the shaft or rotors to break.
Al so reverse the pu in p rotor for adout 4-5 minutes, as soon as the
plant is stopped, to empty the bitumen pipes. Always observe
that the pump rotors are free by applying the ‘V’ ‘belt drive grad-
ually. Slipping of the belt over the pump driving pulley indicates
that the rotors are clog.g.ed, and need heating to relieve them.
Never apply the drive quickly, as this may cattse damage to the
pu in p rotors or shaft.
In case of chain drive also, engage the clutch slowly, and
ensure that the ptirn p gears are riot clogged, which is indicated by
excessive slipping of the clutch.
(6) When the rate of flow ~falls’ during operation, the cause
may be slipping of clutch, hut if this is not so, it would mean that
pu nip rotors are wearing and require renewal.
(7) Most coni monly used ru ethori of rcli.:’ving a clogged bit—
urnen pump is by heating the casc, either by using a blow lamp,
or by heating the case, either by drapping oil soaked waste around
time pu in p body, arm ci igniting,, it. Both the. means are not entirely
satisfactory, as e raked casing. may rcsult, and firing also destroys
the pump gland which has to be renewed afterwards.

(8) Hence extreme care must be exercised when heating by

fire. A.s the pump and body become sufficiently heated, turn the
rotors using the hand wheel provided, rind extinguish the fire when
bitu men commences to flow fro rn the drainage point. When the
pump has cooled sufficiently, to allow the hanrl to he placed on
it, pour a quantity of’ cleaning fluid, anm.l flush out the Pliflili interior
and allow’ it to drain thoroughly.

39
<<
1W :90.1985

(9) Boiling water poured continuously over the pump hous-

ing will be effective in relieving the clogged rotors, and where a
source of supply Is available, this is recommended in pertbrinance
of fire, even though obviously It Is a slower method. The only
satislbctory means of avoiding damage to the pump due to block-
age Is to prevent blockage occuring by thoroughly draining at the
close of operations.
(10) When a new pump Is fitted, or a pump Is fitted with new
rotors, the pump at times may thu to ‘lift’ the bitumen. To over-
come this, uncouple the pipe In the delivery side and pour a small
quantity of heated bitumen (say 10 lItres) at the same time rever-
sing the pump rotors by mean of hand wheel. Reconnect the
pipe and start up. The difficulty should not recur, once the pump
has been operating satlsfactorfly.

(II) Bitumen to be used in the mixture should be healed to

ensure fluidity, before the pump is started, The bitumen must be
allowed to circulate ror at least 13 mInutes before mixing com-
mences, so as to warm, the meter, spray bar, etc. and also relieve
the solidified deposits throughout the circuit. A test cock in thc
return line, close to the kettle, Is an ideal means ofensuring thatthe
bitumen is completely circulated.

7.1.9. General:
(I) Sample and test aggregate aad asphalt.
(2) Inspect storage of materials.
(3) Calibrate and inspect the operation of cold feetrs.
~Setdng of cold feeders should be checked twice daily,
and more fre~entlyIf variations appear In the mix).
(4) Inspect operation ofthe dryer.
(5) At Inst daily check the hot screen, hot bins, and dust
collector.
(6) Daily check weigh hopper and asphalt bucket for free-
dom and sensitivity. Check accuracy of all scales with
test weights at least once a week.
(7) Inspect mixer and operation of the mixer.
(8) In continuous plants, calibrate and maintain check on
hot bin gates and asphalt pump (for smooth unrestricted
flow).

<< 40
 TRC:90-1955
(9) Make visual Inipection ofthe mix and take mix samples,
extraction tests on the mix and asphalt penetration daily
and as required, to ensure complIance with specifi-
cations.
(10) MaIntain contact with placing Inspectors at laying site
to see that mix placing and compacting is satisfkctory.
(11) Keep records for a, quantities and as a check of asphalt
content of mix used.
5. MAUtTINANCE AND VflflP
8.1. Sunny .f BeatS Malate.aaee
Proper lubrication at correct intervals plays a vital rolc in
maintaining machine’s accuracy and Its working life. When time
and availability of machine are at a premium, it is absolutely
inexcusable to have a breakdown resulting from Improper lubri-
cation, since this can so easIly be avoided. The plant should recel~e
attention as follows:
(I) Daily:
(a) Lubricate all parts as Instructed ‘daily’ in the lubrication
chart.
(b) Top up oil and water in diesel engines.
(c) Air filters on diesel engines and compressors must be
cleaned.
(d) Top up all drip feed lubrlcntors.
(e) Gear box oil level should be checked at least only an
hour after plant Is stopped, when it nih settle down and
correct level can be got.
(f) Tighten all bolts after the day’s opt ration, especially that
or mixer arm, tip and liners, elesator buckets, structure,
dryer lifters, and roller paths.
(if) Daring aperatlen:
(a) Bitumen cocks which are nperated during production of
every batch of mixed materIal should be lubricated
c~ery2 hours. Other codis require lubrications daily.
(b) Make a general check on bearings to see that over heat-
ing is not occurring. (This is, sometimes, due to over
lubrIcating).
(c) Turn on all chain drive drip feed lubricators.
(d) Turn the key on the filter, in the burner fuel supply
41
<<
tRC: 90 ~985

