URE 190-1988 GUIDELINES FOR SELECTION, OPERATION AND MAINTENANCE OF BITUMINOUS HOT MIX PLANT Published by, ‘THE. INDIAN ROADS CONGRESS Jamnagar House, Shabjaban Road, New Delbi-L10 O11 1985! Price ts Re, 48 (Phus packing snd postage)CONTENTS 1. Introduction Classiftcation General Description Layout, a 3 4. Selection of Plant 5, Erection and Trial Run 6, Starting, Shutting Down and Storaze 7. Operating Techiiques 8 Maintenance and Upkeep 9, Requirement of Materials and Tools 10. ‘Safety Il. Modern Trends in Techuology Appendis | > Appendiv.2« Appendix 3: Appendiv 42 Appendix 5: Appendix 6 ¢ LIST OF APPENDICES Information Recommended to be Supplied by the Purchascr with an Enguiry or an Order Information Reconimended to be Supplied by the Manufacture? Method of Calewlating Rate of | Hire Charges Output Analysis ofa Hot Mix Plant Sample Calculations to Workout Requirement of Hat Mix Plants Staff Requirement IRE: 90-1985 7 58RE: 99 1985 Fig. 2s Fig. 2: LIST OF FIGURES Bitumen Barch Mix Plant Bittmmen Continuous Mix Plant ‘Cold Aggregate Feeder ot Cold Blevator Dryer Unit Dust Collector Hot Elevetor and Gradation Unit Mixer Unit ‘Typical Continuous Plant and Piping Arrangement Port Chart for Erection and Commission of 20/30 TPH Plant ui 1 13 14 Is 20 29 2TRE} 99-1985 GUIDELINES FOR SELECTION, OPERATION AND. MAINTENANCE OF BITUMINOUS HOT MIX PLANT 1, INTRODUCTION Flexible pavements of modern highways atc constructed. by laying hot mix of stonc aperspite and bitumen of the desired Composition in predetermined thickness. For achieving the designed strength of pavement, the hot mix has (6 conform to laid dewn specifications in respect of erading and quantides of diferent sizes o! stone material, quantity of bitumen, tempera- fire of the aly, ete. Such hot mix with rigid quality control can ily be produsea by the machine called’ Asphalt Hot Mix Plant: Hot mix plant can achieve! () Uniform drying oF eppiegate 0 desitod motnars eontea, (2) Precheating of agusegste 10 the required temperature. 3) Aceurate contro! os the grading and quantity of assrenate W) Accurate contro! on the quantity snd semperature of bitumen und 6) Uniform coating of stone pantieles with bitumen: ‘The above factors ate very vital for bituminous road cons: tnuction of high standasds, and signify. the importance of hot mix plant. The use of hot mix plant ie also necessaty for more Fcicat and economic utilisation of available resources such ae bitumen, the cost of which has increases manifolds in the revent past. For the above purpose, the Highway Construction and Mechanisation Committee constituted a Working Group consisting of SiShti G, Viswaiiathan, JK. Dugad, J.P.R, Moses, VB. Pandit, ‘A tepresentative cach of CPWD. iM/s Marshall & Sons, M/s Sayaji Iron 4 Enpineering Co, and Mis Millars. 1SS IRE; 90-1985 ‘This Working Group finalised the draft Guidelines jn. their meeting held'on 16th August, 1984 and thesc were later considered by the Highway Construction and Mschanisetion Committee. in theic mecting held on 24th September, 1984 (personnel given on the inside of the front cover). The Executive Committee in thelr meeting held on 14th January, 1985 approved these Guidelines which, were- considered by the Couneil in their 112th and 118th mectidg hsld at Lucknow om 3rd.and 7th February, 1985. At this miceting, the Counell constituted a Subcommittee consisting of D.G. (RD), Shri G. Viswanathan and Shri A.P, Paracer and amthotised’ them to finalise the dociinent in tight of the comments of the. members made during the msoting and rectived in wsiting, This Subcom tities in its meeting on 2nd August, 1985 finalised the Guidelines for Selection, Operation and Maintenance af Bituminous Hot Mix Plant fon publication, An attempt has, therefore, been made in this book to present important aspects of oporation and upkeep of Hot Mix Plants so fas to get best out of them, 2. GLASsIEIENTION Hot mix plants are maialy classified on the following basis: ) Capaciy Morivy ©) Fine Mover (® Messuring sytem (1) Capaeits ; Plants are classified on the basis of per hour out put capacity. Plants.of the following capacities are yene- rally available in the enuntry: ( 6tonnes to 10romnes hr 19 tonnes t9 20 cannes} ir {ifl) 20! tonnes to 50 tonnesfar iv) 39.4643 tomes sud above, upto 120 conaesjtr The lower output is at’ per cent moisture content and highse one at 2 per cent moisture content (by weight) of aggregate 2(ee> $0185 The following are the limitations: for ase of mini hot plant 6:10 tonnesjhiour capacity. ix Hot mix plant of 6-10 T.P.HL capacity, docs not have gisdation contiol unit, Hence such plants can be used for pate repairs and premix carpet work. only and i§ not suitable for bituminous macadam or asphaltic concrete, This work is inten ded to cover big Size liot mix plants, Only generally conforming to IS: 3065-1965. (2), Mobility: portable and mobile. i Static plaut: A plant designed to be erected on a ste permancnily, Shih ng special acrangemiest 19 feeiate ts temoval and sbICtiu, GH) Portable plants A plant So detigeed Wat ik may be easily dis assembled ints seotinns, 1o be transported by road oF ral Ga) Mobi A plan’ sodesigned that pay be easily Sepicated isto section and Gach setion equipped. wilh pncumate yr, for Gish movement. ‘The feng, vidih and height Of say section Stike flash, when prepared Tor moving, should prelesaby not exceed 10 m1, 8m, And 4.5 mrespecively, lo mect irate regula on. The plants are generally classified as static, Generally, plants upto 10 tonnes capacity are fully mobile and used for patch repairs or premix work. Plants above 30 tonnes capacity are portable or stationary. @) Prime Mover: Plants are also classified on the basis. of the type of prime-mover, viz, (@) Diesel Engineer (b) Bleeric: Motor. FeniCombartine advantages an disadvantages of diesel engine plants: Advantages: @) The unit is selfscontained, an therefore, the plant can be insiuied and used at propored site without mich delay as it ig not dependent pon any external source of power viz. electrie city. | (b), It can be wed at any site far avay from elties and towns where there is no power line passing nearby. (9 The operators and mechanics ate generally more eon- verseAt ith the upkeep of miechaniesl components, (a) The Department need not pay the fixed minimum charges to the Electricity Board, whether the plant runs or not, 3Re + 99-1988 (©) The supply of diesel oil is now-a-days more regular than electric power which is aifected by powor cuts and erratic supply | Disady (a) Engine repairs are frequent due to dusty and hot atmos: pherie conditions prevailing at hot mix plant sites. yes | tb) Down time is more ag repairs of engives take time. I () To smaller engines upto 5 HP, the stasting operation is by handles. Henec it causes fatigue to the operating staf. [d) Overall performance is no! so good and outturn per arinumn is fess resulting in higher unit cost of production. Comparative advantopes/disadyantages of electrical moter driver plants Advantages : | i) The initial capital cost of electrical motor driven plant is {ess than the diesel engine driven one, Gi) Starting and contio! of various motors, is quieker and ! sinogtli, Operation by push button in easy reach of driver means less fatigue, | (iii) Blectrical motors Tocated at different places can be } started and. stopped from one control penel by 2 single operator | thereby ceducing operating expenditure. | (iy) Maintenance and repair of electrical motors and switch | godrs is negligible compared (0 the diesel engines. | () Electrica] operation is smooth and convenient. | ) Disadvantages ¢ @ Plants cannot be stesight away used if eleetsic supply is | ‘not available within reasonable reach. Gi If power trensmission linss ate to ibe specially, extended to the work ares, located far ayey, from the main high tension Tings, the cost involved will bervery high and uneconomical | (ii) Incase of restrictions on vse of eleetrie power short | supply, Voltage fluctuations, generators are procured at an extra | cost whereby the cost of operation inereases appreciably. 4 aIRC 50-1885 (4) Measuring System: There are two typos of plants, namely, Batch Type aad Continuous Type. Quality and consis- tency ofthe mix will not be affected duc to break down of the plant, interruption in supply OF aiggcceate ot slight variation in Specification of stone chips supplied by different quarries. Batch Type ‘ate and asphalt scales. (Fiz. 1) In batch plant cach batch of avgre- accurately weighed by means of weigh hopper Advaitages : (a) Every baich can be checked accurately and quality con trol will be better as such consistent and accurate mixes can be obtained. (b) The specification can be easily changed st any moment in batch type plant, say from B.M, to A.C.. whereas in the conti- ‘uous plant adjustments at various places, recaliberation of feeders, gradation control, unit filler feeder and bitumen system are necessary and may take 4 to5 hours, Hence ifthe specification OF work involves Trequent change, i may be preferable to goin for batch type plant. (o) Even if the temperature of bitumen is not controlled accurately and the viscosity & low (Volume only varies on this Account), the mix. will not be affected since bitumen supply is regulated by weight of each batch. Disadvantages = (@) Initial cost is bigher. (b) The erection and dismaniing is more difficult us height of batch plant is generally more. (6) Output is relatively low as each batch i t6 be weighed. 1 (@) As the weighment is done manually, by the operator, personal factor is involved in Weighing each batch and this may Sause some mistakes, Also there may. be parallax or zero error in reading dial scale. : Continuous ‘Type + (Fig, 2) In continuous plant the quanti- ties of aggregate and asphalt are measured by volume i.e. the flow through the gates. 50 1985 Advantages {More output since each’ bitch is not weighed befare ixing, ©) Inktal costis tess than the bateh type plant, QP Ais lsege quanta of work ofthe same specifdation isin. apuneeh this type of plant cin cater fo the seguro fairly well, and ‘cconomically. as once the gates/valver oie adjusted, no pessoal Bictor is" involved, so:far as operator is cone eee Disadvantages + clon ae COld feed not stiety contedlied or iit operator B pizsloss it nor watching the: smocth Hoof apgregater the Tesults could be: bad, 2) Bin level indicators are necessary as the tow of miateriais saree on TBP depth oF aggregate nthe ‘a onees gests conveyor. (ie velunie Of chips differs with the mefsnire content and face will not be the same ‘at the feed ened after diying, Henes aveurate mixes are not possible, “Also the mage content item 2 NAP e#eh stack: and’ cach part of the day tea cote extern, a auaihen bsdpplied vohimetsically, and. sprayed eo femperagitt sit miSE By 8 Puttp. geared with aprbe feces If re pe aUut® of ilunien i not controlted, dependins upon viscosity, MeVelume will vary sng bitumen vontent wil serae uniform, (5) Weigh bridge’ is tequited to know the ‘tetual quantity (tonnaye) of mix prodiiced by the hunt. 3. GENERAL DESCRIPTION Hot inix plants should have the followin main components + UC Auarapsle. Peeaee 2) Dever Unit (2) Dast Coueoter, (1) Hot Blevacor (©) Secondary Gradation Unit (0 Minera ie Supply Uni © Biunea Unit ©) Mixer UnitBITUMEN BATCH MIX PLANTBITUMEN CONTINUOUS. MIX PLANT }IRE = 00.1985 (1) Cold Aguregate Reeder = (Fig.3) ‘This can be-portable on | Partners ees or stationary. Ths kas two or more bine orto { paccmenss, each provided with mechanical means. tor Feeding edt oatly tad lonm and predetermined rate, 10 the cord eleva | OF directly into the The feeder provides for the adjust 2rOlal £84 proportionate feed and is capable of betes Woe in i fs a critical control pointin the production e's Chat mix, 45 vapacity should be realistically rede gee ite to TSI, the capacity of the feeder, with the exis sap closed, Shall not be fess than the capacity of the dayer ‘The design should be/such a6 to misinise clogging ot arching Gf Ruereeate in the bins. For this purpose, i ous be preferably | fo have some of the bins with individually reciprocating vibratory Roden. “A gills provided overthe bins to prejent ee pisces | Bren me stick oF root, clogsing the gates. One of the ten eee fines materia} like sand or gait, asthe ease aay be, eats other the cts Teed the agerenate of different sizes. The wanton ey | peiczpestte azgrevate is controlled by adjustable. cate opening Pefare siacharge on the bell conveyor for'beine fede ke dryer | by the Gold elevator, ) sit {eeding height of the bins shoule be about 14 {0/2 metre Alter caite manually, “Feeding. platform ie otherwise ease Stenruaee De titen ttontend-loader 6 used maximum aunties | frerghes oF Tondcr will link the foading height herike kenge the bins. | (2) Diver Chit: It consists nF e614 ayurezate clevater, ayer dem, bumér and blower. || selaceld ausregateslerator: (Fig.4) The aggregate (cold metal) | feed obiained from feeder or shaker feeiler is Taser ia sufficient i Aaa, Mth the help of cold elevator, end discharged eros | Feeding chute of diyer drum. “The drive far cold clemeeh siven | SpreeeethPGt shalt sprocket, and is obtained fiom the shart act Simpeket riven by diyer dium. The cold elevator a normally 4 fucket conveyor, but onn ali be other types like bell conveyor, ate ake (AEE, made Of malleable icon saalingss The buono made of M.S, sheets with hard edge. {2} Diver drow : (Fig.5) The‘ dryer drum isa revolving 6 gical dn oF MCS. Plate sbout (2 mm thickand obs wee {ia 2d 3 to12m tong, dopending on the capacity ceahe plant. Pcs, AaBeBRLG 18 dried final moisture coment Shoutn eee mote Wen 0:5 per cent by weight) and heated to proper tenors . | —_—————————JRE | 90-1985) wre. The dryer should have capacity to heat the ageregaie upto 180°C, The drum generally sotetes al about 10 10 20.p.n, The burner is located at the discharge end, so that the aggregate get less heat initially, and maximum befoie discharge. the hot pases and aggregate ‘moving in opposite directions. A fuel pump linked with the drum drive (to prevent the use of the burner with a stationary dium) supplies fl fo tke burner. ‘The flow of the apgtegate through the drum is achieved by tither inclining the dium avay trom the feeding end (in which ease the fights are stright) or having horizontal drum (in which case the flights are inclined). "The series of longitudinal cups or channels called ‘Lifting fights? pick up the agereeate, and cause them to caseae through the burner flame, during its travel rom feeding cnd to discharge end, A pyrometer is fitted at the discharge end to measure the temperature of hoi aggrocate. The slope of the dryer, the arrangement of the flights, the speed of revolution, the length of the dryer drum determine the time requited for the augregate to pass through the diyer drum, and hence they cin be varied toa certain extent. The controls ars, no doubt, available for varying aguregate feed and eat From the Burier (©) Blower aad burner: The low air pressure oil burner which uses Tight diese) oi) or huraace oil, as fuel, is used to heat the agyreaste in deyer drum. It is mounted et the front end of diyer dium, and refractory brick sad clay lining is provided ty prevent buming of mouth of the dryer drum. It should be ensured thet the flame of burner js directed centrally in the cryer drum, ‘The burner should be of adequate capacity and shoold ensure: complete combustion, without leaving a filin of carbon on the aggregates, which would prevent the asphalt from Sickins. Incomplete combution also reslls in excess Comstimp, tion of fist, ‘The consumpiion of fuel of the buener 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 augregates, ambient temperature, type of mixete. The consump- tion O° fue) cil in the burner being large, the economy of the plant operation would be afected, unless the jets in the burners fate of the right type, size and well maintaived. Air is supplicd ‘by high speed low pressure blower to ensure complete combustion. @) Dust Collector: (Fig. 6) ‘The exhaust fan which pro- vides the Graught fo draw the flame and hot gases through the 0uodnesg, 861-062 OTIRC; 901985 Description Fig. 6. Dust collectorTRC 190.1985 dryer also draws out @ portion’ of the fines and dust trom the agaregats as it passes through the dryer and sciceas, Tn order f reduce the dust nuance and torccover usable fines, a dust collector ie used as an integral part ofthe dryer draft systeni, Generally, the collector is of the cyclone type in which the fines are separated by centrifugal force. The air and hot gases aden with ‘cust and fines enter the cyclone tangentially at the side nea top, and exkaust through the outlet pipe which extends part Way down ‘into the eyclone from the topiat its.centre. The Gollected fines are drawn from the bottom by means of screw conveyor. If the fines ate suitable for use in the mix, they are then fed. in contest measured quantitiss info the mixer by the Inineral feeder. Some mixes require more. fines than are recovsted by the dust collector. In this case, edéitional fines or min- eral filler are added through the filler feeder or an auxillary fines feeder. (4) Hot Elevator; (Fig, 7) Het elevator i a bucker and chain conyeyor similar to cold elevator, but totally enclosed, whick lifts the dry agarcgatos to the sereens. The bucket size fg almost double that of the cold elevator buckets: The ol elevator can be @ single chain with centrally fitted buckets, or Gouble chain, im which ease bucket iy bolted at the end 10 each third link of the chain, However, the double chain cleyator is not recommended, singe the piteh of chain sprocket gels disturbed due to differential expansion during working. (5) Secondary ation Unit: (Fiz. 7) This consists of sereens and storage bins for proportioning the aearagstes. (@ Sereons: Normally four deck sereeas are provided, which are flat, vibrating type, inclined downwards and vibrating at high speed. The amplitude of the yibration is adjustable. The screens have a normal capacity sliphily ini excess of the full capacity of the mixer_or dryer, and gperate on the ‘reject system’ whercin the feed is first defiveted to the largest. sperture size screen through which material passes (to the next smaller she, aiid 0 09, ‘Ne over-she or ‘reject’ material from each going to the appropriate storage bin. (if) Storage bins: ‘There are four ageregate stoxaye compart- ments, with dischergs eates ineack.. Each hiot bin is provided with an ovérllow pips of sufficient size and lovation, to prevent any bac- king up of material into the bin, or against the screens, “Adequate giistale devices should be provided for indicating the levels 15IRE; 90.4585 of aggregates in the bias, to warn the operator when aggregates level gets very low in any bin and regulate the cold feed suitably, (il) Aggregate proportioning unil Hateh type plant : In butch type plant, means for accurately weighing cach size of aggregate and mineral filler, in a weigh box orabhepper, suspended on scales, ate provided to hold a full batch. Normally, the sveigh hopper issuspended on a balance lever