pipe., periodically, during the day, to remove water and

sediment.
(e) Open the tap of moisture seperators of air receiver twice
daily.
(f) Check the gland on the bitumen pump. Tighter, if
‘weeping’ is evident.
It’) Bc alcrt for undue norscs, whlLh n~rghtmdii ate loose
bolts, as the plant settles down.
(h) Tighten the bucket bolt on the hot material, and flUe
elevators.
i) Recheck the angle of the dryer under frame. to ensure
that no local sink age has occurred,
(iii) Weekly (50-60 Flours)
General The hot mix plants generally have open gearing,
open chain drives, o.pen vee belts/flat belt drives., anti-friction
metallic bearings, in view of low R, P.M. drives, The. grease,
used ,fbr gear lubrication becomes a grinding material when it
absorb the dust and fine sand. Running them in oil bath will be
costly. Hence, they should be cleaned at least once a week and
new grease should be introduced.
In hot mix plants, trouble does not happen in a moment, hut
usually, it is the slow unloosening of keys, slackness of belts!
ch ~uris loobe bt or ings etc th’it grvt tr oubli. Thi adnge A stitch
in time saves nine’ should, therefore, be remembered always.
(a) Luhi Kate ill parts as insti ucted weckly’ m the Lubr i
cation Chart,
(b) Clean the filters, on the suction side of the burner fuel
and bitumen pumps.
(c) If filters are fitted on the blower, remove the element,
wash in paraffin, soak. lightly in fresh oil and r~e,fi.t,
(d) Check the level of the electrolyte in diesel engine starter
batteries and clean the terminals,
(e) (,~heck~.rllvee belts and chain drives particularly after
the.. first week tend to stretch to a “working” length
after 30-50 hours, make adju:stments accordingly either
by torque arms on speed reducers, by in ving motors
on slide ralis, or by jock:eys as fitted, Careful tension-
ing. of vee ropes .at the correct time (it is too late if the
ropes have been allowed to slip fin 2 days) will ensure
an excellent wearing life,

42
<<
 IRC 90-1985
(f) inspect vee belts for general signs of wear. Do not
allow ropes to run on their sides, Replace in matched
sets.
(~)Inspect feeder and conveyor belts for tear and broken
fasteners, etc.
(h) Check that belt scrapers on the feed units are in good
condition and effective. Renew rubber lips as necessary.
(i) In extreme dusty conditions, it is advisable to clean
cyclone at least once weekly. Access doors are pro-
vidcci,
(jt Retighten the paddle mixer arm and tip bolts after the
first week, however, that for the continuous production
of special mixture (e.g. sand or fine asphalts) intelligent
control of the feed is essential, if the advantages of this
feat ure are to he fully realised. Bin level indicators
may be supplied, and adjustment to this equipment will
of course, be necessary, if the increased bin capacity is
employed.

(iv) Monthly (200.250 Hours)

(a) Burner nozzle should be cleaned as instructed.
(b) Check all wiring and cables for loss of insulation or
cor rossion.
(v) Three Monthly (800-1000 Hours)
(a) All gearboxes and oil baths must be drained, flushed
with flushing oil, and refilled to the correct level with
recommended oil,
Note This operation should be repeated at six monrhty inlervah
after the first three months.
(h) Iuspect the dryer chain ring for worn or broken pins.
Remove affected segments of the ring, chip of weld on
inside diameter to free damaged pin, and tack-weld a
new pin in its place.
(c) Check the oil level in the exhaust fan bearings, top up
as necessary.
(d) inspect the liner plates in the dryer feed ring, and dis-
charge chute, elevator discharg.e chute, and interior of
the paddle mixer. Note when replacements are likely
to he required and order accordingly.

4:3
<<
I RC’~ Q’r~l055

(e) Esamine the burner cumbustion chamber refractor3r, for

carbonisation, clean and repair as necessary.
(t) Examine sci e.e n cloths an cl note when replacement is
likely to be necessary. order meshes in advance to sm e
down—time.
(g) Clean electric contacts, and relays, with ‘serviso I’.

Other ~laintenance
(i) Changing Screen Cloths Screen meshes, especially liner
sizes may wear very quickly 1 week to 3 months) always
hold replacements.
(ii) EIe’~titer Discharge Chute Adjustable The. rubber’ lip
which prevents spflage of material is adjusted by a
lever, and pin ned in position. As wear becomes evide nt,
the lop should he moved closer to the downward
nioving. buckets. Rent n the lip when further adjust—
merit is impossible. Examine chain pins, the chri in links
will outwear’ approximate 3 scts of pins.
(iii) Adjustable Overflow Spouts : Most plants are equipped
with sonic form of adj istment to overflow levels in the
storage hoppers. it rn ust he borne in rn md.

Precautions to be taken to Ensure Long life of Bearings

and other Associated Machine Elements
I. Types of Bearings
(a) Plain or Bush Bearings: As a standard practice, ‘Lea ci
‘Bronze should be used for hush hearings. It should be ensured
that lubricating grooves are provided in sufficient numbei and
depth. Axial grooves t.rsnally not be on the thrust face of the bear-
ings. Vt hr never, these bear ings are required to work under s’ery
dusty conditions, oil seal type of seals should he prodded to
preel tide dust. ‘These should be installed in reverse direction so
as to prevent dust cntering the bearings. Excess greasing would,
therefore, serve to push out dust at the seals and prevent grinding
aclion at the seals.

rite elea’ ance’ in bush bearings in low speed shafts should

he between 003” to .0(15 l:~~r
inch ci tam eter at overhaul, but rnag
~‘

be. a I owe cI tn wear ii pto 0.06w to 0.08O~per inch diameter during.

operation before replacement, provided this clearance does’ not
cause any other problems, e.g. gears chattering, etc.