system, with knife edues. The weiohtcare recorded on a latee diameter springless dial scale, Thus the weights indicated in the dial are the cumulative welshts of various types of Bgereeates discharged from the bins fo the weigh hopper. ‘The radial discharge gates of the various storage bins are eperated By hand, oF power opemted. ‘The proportioning unit for measuring for the asphelt issimilay to the sgerexate, excopt that the dial seales for weighing the Bitte men usually readl to the nearest? ke. Af the right amount ofasptali and aggregate are not mea- sured out, a good mix cannot be had, Not enough asphalt aives amin that does nothave all the agercaic coated, und therefore, it will not hold together on the road as well. Too. ‘uch asphalt will give a soupy mia, with little stability and. blee= ding will result, Inrecent years, there isa trend towards fully automatic Operation. Such plants handle the entice measuring and mixing phase aulioniatically and include safegnrads to ensure accuracy, atch after bateh. This frees the operator to-co-ordinate othet plant operations, such as proper bin bulancing through remate. feed control and regulation of aggregate temperature through remote burner control, Continuous type unit: While in batch plant, the agere= gatevand asphalt “are generally measured by Weight, the same are measured by volums in continuous plants, This, thsreforg, hecessary that convenient amd accurate: scales and ficilities shall have to be provided separately for cross checking the neces sary devices by weight, Tn continiipus plants, each bin or compartment has an aoes. rately controlled individual gete to form an orifice, for yolunetri« cally measuring the material discharged. from cach compartment, The orifice Is sectangular with its width constant, ané height variable by means of mechanically operated gate, which can be locked inany position, Indicators are provided to show gate 16THRE 19021985 openings in centimeters, Plate apron feeders couvey the. material from the bins. The plate agron feevers: are equipped with a cust proof tevolution counter to compule the day's production. The Aggregate fom epion feeders is dumped fito a single discharge ‘ehitto, which Feeds the mixer, A metering pump. supplies ‘bitumen in metered flow to the spray bar placed above tlhe pugmill. A specific amount of bitumen is discharged irom tbe pump at every revolution of the pump shalt, Hence the discharge can be varied by varying the RPM ofthe pump shalt. Foy this purpose, sl sot ‘of sprockets are provided. ‘The mictering pump is positively interlocked with plate apron feeder to ensure synckronisation of aggregate and bitumen feed. (G) Mineral Willer Supply Unit: Some mixes require more fines than are received by dust collector, Hence means are rovided for conveying, proportioning, and charging mineral filer, direttiy into the mixer (> the extent of 6 pet cent by weight oP the hot mix plant output. () itomen Unit: Tanks for storage of bitumeh shall be equipped for heating the material, under effective end postive control at all times, to the temperature requirements set forth in the specifications for the paving mixture, Heating is accomplished by steam or oil coils, clestrisity or low flame tempeiatere oil barners: Woil burners are usec, fire brick, cast iron or other Suitable liners shall be provided so that the flame cannot impinge Girectly oft the tank plates or flue tubes. A circulating system for the bitamen is provided for proper and continuous circulation beiyeen storage tank and propoitioning units during the entire operating pericd. Suitable arrangement is provided for recording the temperature at the tanks and in the circulating system. ANI pipelines and fittings are steam or oil jacketed and properly insula- fed to prevent loss of heat. Stotege tenk capacity should be sufficient for at least one day's tun, If $ required, means are provided for the filling of the storage tenks with packed bitumen by means that will engure the complete emptying of bitumen drums ata rate not less than the meximum demand of the plant, Satisfactory means, ty Wwelghin ing. of -volumetris nieas urements, are provided to obtain she requited percentage of bitumen in the mix within a tolerance of 2 per cent of the quantity required. Where the quantity of bitumen is controlled by. meter- ing or by volume, provision is made whereby the amount of bite ‘men delivered through the moter or the bitumen bucket may be 7Hee votes seadily checked by weight. Suitable insulation for maintaining the temperature of the bitumen in the tank, pipe lines, melers, oi Buckels, spray bars, flow tines oF other containers 8 provided, An armoured thermometer reading from 90°—200"C is. fixed in the bitumen feed line at a suitable location near the discharge Valve at the mixer unit. In case anti stripping agents are to be used suituble. stirring arrangement ip the bitumen tank would be necessary. (8) Mixer Unit : (ig. 8) Batch type: The hot apgreuate from ihe giadation contre Unit via Koppors and hot bitumen are fad into the pugmill. Pug: mili or mixer box isa semi-circular box made of cast steel plates with renewable linings, It has two shafts, on which paddle arms and ps aie fitied. The tips are adjustable to take care of the wear and also to ensure that the clearance between the liner plates and padéle tips js less than 2em. Mixer liner plates and paddle tips are of high manganese steel or equally wear resisting material and-are replaceable, ‘The sepacity of the ming enis ot pugmill should: be spect fied to ensure the mix output of sey 30 TPH at2 per cent. mortar content of the eegregate in case of 20-20 TPH plant. Assuming Tp minutes of mixing tne for aixing e¢ch bated Gioroushiy s Dligmill capacity of 000 ke’ would be sufick-nu.. Most pisnt anufacturers sch a plate showing Weir eapaciy tauig Toe, the tigers Thr rating should ever be exceeded The arrangement of the paddle tips of the mixer imparis's secondary sideways movementto the matetial, in addition to. the primaty motion of material teking place along planes parallel to the planes traced by the paddies, For this pixpose, the paddle tips in both the shafts are slightly inclined tthe direction of, tuavel. Singe the two shalts of the pusmill rotate in opposite, direction, this arrangement results in one shaft moving the material to the right and. the othor shaft nioving iito the left. The side Uhrust sreated by this system is taken care’ of by tivust bearin ited in the shaft i ‘The mixing period is uulied by the opefaior in weigh. bateh hoppes, snd of Weighing the frineral filler and the binder to get) ‘@xinitin output | 1sDeseciption ze 7 Ditke Actelion Assy.1Re-+90.4988 Description Zz 1 2 3 4 2 6 7 8 ° 33 Bec 20,Ine 150-1985 Costinuous plant + In continuous plant; the ageregate feed- ing, the asphalt flow, the mixing, and the discharge of the mix go on continuously. The paddles ate setto mix and crowd the mix | Wont the slphy elevated infeed and, ove an adjustable iam a the lower end. They are als of @ type adjustable for enpular | position onthe shaft and reversible to retard the flow of mix, fn this case, ifthe pugmill is under-Alled, or over-filled it can be corrected by decreasingjincressing the mixing time, ‘by lowering) raising the ram, by reversing some of the paddles, or ‘by. inereas- ingjdecreasing the amount of material bemg fed into the pugmill. The mix irom mixer box is discharged into the w lorries. 4. SELECTION OF PLANT General : (1), The hot mix plant should generally conform to the Indian Standard Specifications: 18: $890 for mini hot mix plant and 1S: 3066 for biguer capscity hot mix plant. (@) The information (0 be furnished ty supplier/manufacturer oneach component, as specified in the Just page of 1.8.8, (extracts ft Appendiv 1) should be finalised Keeping in view the advantages) disagvantages of that component enumerated in the previews chapters, @) Furnishing of the following information will help the Suppierjmanufacturer to offer a plant most suitable to meet the specific requiremeats + ) Output capacity + Torel qoantum of work, Neng of Head, tine | aiid or completion, esing of workcand avaiity of resources, Tavpely,man-nateual and money wil Relp in determining per Nuh Shtputsapactty of te plant (i) Number of separations of siaterials Mix design and gradation of Available apgeeates will delcensing the number of stoegpiles or bins required at sell as tne methous of reclaiming, id) Type of material to be bansled: Tho charsbtersties of the aggrexate robe handea aie the etic of Gai commgneth ‘Sample, excomely abrasive aggregatessuch as ap 109k, or ste Bee at aa aie eter oat epatied gy ster ent feet du) Plenty eared Nesesiary desies of mis libs for insienee eer say et mixes ll be rected over Short pziod of hie wt Ua ied dots apse thal wll permit quiek end sson0 hia svitching af mikes : (60 Portability» Wether thr plant operation 16 16. be poriable semi Sortable ar siationary will help determine its configuration, 21OO I te: 60.1585: i) Aldknles Pop atsiuce of wosk (about 180m), lose oF Io 0 Goats doc ie doraon ed de (4) The following aspects may be kept in view while evalua. ‘ing the various offer ( With equipment (ike: hot mix plant intial purchase price is usually 4 small part of ts oval Goat at onmeraeiy eae ns Rata Excessive’ P.O.L, corsumption, frequen’ reqairs and down. Une Gflen associated’ with Jow bid. machines, cuickly cat up savinge But for “eseesing the ‘To.al cos of ovning and opesatiogrine eau tent" ove: [sence life, accurate cost recoeds cf similar machines oinponents erestentt), Gb Standard plenisascomblies manufietured in terse quantities, keep. ingin vie! the makes and model already avaliable may be. picteied as standardization” has t aumber oF aévaavages, (Gi) the responsibility for ensuring completeness ofthe pntat destination site should rest with the suppher () Thesupplir should ensure quick erestien and sitisiactogy ial vue upto steeiies working hows (6) Alter sale service and supply of spar parte hould be guareniccd (A) Training fecilties bouh st Work sie ad at the manufacturers work. shop should be avaiabe. (Vi) Literature like operators. manual, service manuals, spare paris extn Ingus aad lay ou! drawings should be supped. (ity Warraniyigumtaniectfor satisfactory nerormance should be avaiable, 5 LAY-OUT, BRECTION AND TRIAL RUN Sil. Plant Lay-out S.L-. Ovientation : Orientation of the hot mix plantin velae } tion to the direction of wind i very important, since during working ‘ofthe plant, a lot of metal dust and fumes are generated and given away into the atmosphere, Although’ cyclonic dast colle: tor atrests the usable fines of aggregats, still a lot of dust escapes into the siniosphere, It becomes a hazatdous problem for the health of staff as well as engines, bearings, and all working parts, 1 is essentie} that this dust, ay well és ehiainey exhaust, is carried by the atmospheric wind, away from the plant. Hence the dired- tion of the wind blowing for most part ofthe year in a particular area should be kept in view as far us practicable while deciding the ovfentation of the plant: } 5.1.2, Sie: Many factors are important iy, selecting a Satisfactory plant site. The size of plantsite should. include sufi Cent work space, as per layout reference drawing, An area Sppreximately 14'x 27 metres is required for machine alone Acequate space for site office, storage oF of] and lubricants, tocls 22 nan nnEREEEDEEEeee etlIRC? 90.19 and tackles, aggregates, bitumen space for parkingof tippers, tront end loader and such other matching equipments eke, 8 required Tor continucus operation, This greatly affects the cutput and hence economical working. Proximiy to job and preferably nearer to city (bul away fiom residential area), traffic considera ions, location of availability of drinking water, noise abatement and dust nuisance regulations, availability of clectric supply are also points worthy of note, ‘Once the site bas been, seletted, the plant should be lecated ‘with prime consideration given to truck traffic patieras and pre- Vailing winds, Tanks and heatcrs should bese lovated to mint. mise piping, and to facilitate the delivery of aspalt and fuel ‘without Interfering with piant operations. Representative arrange- ments are shown Fig. 9 oust GRADATION COLLECTOR GME COLD FEED. 1] UNIT ora Fier HEATER i HOT OIL LINES: f ua) ~-> FUELOM LINES i OL] — vackeTeD continuous — ASPHALT LINES asbnacr MIXER THREE WAY. VALVES “TANK GaTe VALVES “© > TEMP CONTROLLE © toto vaures ig, 9, Typical continuous plan: ard piping anrangement 5,13. Location of component units; Foundation diawings of the plant should be well studied so as to take enre of functional layout of various assemblies, The storage anid input of aggregate, the