44
<<
 LRC :90.1955
(b) Bali aS Roller Bearlags: Considering the load and
speed, single ball bearings should b~used where the alignment of
(he shaft can be assured and there is axial and radial loads, roller
bearings should be used where high radial loads are to be taken
with no axial loads. Tim alignment of the shaft to very close
limils must be assured In such cases. For all olher general uses,
self-aligning double row ball bearings should be used.
Extreme care should be taken to ensure cleanliness or (hew
twa rings from the time of intallation onwards. Cleaning of
bearings should be done with kerosene. in case, compressed air
is used for cleaning, care should be taken to ensure that the air
is completely dry. It should be packed immediately with appro-
priate grease, should not be allowed to stand dry from any length
of time. New bearings should always be cleaned to remove cor-
rosion preventive compound before use.
Proper seals should be Installed on the bearing housing to
ensure that dust does not enter. Neoprene seals for lj’ and 2’
dia. shafts have been specially made.
The mating surftces between shaft and tapered cone, and
tapered cone and bearing should be clean and dry before instal-
lation.
2. Genial Preematlom
(a) Standard button type grease nipple should be provided
on all bearings.
(b) Extension pipes should be used whenever bearings are
inaccessible for greasing directly.
(c) Whenever bearings housing are mounted with elongated
slots for adjustments and alignment of gears, chains,
belts, etc., a positive Locking lbr the pedestal should be
provided to ensure the bearing does not slip from its
adjusted position.
(d) The equality of bearing housing should be high as a
good bearing could easily be maaaged by a poor quality
housing. Apart from general quality of workmanship the
following points may be inspected: -

(I) The housing should grip the outer race of the bear-
ing preferably at two points and not allow It to
rotate, however, there should not be any squeezing
at the bearing.
<< 45
lRC’ 911. 1955

(ii) 1Jnifornr and deep grooves should be provided for

the installation of seals. In case of special applica~
tion, housing with Iaberinth seals should be
provided.
Stock of Spares
It is advisable to hold certain components which are subject
to fair wear and tear, broadly speaking, these are as follows
L,inder plates, dryer feed ring and discharge chute.
Elevator feed and discharge chute liners.
Screen meshes.
Paddle mixer tips and bolts and liners with bolts, Certain onus oL’
transmission, i.e. vee ropes, chains, and flexible coupling hushes etc.,
etc. Sealing rings etc., for pneumatic e,%uipnlent. Your spares catalo~
gue itemises all recommended stock spares, these should he studied and
ordered according to assessed requirements.

Maintenance Guidelines Important Assemblies

for
Prime Mover

(I) Diesel Engines

(a) Do install the engine, at a convenient distance away from
the hot zone like dryer drum to avoid over heating.
(b) The protection given to the engine by way of tappet
covers, canopies etc. must always be in position. They
must be promptly replaced, in case they are removed
for maintenance and repairs.
(e) Do read engine manufacturer’s instruction book and
follow instructions fully.
(dl Heavy duty air cleaners should be provided, it is
preferable to have a dry type and an oil bath type. air
cleaner fitted in series to ensure supply of dust free air,
(e) Due to vibrations, the hoses hose—clips, etc. become loose
thus, allowing dust to enter the engine directly by pass~
ing the filter, It is of paramount importance that the
maintenance staff check these joints for tightness every
day before starting the engine, cracked hoses must be
instantly replaced.
(I’) Oil in the air cleaner should be replaced daily, otherwise
dusty air will enter cylinder resulting in rapid
wear of moving part, loss of compression and power.
Similarly, paper elements of dry type air filters must be
replaced as and when necessary. The element life is
<< 46
 IRC: Sf915
normally about 250 hours but in heavy dusting condi-
tions, these have to be replaced much earlier.
(g) The fuel filters and lubricating oil filters must be
replaced as per engine manufacturers recommendation.
(h) if the radiator. get clogged due to dusting conditions,
it should be removed. Even provision of overhead tanks
can be considered for entering adequate coolant.
0) Do use clean and correct grade lub oils and chick oil
levels daily.
(J) Do watch for unusual noises, vibrations, leakages of POL
and other defects during operation and report for rectifi-
cation.
(k) Do check readings of all pages.
(i) Do cover parts and exhaust pipes to prevent ralnl
dew entry.
im) Record entries regarding horns run, fuel(oil consumed
In iog books and machinery history card.
(n) Do use genuine spares and avoid spurious ones.
~2)Eleetrleai Meters
(a) Isolate mains supply to pretent unauthorised starting.
(hi Cover exposed motors starter panels, and controls by
tarpaulin oi plastic sheet to prevent damage due to rain
waler.
(c) Monthly check all wiring cables for loss of Insulation or
corrosion.
(d) While replacing always use the proper size fuse nevcr
substitute a different size.
(ci Do earth the entice supply system suitably.
(f) Keep the motors and contacts always clean, by bloning
away the dun.
(g) TL’st check, no volt coils and over load protection devices
for proper operation.
Colt Aggregates
(I) When starting a newly set up feeder, first operate it
without aggregate for about $ hours.
(2) Check all moving parts for binding or overheating.
47
<<
1R( :‘iO.1985

Check conveyor belts (or correct alignment and tension.