location ofthe asphalt storage tanks, and epproach read to the Plant ‘or tippers having been planned, a layout should be drawn oom the plant site, and proper foundation/excevation shoule be done. 5.14 Site drainage and foundation : The site shovid be so selected that contour ofthe ground will drain the water, avay from the plant area, In case this can not be conveniently achieved, then suitable drains should be dug with sufficient slope, so that 23IE: oe-1955 water does not ascumalate at plant foundations and neat of the plant, Rock formation neat the surface is als PIL must be excavated for elevators, ete, ‘The foundation will be required tor elevator aad (2) Dryer drum and hot elevator, (A) Asphalt tanks, (5) L.D.O. tank, ete, The foundation conecets, mix should be properly designed, to PUG juice sitenath. Proper ‘care. should be taken to inet foundation bolt, Ttis advitable to prepare the wooden fora Rethatrelative centie distance of all foundation. bolts will, accurately maintained before the concreiing is done. The woo ‘Gigs sleepers of size 0.3m width by O.15m depth should. be pr vided on the concrete foundation, s0 28 to minimise vibrations, 5.2. Ereclion While erecting the machine, ensure the following: (), Power jupply of about 95 KW, iit i an electrical driven plant, 20-30 TPH capacity. about 19 days, (8) Eréstion oun be jn the following sequence : (9) Plose the vibratory sereen “over the gradation sonia uid (b) Position the radation contol wits and orher i (©) Hest xe ub including the sseondary tot (8) Breet primase \ea hot elesatpr (9 tect dita unt seine det coieeor assembly, “tind cold clevator I rec: bituminous tank including bine 10 Ths tes Beem ee a am, (5) Bee (0) Assemble tel ol att oi pipe tines. (i) A “PERT” chart, sitnilar fo the one given in Fi for sui may be preptied and Followed. Details of eateuisiin forthe chart are given in Tablet 1 and? respecilvely, 8 24)Fig. 10. Per chart for erection and eomaission of 20:30 TPH plan Tan |. Acrurry OunruT-Sack Chany wredecesor] Successor | Averaze | tatex | caien |, slace ee ee |) | ante | Se] ee | at | a | ae | = 3 = = a 0 3 i 2 z fl i 2 ; 3 ; i : 3 i u : 0 | ; 4 i : ¢ 4 4 3 1 3 5 0 | : 7 i a 5 4 : é 2 7 7 Q $ 5 i 3 * a | 4 2 ; a a 0 } - 8 i u 1 : i : ¢ 4 | ‘ icy : & & 5 i i, i : 7 4 | | : s. i s “A 3 i i: i ae A | 4 4 a 3 ee 1 4 as y 10 hho o 1 te is 3 5 6 W 2 15 1s o q h e ce ae a 18 0 e At! » 0 Criseal pacts o- 25 itTRC : 90-1915 ‘Taute?, Acriviries Iwvorvan 1 rar ERnctron ANP “Commission ov Hor Mix Pas Gantry erection. Fiaing vibration it Figing secondary hot elevator Positioning of al units Lifting the giadation vnit to required height Erection of vertical hot el-valor Lifting mixer unit to required height Lifiing dryer uit to required height leretion of elone assembly Erection of old elevator Lifting the bitumes tank ‘6 xequired height Litting thee bix Feeder (o eequired beight ‘ising loose pats of Bitumen unt nd ‘eradation vatt Fixing loose pacts of mixer and dryse unit Blectrical wiring oF the plant Final check up of various units Final check up of eletrical unite Individual uit testing on the Tox () Position different units as per the erection drawings, ‘on the ground, so that no further change will be required later on, Once the machine i jacked up, it is difficult to change the. position, ) Jack up unils, and provide timber packings under the frame to form a uniform contact between ground and frame, ‘When. last tier is placed, lower the anit slowly, so that fam rests on the sleepers evenly and firmly, (1) While erecting different assemblies, care should taken to maintain accars horizontal and yertical levels, 1 Well as intor alignment of diferent units, This wil ensure that no undue strains ate developed, and all shaits and drives shall work smionth'y. IFsuch cate iy not taken, there can be frequent and costly failures, due to misalignment, 6IRE: 904985 $a, Tela! Rus 5.1, With anew plant, o: one that has been inoperative for a fey Weeks, itis alays advisable to run a short mechanical test without fecding materia), or Groulating bitumen, This affords fim opportunity to cheek visually the drive tensions in belts and chains, alignment and pnesimatic pressure, ete, 5.3.2, Safely precautions: ‘Phe Chief oporater should wake precautions to enstire that all personnel exgeged ia “preliminaries” Grenew cleat of moving parts, See also that tools, ete. are not Int where they might vibrate and fall into moving parts. Also ‘ensure that all uards are proper'y fitted and that inspection doors end covers are closed, Make sure tat the plent can be started with no. possifie risk of injury to personnel. 3. ‘Feial starting up : {i) Diesel engines: A-copy of the manufacturers instruction manual, specially dealing with fuel, Lubrication, coolant, and stas- ting procedure should be shidied and understood. Check whether batteries are charged fully. Seast the engine With the power take- of clutch disengaged, and allow. to run light for about $ minutes, ‘whilstthe lubsicating oil warms up. Disengave the bitunen pump clutch before engaging the power take off clutch with a firm and steady moveinent, (ii) Slariing op electric motors (Diesel generators) : Start the power pack, and whet warm, engege chutoh to start the generator. The generator supplier may prefer starting the biggest motors first check this in the manual. (ii) Starling up electric motors (Main. supply): When wiring up electrical motors at Site, uncouple the drives to the unit, so that Girection of rotation ean be checkee. 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 for starting is “largest motors first”, whilst much of the pyerlead power "in hand’. Th: remainder may be started in any orders thoueh it 15 geod praciice to work fiom screen to feed, excluding the Bitumen Pump, which should be started only when bitumen ishot and reacy for ciranlation. The motor manufac- furere instruction mianeal and plant wiring diagram: are the best auide. Note Sines bitunel & ist to beoielated in the ‘jal run, do. nor stil the pump motor for engaxe ie-chatc) the pump shootd Wo: be tan "dry", unee IRC + 90.1985 JG) eubtlcaton “Application of correct grades and. quan nes, OF ie And eseases i very important, specially geet boxe ally Ms 8 they are usually, drained beiore aivpmeee, ee Pe Tee (bok Ht flied Wit 3 plugs tse, Ieper ad oe Pluss. To all cases, upper mostis filer, middle ove level, and Or ogPiae BME drain. To fll a gear box. add reeeste sated Qi antl, flow comaences at whe level of imicele plug holy Replace both the plugs. Drip feed jnbrien tors should be filled with oil, cpatte all beatings Atted in belt conveyor rollers, cold eleva reeaials, apron feeder soMers dryer drm Supporting roller, hq slevaior shaft and all driving cheins, i Pian 8 mow fn iN mectianical operation nd can switched to regular production. & STARTING, SHUTTING DOWN AND sroRAGH 61, Cheek List Before Starting (0) Hae yeu carried ou} dely maintenaiee a pet ineirietions # {) Have seu lopred up alloit tanks and. gear boxes with pro ginde of oitand face? ‘ ba | "| Have yu checked io eet inthe a ctennes and opel ©) wave JU Ohh che Uighiness of the -V" bos, Og, © caine? : (©) Have you checked atthe grease points? <1) eee youeheoked thai all guards and covers ae fitted ? (2) Hive you heated the bitumen pipe line to ackiove free No 9 “hy Haveyou ditensaged the huches befoe'aarting he eapine? OO eke at, eteed the rcéknnultd stones, before starting pucker elsyaior ()) Have youchsoked ihe conveyor hols for any damage or wear’ 6) Have sou checked the ponvesor rolls fo ree evening? (9. Have yeu shen A Re MN fl sprayed ino (Pere SON eed that, there: it no Water Ihe Bitumen th before pouring bitumen > “for Engine Driven Plant only 8 SSIRC: 90-1985 6.2, Stopping and Shutting Down (J) About ten mintites before production for the day is tobe ceased, or fo of three batches short of the desired number of batches, the feeder unit should be stopped. (2) As the last aparegate leaves the dryer, shut off the burner by closing down the fusi oil supply, at the shutoff cock cloge to the bumer. Then'shubolt the dryer mictor. (In engine driven plant cisengage clutch and then stop the engine). @), When whe final batch has Seen mined and disehatyed, clean “with L.D.0. or H.S.D. at both ends of paddle shafts to censure that they are free fo rotete at the time of starting the plant next day. (A), Bo not stop the plant while msteria is in transit, When the dryer, elevator, sereen, bins and mixer are empty, the plant tiay be stopped. (9) Turn off all drip feed Lubricarors. (6) Now, put ofthe bitumen tank burner by stopping fuel Supply, Stop the bitumen pump, and, immediately reverse its drive, cither by handwheel or reversing the motor rotation, Move the lever on the pressure tegulator (metering system oly) to the *draining™ position. Fix the discharge of weigh/spay system hopper in the open position. The bitumen system must be diained thoroughly, and eare teken at thisstage will pay dividends in easy starting the nent day, Al) bitumen piping show therefore slope downwards to the kettles to assist diainage, and a tap should be fitted in the delivery line immediately “after” the pump which may be left open overnight to prevent clogging of the pump. Note: ifeloaning solvents are wsed, these should be thoroughly drained off elore resienlating the blame sos (7) Fitl up fuel tank. (8) Report ony defects oy unusual sound tb’ the Engineer-in- (8) Chsck ‘and teetify aay Teakege, specially in asphalt and hot oil system. (10) Cheek all bolts and nuts for tightness, and cheek chain tension. 29a IRE : 90-1985 {1D Inspext the blower of exhaust fan for balance and pay of bearing, (12) Weld cracks in sheets, it aoticed, (13) Clean machine, speciatty duitiaseccgaie collected Indemesth belfchatn conveyors, and tuba geeh points, ra eel MOLOKE: slartor ‘sapine paris, exhaust. pipes ta, avoid raln or dew entering insite (15) Fill in-the tog book. 63, Hints on Storing the Piant Tf Pant isto be Veh in the open-for moze than & month mobile mck Settein precautions: should bo takes, copccially of Rabie machine's, and in cacreme si tie Conditions, “These are 8 fo! lows: GG) Remove batteries and. store them, fa a ary place one, “inickle” charge, or recharge bate reitting, | (i) In severe conditions, drain the rediaior even if anticfreem F has been added. (ty) Bolate the maine supply to electrically driven. plant te Prevent unauthorised starting, () Cover exposed starter paris, (i) Weap oll vee belts (and their pulleys) with a strong, self dines” PAP and tberaly greasy ti chaig drives, (i) Protect the dryer cytindsr bummer noztle, (3) Ie advisable to remove th & mobile plant to stgrag. axles, le pheumatio tyred wheels or and protect the hubs of the G) I 4 mobile: plant is ‘not ore ted, the weight shoutd ty ‘akon off the running sen 30 |SIRC 190.1985 (ci) If roller shutters are fitted on thermizer housing, lover these and lock up. (aii) Closs the windows of the control cebin and lock the doors. i (it) Cover the top of the exhaust fan to prevent ingress of svater, | (aiv) Cover the inlet of the burner ait blower i (ev) Ifthe door is fitted inthe dryer feed end box, pin in the closed position. (avi) The whole plant may, be preserved to some extent by frequent attention to paint work, especially, where. chip= pring and burning, ete. has oceurred, 7, OPERATING TRCANIQUES Tal, ‘The following-are general operating tips in the sequence of operation which will heIp ia bettor performance énd optimum titifisation of the plant. Aske Cold aggregate feeder + (4) Seerezation of aggregates at well ae iotermixing should ber prevented, when loading inte honpess. @ Hoppers should contain the correct size apstceates, and Ten hd always be Kept sullciealy full, to allow even flow Spemueh the feed gate ina particular set position. Most tnrerfaoturers give approximate tonage/hour for gate Spenings in the form of calibration chart for ench gate. ‘ (@ Arching of fine aggreantss J& prevented by plasing a aarutue, preferably, under the fine azgregates hoppers. | (4) Moisture on fine agerepates should also. be avoided, oF driest necessary allowance should be made. (5) To eveid any agerenate damaging conveyor belt by Bet: fing stuck between gate and belt, i & bei: that Ghehage gate openings of bins is at Teast 1.5 timer max- chs size of agzreuate fed, A atizaly may be kept over’ {he bins to. provent large pieces of stone, stick root, ete. clogging the gate. 31IRE: 90.1985 (0) Mee dliys Work, bins should befell with miniiwm 9 feast ciiggpveitlly duilor rainy season, "This will ena least strain On belts, end drives, when three ti het is started next day, () Chie periodically for material build’ up, preyon rollers from turning-and remove the sane: () De not lose disshurg: gate, and sun belts, to stop fay Pr gogreeates, but discnssge clutch ofaunitany ooye and then stop prime movers Cold aggregate bicker elevator : Pcer fe Feduce dhe feeding height of three bin feeden {Pu el approximately one metre depth should he sa {0 place the told elevator mounting feame, (2) Ensure bucketé reocive material directly, climinatin Stesing, althouslvedues are hard faced to give ons life, (@) Ensure 19 cold mix (or Peeregate) is accumulated in pit dug at bottom of sold elevator. 