(31 Tilhten all bolts and nuts daily, before or after a day~s
work.
(4) Dust or aggregate collected underneath belt conveyor
should be removed every day after a day’s work, and
greasing should be done at all points specified In the
maintenance.
(5) Holes or cuts in conveyor belts should be repaired
Immediately by lacing or vulcanising.
(6) Ensure proper tension in the transmission chain, main
conveyor belt, by adding shims under gear box. Remove
a half link, if chain becomes too loose.
(7) Check transmission roller chains, and belts weekiy (am-
ount of tension on vet belts should be such that there is
no slipping of belt; and a sag is apparent on slack side
of belts, pulleys will then run cool.)
(1) Conveyor belts dcteriorate In storage and hence, should
not be kept In stock for long.
(9) Petroleum products such as oil, grease, must not come
iu contact aith belts, since they reduce the life substan-
tially. (Life of conveyor belts Is about 400 to 600 hours,
but it can be raised, ifvuleanised in time).
(old Aggregate Bucket ltlevater
(I) Ensure tightness of bolts and nuts daily.
(2) Ensure greasing all points after a day’s work.
(3) Check especially for tightness in bucket bolts.
(4) Ensure proper tension in flat belt driving cold elevator
gear box by shimming gear box.
(5) Check condition of bucket, chain links and pins for wear
often.
(6) Ensure proper tension in cold elevator chain, by adjus-
ting the foot shaft plumber blocks. The correct align-
ment o( drive and driven sprockets and chain itself, Is
highly important for smooth running.
DrysrUnk
(I) Before starting a new Installation, see that combustion

<< 4$
 I k( 91.J •. 19H3

din niher, a ad dryci drum, are completely d~y. F~rc

etc. iiliiig ol corn bastion chamber should be dried by
means ala low v~oodfire and not by oil firing.
lo ensu~c proper tension in main counte rshait drive
belts add shims to the motor.
(3) Cheek dryer roller chain and sprockets for wear, and
tear if need adjustment, may he done,
(4) Ensure proper tension in roller chain, driving dryer
drum counter shaft, by ad ding shims to el rye r drum
gear box.
(5) Cheek bolts and nuts fbr proper tightness.
(6) Since drye is inclined, cheek for proper thrust wheel
adjustment, so that no flue gases escape from feed box.
Preventing excessive thrust will ensure life of support
and thrust rollers too,
(7) Check weekly, chute’s renewable steel wearing plale,
for any wear and tear.
(8) F.!nsure proper tension in belts driving blower and er~
h aust fan by removing shims from p1 urn met blocli s of
main counter shaft,
(9) Ensu ic proper alignment a rd play in impellers of ex~
haust fan, If exhaust fan impellers are coated with dust,
the balance. will be affected. inspect and clean weekly
or at least fortnightly.
(10) Check blower for ope.ration~unsua I vibration, housi rig
tin cracks, d rivin t~pulleys a net belts for condition

Burner

I Clean the coarse strainer (pump section) once. weekly.

(2) Fuel ta riks should be installed sloping ~‘ pe. r loot away
from the front and fitted with a. sludge draining cock ai:
the hack. Close the delivery line cnek d a rimg tank
re plc ri ishment and leave closed for 2 hours. Drain away
sludge twice weekly.
(3) Check ‘weeping at fue,l pump gland by tightening gla rid
tints. I he gland must he repacked, if a serio us leak i~
allowed to develop.
~4’~Everyday evening, burner should be removed and dc,-
49
<<
 aned ~ ith fresh kerosene oil; when burner runs in fur’
nace oil a lot of carbon accumulates; which affects the
temperature.
hot Ele~ator
(I) Ensure tightness of bolts and nuts,
(2) Ensure proper tension in conveyor chain.
(3) After every 300 hours, the chain should he dismantled,
checked and re-assembled with graphite impregnated
grease.
(4) Ensure proper lubrication of hearings.
(5) Hot elevator discharge chute is provided with liners, it
should be checked weekly to determine extent of wear.
(6) To tension flat belt driving counter shaft shim-up plum-
mer blocks, on which counter shaft is mounted.
(7) The bottom shaft of the vertical elevator is mounted on
plnmmer blocks which can be adjusted by means often-
sioning arrangements to give required amount of tension,
The alignment should he such that chain and buckets do
not rub against casing.
Our tensioning of cunveyor chain would also affect the life
of the bearings. The life of chain is about 1000 hours.

Gradation Unit
(‘are to be taken during Operation
A. Screen Unit
(i) The screen must of adequate area, must have correct size
openings and properly arranged.
(ii) The screen must he set at the proper slope.
(iii) The screen should not have holes, The clogging of
screen will not allow the aggregates through. Frequent
inspection and cleaning of screen is, therefore, a
itiust,
13. flopper ‘Unit
(i) Ensure that sufficient material is stored always in the ‘four
hoppers bins.
(ii) Watch the automatic devices equipped, to ensure that
the plant is stopped when the aggregates level gets low
<< 50
 1RC: 90-1985

in any bin, Similarly, watch is to be kept to ensure that

overflow from any bin should also not occur. The cold
feed should he controlled accordingly.
(iii) ‘rake a sample from each hot bin and check for the
proper grade,
(iv) Ensure proper gate openings, as the output and propor-
tioning depends upon the same.
C, Apron Feeder
(i) Ensure tightness of bolts and nuts
(ii) Ensure proper greasing of all points
(iii) Ensure proper tension in belts and chains and check
alignment
(iv) Check for replacement of wearing plates of chute, screen
and hoppers bins due to excessive wear
(v) Check for replacement of apron feeder plates due to
excess wear
(vi) Everyday check up the scales for zero error at no load
(vi F) Check flight tin alignmnent and bending, Even little
bent flight should he replaced without delay.
(viii) Cheek flight support angles for cracks,
(ix) Check gap between sealing angles and apron flights’.

q, REQUiREMENT OF MATERIALS’ ANt) TOOLS

To ensure smooth working and better outturn, it is desirable
that sufficient stock of all consu mable and other materials should
he kept at site,
I he following are recommendations for 20-30 TPH plant
considering the daily outturn of the plant as 135 m, tons.
(a.) Aggregate 60 en. tnt.
MATntRL REQUIRED rOlE 7,0 ~ ORKINO DAYS

Requirement of For 50 mm
metal chips thick SM

15 mm metal 700 cu. mt,

12 mm metal 340 cu. nit,
tO mm met at 300 cu. mi,

51
<<
IRC’ 90-1985

For 75 ni nt 13M or any other different work, require nient

should be worked out accordingly.
(h) Asphalts Daily consumption may he approximately 9 to
10 tonnes, Hence 2 Nos. of asphalt tanks about 10 tonnes capacity
should he always kept, one for operation of the plant and another
to receive from tanker lorry. There should he one bonier of
10 to 12 tonnes capacity to transport bulk bitumen f’ro rn reline ry
or bitumen depot to plant site,

(c) Lao. ~:.Jgbt Diesel Oil) The consumption of I.... D,O.

for heating the aggregate is about 20 lit.Jcu. nit, Hence the da,il3’
consumption will he 20 x 60 i.e. 1200 litres. For heating the
bulk bitumen in the asphalt tanks, 300 litres of L.D,O. will be
require d pet- day. As such the consumption ~s’illbe i 500 litres.
i’svo numbers of ‘L.D.O, tanks of 1000—1200 lit, capacity should
he kept at site, for receiving the hulk supply. Further, recoup-
ment after every 4 to 6 days should he arranged. In case
furnace oil is used, similar arrangements will he required~
Fuel for ‘Prime Mover The fuel (H .5, D. oil) required is us
under
(1) Fuel consutnption 12 to 15 lit.fb r.
for 110 H.P. Engine — 3Nos. (depending on load
factor)
(2) Fuel consumption 2 lit,jlhr,
for 5 H.P. Engine — 2 Nos,

i’otal consumption per day will be 17 x S = 136 lit./day.

Minimum 2 barrels of 200 lit, each, i.e. 400 litres should be
stocked, at site,

Hot oil One drum of 600 litres capacity.

Grease and Engine Oil Per day requirement of grease is

3 to 4 kg and of engine oil 2 litres. Hence a supply lasting On
a week’s duration should he kept at site,

Power supply : in case of electrically driven plants, maxi-

m urn full load power consumption is about 82 KW. Hence 4001440
volts, 3 phase, 50 cycle supply is needed. In addition, power is
also needed for welding set, small electrical tools, lighting, etc.

Besides the above materials, a smttl I workshop at site should

<< 52,
 tRC 90.t985

be established. it should have a work bench with vice and a set

of standard tool set. The following list is recommended.
I) Hand tools such as spanner, screw drivers, hammers, diem span
ners, screw spanner, chain and pipe ~ renches, etc.
(2) Portable drilling rake (single phase) ratchet with stand, power ties-
ible grinder, electric and gas welding set.
3) Chain pulley block 3 Ion lay with triped.
(-It c~e~s~guns, oil cans, trays, etc.
(5) Hydra ulic Jacks, including tO Ionne travelling jacks rci r erect ion of
plants.
(6) I 00 feet of I “ M anit Ia rope, 100 mm wire rope ot about lOt) feet,
wire rope clamps, packing timber like Railway sleeper, etc.
7) Items of general stores like bolts, nuts, washers, pins, fan belt, jitter,
cotton waste, etc. should also be adequately stocked,
tO. SAFETY
10.1. Work Site-Safety Precautions
Ia Develop safety consciousness
(h) Promote safety as a second habit
Ic) Remember safety is up to you
(d) No slip-shot and short cuts
ret Provide proper training
(f) A tways employ a sk dIed ira mcdl worker For the job
(g) Every worker must be medIcally lit for the job assigned
(h) Provide %rst-aid boxes with adequate supplies
(i) Keep tire tight ing equipment in tip—top condition
(j) Use safety material such as helmets, safety belts, goggles,
sprons, etc.
1k) Use proper tools and tackles
ii) Ensure proper and clean platform~pathssaysFor the
workman to pass through
(n’s t Provide adequate illumination
(n) Provide gtsards and railings ss hereever necessary,

10.2. Heavy Equipment-Safety Tips

Ia) Keep the machine in good operating condition,
(hi Never operate an unsafe inachinc,
(c) Re familiar with alt controls, gauges instruments, ci c.
di Look around before starting
c) Neser leave Ihe machine unattended with its engine sinning
1) Keep operators platform dean and free from oil and grease

<< 53
 (g) Operate the machine only from the operating seatiptatform
(hi Never carry out servicing, adjust ment and repairs when the
machine is running.
(i) Never permit unauthorised persons to handle the machine -

(j Ensure operating platforms are safe and t’ree. from oil anet
grease.
(k The operator must have the maximum tine estrcted s rev
of the operating area,
(1) Avoid loose connections in electrical system-
(m) Ensure that the engine is switched otT and immohitised
against unauthorised use.
ITO Do not race the control when the machine is working
(o) Exercise care when removing the radiator cap after the
engine has been running.
(p) Replace alt protective guards,
Cdt) Avoid leakage and over heating of bit ant en
(r) Take precautions against back tire from burner.
(5) Store ‘fuel and lubricants away from plant.
It) Keep awa) Fr out hot bitumen.
(u) Re carelitt while attending to lighted burner.
(v) Periodically inspect all cables on the machine.