4 (@) An onse oC rai duuing previous night, ensuite ater lopgeh in pit of cold elevator is removed? (©) Do not stati: tie feeder pnit until the dryer eying burner has been incited, 71.3. Dryse uni (). Baily before starting diver: ensure feed box bottom ded is opened! and cleaned to remove dust a (2) Before staiting the plant, the nozele and burner shoul be cleaned with kerosene, 2) Do'not allow ageregate lo ow through ine dryer dru Ov when the vertical hot elevator) buoket is net Toe (4) Bofore sai td diver dean there sould not ‘be ‘speregtts inside it, since a very high stating to jequited ta stat dryer drum with faaregate, GS) Ifarnace off wed to. fre’ burscrs, then it shout b Freheated to brine downy viscosity betone passing | shsough burners, (6) Do not permit oped fite around fuel oft tanks, 22IRE: 90.1988 (7). Atways stand ané hols torch at desired length to prevent getting burnt in oase burnor puffs back, (8) When lighting burner, never allow excessive fuel to be sprayed into Combustion chamber and drum. () Do not keep burner lighted fora tong time not more than 5 minutes even without aggsepate inside Uryer Geum, asit Will damage the dryer itselh Operate on ow flame, when it i: not loaded fully. (10) Shape of flame is reyulated by. means ofan air Marinium swirl will produce a short wide flame and a tsinimum swvinla long cigar shaped flame, (11) If Mel pump delivery is irregular or negligible, psime the pump and sce that pump doesnot suck alr through joints on suction side. (12) Watch exhaust smoke, if it is black, it Would mean exozss fuel is being fed, and white emeke means excess moisture, (09), Ensure that no holes are formed in cyclone ait, This may add to excess dusty condition at site. (id) The dyer should not be overloaded by passing more aggregate than itcan handle, Por this, check regularly hot aggregate temperature to maintain at about 180°C with the help of dial thermometer available, end the. moisture Content should not exceed 0.5 per vent. (15) Determine the desired temperature of agerogate dis: charged from the dryer, by checking heat loss. @), From diye to mxen, (bj, From mixer {@ road, and (© Tom the temperatuce of mixing for proper viseocity of asphalt Keep flow of material theovgh dryer uniform, and at w rate dryer ean handle, with st proper dranght and rate of heat input (16) At the end ofthe day, put offic dyer drum burner by Hopping Wael eapply. and then step wpdne mover. (In case of engine driven plant, first disengage clutch and then stop ensine, qld Burner (1) Ensure prope’ adjustivent of bumes fitted on dryer unit to ensure uniform and detired aggregate temperature, 33IRC = «0.1985 | Shoyter and lonyer fanic length will atfect proper heal= ing of aggregates and dryes énds, (2) When the burner works properly, the smoke eomit out ofexhavst will be light colodted. “Bla ng cut indicates that ofl is not burnt ca stating inefeasing the Blower or draug decieasing the flow of fuel oil, Excess moist aggregates-form steam and results in light colour, FAS. Hot eleraion + (i) Daily boloje starting plant, any material at the foot of | elevator should bs removed through flap door. 2) Do-notallow senregate to flow from dryer drum, when ‘ vertical Tent oavator isnot working. | (3) Hot elevator discharge chute is provided with lines and. is checked weekly (0 determme extent of wear. | (4) Hot aparepates from dryer drum should be delivered to © vertical elevator, only after motor, or engine driving elevator picks up speed and run at rated r.p.m. (5) Care should be taken to see that buckets receive the nialeriel directly without having to ‘dig’, { 74.6, Gradation init = A. Seteen unit = / (i) The scien must be of adequate gred, must bave correct size openings anil properly arranged. Gi) The sereen, musi be set at the proper slope. (iil) Tho sercen should aotiheve holes. The clogging of seveen will not allovs the aggregates through. Breq- ent inspection and cleaning of sereen. is, therefore, a must, ; \ B, Hopper unit : {) Bosure that Sullicient material is stored alvays in the four hopper bins. (i) Watch the automate devices equipped, to ensure hat the plant is Sopped hen the aggregates Level upton i auy Wa, Silay, watch iso. be tent to entire that overfiow from any bin should also 341R@: 99 1985 not ovcur. The cold feed sould be controlled ascordingly. (ili) Take a sample ftom each boot bin and check for the proper grade, {is) Ensure proper gate openings, as. the output and. proportioning depends upon the samc. Proportioning Material : Gi) See that aggregate feeder gates are set as ger elie bration chart fer each gate. (i) Run gradation tests on euch sample taken at intervals. (iil) Every day check up the stales for zero ertor at no oad. (ix) The aguregates should be discharged ftom the hot bins into the weigh hoppers, starting with coaiscs ind progressing dows to the finest, in the batch plant, () The aggregate Giller and_ bitumen weighing scales should be correctly calibrated ah periodically Checked, say every week. Ta. Mixer uni (1) The puemill does the job of proper miking, when the tips of the paddle show clearly above the mix, Am raderfilled pugmill aes not allow the paddles! to. work properly, 13. an oyer-filied pagmill, the material floats Ebove the paddles and is not filly mixed (2) The mixing should, however, be done inthe shortest possible tine necessary, to produce uniforin ini, I the Fixing time ix too short, the particles would not have {uniform coating of asphalt. If the lime too long, the asphalt coating will hardep, because of the Jong expo- Sure to beatand air, Aivayerage tihe for dry mizing Could be about 15 seconds followed By 30 to 45. seconds ohmixing, after bitumen js added. (B) Over size aggregates entering mixer, cause mixer arms to bend, ae the clearance between the paddle tips and inside lining of the mixer box is generally, not to be wiore than 2 em. 35