10.3. Shut i)own-properly

(a) Pttt all controls in netitral.
ib) Shut off the engine after allosving it to idlr’~sndgraduttlt~
cooled down,
10.4. Loading and Transportation
(a) l,,,oadt and unload ott the level ground.
(b) Use the indicated lifting points while lifting tIre machine
with a crane.
(c) Watch correct loading and unloading procedure for the
different type of equipnrent.
(d) Use ramps of’ adequate strength.
(e) Block transport vehicte so that it cannot move,
)f) Tie and block the machine securely for transport -

10.5. Maintenance—Without Accident

ia,t Avoid tire hazards; close fuel shut 01:1’ valve.
(bt Carry otit servicing and repairs in accordance with the manu-
facturers recomtnendat ions.
(c) Before working on hydraulic system make sure the hd aui
pressure is released,

<< 54
 IRC: 90.1*5
(di Before p,epaitn~the electrical system, the supply hat tei~
must be dIsconnected.
Ic) Protect your eyes with safety glasses while striking metal
perth.
(I) War sieves while handling bitumen and parts or sharp

II. MODERN TRZND IN ASPHALT HOT MIX PLANTS

In India Asphalt Hot Mix Plants presently being manufac-
tured and used are of older and simpler design. In the developed
countries the technology of hot mix plant has gone a long way in
modernisation and sophistication ofthe plants. In fact, the pro-
diuction of the bitumenous mix has become a Ailliledged industry
with the hot mix plants working like regular factories.
Modern hot mixing plants incorporate uptodate process
techniques, design, and construction. Emphasis is given to quality
control of the mix, longer component life, easy control and main-
tenance. Production capacities go upto ~ MT an hour.
2. Some of the salient features of the modern hot mix plant
are given below:
(1) (‘old Feed: flopper with capacities to meet requirements
arc fitted with either electro vibrating tray feeders or wIth variable
speed belt feeders to give highly accurate feed control, particu-
larly when handling sand and awkward fines.
Drysr: The dryer cylinder revolves on machined roller
paths mounted to the cylinder by an expansion compensatin
method. On the smaller cylinder sizes rotations Is by chain ring an
roller chain and on the larger Sea by frictional drive.
burner(lii)
Is used. It is Instead
Suns,: of conventional
a multi-nenle burner,
single lame a 4Turbo-Jet’
burner using an
oil atomising principlc, with oil pumped at the required pressure
and combustion air being supplied by an axial blower. No com-
bustion chamber nor air compressor is required. Burner controls
can include remote ignition and settlngjflame indicator failure and
filly automatic temperature control. In this system Ibel and
maintenance cost are considerably reduced.
(lv) Aggregate Seessu: A vital factor of the quality control
is the highly accurate sizing in a vibrating screen. The amplitude
of vibration can be quickly changed. Four to six sizes can be
screened, In addition to the rejects. Dust and noise nuisance
during screening Is overcome by a complete housing over the
screen.
55
<<
 (v) iontrol System A whole range o.i rd ia ble and as~ly
maintained control sys(i:~ms are available giving choice of man ual~
scm aulomatic or ti~lly autornatw operations, to the ‘atest degree
01 sophistication md ttdlnp computer control led accounting systems
n ith V,i).O, and print facilities. The controls are housed in a
roo my air-coiditloned cabin, it can be adjacent to the plant in
a remote position. Close circuit IS. monitors and a ni niic panel
br remote control of the plant with irn mediate notification of
mal.tunction and its location are also available.
(vi) Hot Mix Storage : if required, mixed material can
he transferred by skip system into hot storage bins with capacities
upto 300 metric tonnes, where it can be stored for a couple of
days before use,
(vii) Dust Collection in most of the countries, due to
environmental regulations, the exhaust of tine dust from the Cl rye r
is not allowed tC) he discharged in the atmosphere. Hence, dust
collection equipment is invariably an essentia unit of the hot mix
plant. The collected dust is mixed with ~ atcr and pu niped oil’
as slurry.
Drum Mix Plant Besides the basic hot niix plant having
usual units, one of the major de~elopments in the hot mix plant
has been Drum Mix Plant.
In the cl rum mix plant, the aggregate are Cl ned, coate cI with
bitumen and mixed continuously in a drum in a single pass. The
drum is divided in 3 compartments first for heating aggregate,
second for bit umen spi ay and third For mixing.
Thus in the drum mix plant, hot elevator storage bins and
gradation control arc avoided, This makes the plant highly
economical in the initial cost and subsequent maintenance cost
because of fewer components.
Drum mixing is cleaner too as exhaust gases contain less
emission because fines are trapped and absorbed by mixed
material in the drum,
Drum mixing is a revolutionary change in reducing th,e pro~
d uction cost of the mix without appreciably sacrificing quality.

<< 56
 IRC 9tl-l98~

Appendix I
INEOR\IA flON 1Ui~COMMENDEU‘u 0 BE SUPPLIL:D
Ifl THE PUItCHASER WITH AN EN~QUlRVOP AN ORDER
I’he nfi:irmatioo in regard to the rcqurernents in A—I. to IS
should b~supplied to the tnanul’acturer white making an enquiry or placing an
oi’der for hot asphsll mixing plants.
I, , The rating ol’ the plant in tonnes per hour when producing
mixtures having aggregates ol d ifferen I types.
A- 12. l’ype of Plant
in) Static
(h) Portable
(e) Mobile
(d) Mixer I o he b~teh I ype, con) hutous type or either
A-I,3, Site Conditions
(a) tirbamt area where ito dust nuisance should be crea ted,
(hi Rural area where $0 per cent dust collection efficiency would
he satisfactory.
ict Rural area where dust would create no nuisance,
(dl ‘Temperate or tropical climate,
(e) Approximate altitude above sea lesel,
(1) Any other special conditions under which the plant is to
he used
1,4. Motive Power : State, t~ pe of prime movers required or full
part ie ultirs of external electricity supply
‘1 5. Requirements For ancillary equipment, stating
a) The number of compitrt men is required in the aggregate feeder.
II,) I F dust collector is to be supplied and the type of dust collector:
1.1) Ordinary dust colteck i’ (efficiency below SO per cent
(2 Ft igh elliciency dust collector (etficiency over $0 per cent).
ct I [screening unit or gradation control unit is required.
(dl it’ proportioning of aggregate is to be by weight or b~ volume or
by either met hod
Ic) If measui:ing of bitumen is to be by weight, by olume or by
either method,
(F) it’ preheater for oil supply is to he supplied and if so, gise
viscosit5 of fuel Ciii,
(g) I he met hod ol plant opet at ion reCluired
(I) Manual
(2) Power assisted manual control
(31 Fully automatic control on inning plant
(4) Fully automatic control h rought out
(51 Any alternative rettuirement
itt) If bitumen heating and storage ui:tit is required or not and if
lacilities are to be supplied For handhng packed bitumen,

57
<<
I R.(’ 91.). I

,tppertdLs’ 2
INFORMAl ION K. COMMENDED ‘[0 BE SUPPLiED BY
THE MANUFAcTURER
13-I , 1”he information in regard to the requirements ibI J to B~1.4.
shall he suppiie.d by the manuFacturer w’iih the tender,
ii’ 1.1. The model and type of plant offered, Drawing or catalogue
ii timber,

13-12,. A drawing or diagram o.I’ tite plant shmvin.g the general artange-
merit and the overall dimensions
(a) ‘When working, and
(hI When disassembled for travelling, if the plant is portable. or mobile.
Ft—i ,3. l’he weights of the varoius units and the axle-loads, if the plant
is pot.:’table or mobile
il—I .4 .A general speciticat ion embodying the following info.r mat ion
(a) The rating”’, model and makers ol’ th.e. power units offered and the
n:tethods of the power transmission
(b) A description of each unit of the plant givir,g dimensions a n.d
capacities.
(c) A description of the ruttning gear an.d’’brakes supplied, if the plain
is mobile,

<< 58
 I RC : 90.19:R5

AppendLs’ 3
METHOD OF CALCULATING RME OF lURE CHARGES
Hourly rate of hire charge’s l’or 20.30 ‘FPF’I hot in ix ‘plant for etluipmeat osert
depart mentally
(A) Total investment Rs 18,50,00(1
(B) Salvage value 1111 IS per cent of (A) ~ x 18,50,000
2,77,500
(C) iota I investment to he depreciated )A) --- (13)
18,50,000— ‘2,77,500
Es 15,72, 500
i) ) Economic life of the machin.e 15,000 hrs
15,72,50(
(F.:l Depreciation per hour ,,:,,,:
15,000
104.83
I F’) Storage cl’ta rges per hour (1 per cent of C spread over the economic
Ii Fe)
001 x
0,01 x 1’04,83
Es 104
iCti al ownership charges = (El) “F’ (F)
104,83 ~ 1.04
105i7
I. Operational charges
Repair charges p~hour including ma intenarice and t epiacemen.t of tyres
1 ~lt pit CLut ot C ‘p1 isd os~rtsonomtt lilt)
1.5 :.< 104,83
Es 157.25
Ill * 0 e’rhetid charges
i/,iu5 per cent oF ownership tind oper~ttionaicharges
(105,87 ‘f 157,25)

= 2113,12
Rs 13,, 15
IV . Running chtirge:s’
(Ci) Operating stafftl,ahonr and wages
Designation No, Wages/month Tot a.
ii) Operator 1 1000 1 x 1001) = 1000
(it) \ ssista nt Opt itt iii 2 01.1 “ ~00 16(111
(iii) Mechanic 2 100(1 2 1000 ,;:‘: 20(1(1
Iiiv) l telper 5 40t) 5 400 = 2’000
(1600

<< ‘5,9
I hf C3~...I 5i3 5

( )pera iion charges honr

6600, !1. . =.,, Its 52,80
I 500
I Fl) Fuel Consmnpllon
(a) For three engines
HHP load factor ‘s lb ot’ Fuel pet’ HI’
110 .~ 060 x 0,4 ~2(i,4 lbs
15 lilies hour (app)
(hI For two 5 II P engine
0 :s tt.6 04 2,1 lbs
2 litres’houir
Isle I eonsumeCt 11 litres hour
Cost of fuel 17:’ 335
= Es 56,95
rei l..ubricating oil charges vs 30 per cent of HSP oil
0,30 >: 5695
Rs 17,0k
(dl (1 ott of I, DO
Consumptton of EDt’) tst 2flft litre’s pci’ hour tom both the hurner.s fitti::d
in dryer and hituirien lartk,
Cost of I DO 2(10 ‘ ~ 80
Es 560
(e) Miscellaneous charge s such as cotton ssa ste ci e
Running charges 52,80
1,,,,::. .~ 56.95 = Its 1(1 ho ut
..i. 17,08 560
“I’ tO
Es 696,83
Tot) hire eha rges
(a) Ownership charges Es 105,87
~h) Opertitiona I chit rges Es 57,2(1
(c) Over tteaCl charges Es 13,15
id) Rttnning charges Es 696,83

Es 913,10 sa~’Es 073,00

Thud hire charges per hour of plant otieration works’ out tn ‘Es 9~3(to
Note When plant iv given io contt’tsctor iii tnteresi and instirarict:’
charges @ 0 per cent o” the average investment should he addesi
to tCoal Ct’s nenship cltttrgcs, talCing average investment as
to pLo’ cent sit cats iia I cost and I 1.100 working hotirs per year
I 8,50,000 61) 1 I,l
(~ 000 :‘‘ ‘ityi K Ill (10 Per hour
(ii) Mini mum is orls dig hrttir pci das’ for lesy iii hire charges should he
p ‘eseribmd
(2) ‘1 lie atnos e calCtiltst,00s tire only seheniat ic to illustrate method,

60
<<
 IRC 9O~1985

App~md/x4
OUTPU’ ANALYSIS OFA HOT MIX PLANT’

Period for completion of t kin bituminous pavement construction by 2.0-30

TPH plant
Si, No, Type of pavement Quantum of work involved i’onnes, km a.sstrm~
in 2. lane National Highway lag density of 2,2
in cu, m,
075 m :‘~~.: 1000 at = 525 525 ~ 2.2 “ 1155
75 nina ‘B.M, 7 rn ‘.t,
tonnes per km
:2, 50 mm tiM, 7 :“:.OSO bIb = 35:0 770 bones

40 mm asphalt ‘7’ ‘.: ,04.0 ::~~:: 1000 = 280 616 tonnes

concrete
ml, 2.5 mm semidens’e 7 >‘: ,(125 :‘< 1000 = 175 385 tonne.s
car pet
Average ou.tpu.t ~ 25 tonnes per hrtur
NCi, of’ working h.Ciur per day “ 6
ifroctuctiCirl per day ‘ 6 :e, 25 .— t50 tCtnnes
lo complete. 1 1Cm of 75 mm 13,M. 2.5 mm semkdense e:aepe.t
“I,’otal tonnage involved 1155 f. 385 “.~ 1541) ton.nes
With one’ hot ntis plant of ‘F~3Oi’Pt’h capacity, tinie. required fo’r com-
pleting I km of B .M, a rtct

~154(1
iC ~ ‘F~i)say II we’rkmg Clays
Note .‘ I, ‘[lie time peniorl s:if completion ss”iII obviously eh:ange according
io ihe vutritttion in site osstputz Clue to variation in the nuniber of
~‘,“orkng hours pru:t.sihle., the inois.ture content ot’aggregates, the
pI~sriisct’hiciency utnd the t.iianagi ment aspects.
2. ‘the above calculations are rmiy schematiC: t.rt illustrate’ the
rue t hod,

(I
<<
I RC 901985

AppendCs’ 5
s’A\ILF: CALCI:’l,A’tlONS TO %VORK. OW’ REQUIREMENT’ 01’:’
HOT MIX PLANTS

Assumpi iou 200 k ni of road’? metre wid ih to lie strengthened v,’irli 511 mm
13,NI’, and 25 mn’s SDC in 5 years,
(I) Quantity o.f 50 rnmrt “
770 ‘ , 200 =“: 1,54,000 rut tons

[I’M work’
(ii) Quantity Ctf 2.5 runt S’DC’ work ‘.“ 385 :‘: 200 ‘::= 77,(t(I’0 its ions:

‘liii) Out turn of’ itot 15101 plant per hsaur .“ 25 torts
(iv) i’ime period for conspletion saf ~oh .“ 5 years
(v) ‘Working hour o’t’ plant per year =‘~ I (iOU

Calculations
total quantity of EM and SDC ~. 2,31 ,[t0 tCurts
No of plants uquiitd ‘ It (loll

5:”c25 “.‘.:1000::~:’l84
say 2 Nos,

Note.:’ 1. “the absise calculations ire only s.che’ma.ti’r’ tCt illust rate thi::
mtiet hod,

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 TRC 90d985

Appendix 6

STAFF RF:QumEMFr~IT
Staff generally required for ope rat ton and maintenance of one 20-MIT PH
per hour capacity Hot Ni ix Plant.

S. No, Designation No. of Staff

I, Junior Engineer (Mech.)

2, Chargeman
3. Senior Operator
1. junior Operalor fl

5. Senior Mechanic
6. Msist tint Mechanic
7. Fitter
8. Electrician (Etec. PlanQ/Aoto
Electrictan (for diesel plant~
9. Helpers GreaserstTar, men Iii
10. Choukidars 3

Motes
the abo~t. stall strength is ~,tnt r iii guidelines Ior thi tqu I U nient of
stall for opuatinn md mamnten tact ol one ‘0 10 1 PH Hot Mix
Plant in one shift.
It also includes maintenance staff for doing routine maintenance
after the day’s work say one titter and two greasers.
iii) Helpers Tar~menwill also at tend heating of bitumen before starting
of regular shill.

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