4.

Construction plants

3.4.2 Asphalt mixing plant

3.4.1 Aggregate production plant

3.4.3 Ready mix concrete plant

3.4.1 Aggregate production plant

The production of
crushed-stone aggregate
involves:
 Drilling
 Blasting
 Loading
 Transporting
 Crushing
 Screening
 Product handling and
storage
 Production of aggregate

In operating a quarry and crushing plant, the drilling

pattern, the amount of explosives, the size shovel or
loader used to load the stone, and the size of the
primary crusher should be coordinated to assure that
all stone from the quarry can be economically
utilized.
Production line of stone crusher
 TYPES OF CRUSHERS

Crushers are classified according to the stage of

crushing which they accomplish, such as:
 Primary
 Secondary
 Tertiary
 A primary crusher receives the stone directly from a quarry
after blasting, and produces the first reduction in size.
 The output of the primary crusher is then fed to a secondary
and tertiary crusher, which further reduces the stone size.
 Crushers are also classified by their method of mechanically
transmitted fracturing energy to the rock.
 Jaw, gyratory, and roll crushers work by applying
compressive force.
 Impact crushers such as single rotor and hammer mill
apply high-speed impact force to accomplish fracturing
JAW CRUSHERS

 Jaw crushers operate by

allowing stone to flow into
the space between two
jaws, one of which is
stationary while the other is
movable .
Gyratory crushers
 Gyratory crushers provide
continuous crushing action and
are used for both primary and
secondary crushing of hard,
tough, abrasive rock.
ROLL CRUSHERS

 Roll crushers are used for

producing additional reductions
in the sizes of stone after the
output of a quarry has been
subjected to one or more stages
of prior crushing.
 A roll crusher consists of a heavy
cast iron frame equipped with
either one or more hard-steel
rolls, each mounted on a
separate horizontal shaft.
SCREENING AGGREGATE

 Screening of crushed stone is

necessary in order to separate
the aggregate by size ranges.

 Most specifications covering

the use of aggregate stipulate
that the different sizes shall be
combined to produce a blend
having a given size
distribution.
 HANDLING CRASHEDSTONE AGGREGATE

 After stone is crushed and screened to

provide the desired size ranges, it is
necessary to handle the stone carefully
or the large and small particles may
separate, thereby destroying the blend
in sizes which is essential to meeting
graduation requirements.

 If aggregate is permitted to flow freely

off the end of a belt conveyor, especially
at some height above the storage pile,
the material will be segregated by sizes.
3.4.2 Asphalt mixing plants
 3.4.2 Asphalt mixing plants

Cold Feed Systems

• Cold feed bins provide
aggregate surge and a uniform
flow of properly sized material
for mixing. The individual bins
can be fed from sized aggregate
stockpiles by front‐end loader,
clamshell, or conveyor
Drum Dryer

 The purposes of a drum dryer are to heat and dry the

aggregates of the mix.

Hot Screening
 This enables gradation control of four aggregate sizes into
four different hot bins
Hot Bins
 The aggregates from the hot screens are stored in the hot
bins until the plant is ready to make a batch of asphalt
concrete.
Weight Hopper
• Aggregate from the hot bins is dropped into a weight hopper
situated below the bins and above the pugmill. The weight
hopper is charged one hot bin at a time to control the
gradation of the blended aggregate. The aggregates are
weighed cumulatively in the hopper. After charging, the
weight hopper gates are opened to discharge the aggregate
into the pugmill.
Asphalt‐Handling System
 The asphalt cement is stored on site in a heated tank. The
asphalt is pumped to the weight tank, ready for discharge into
the pugmill. After the aggregates are added to the pugmill,
the asphalt cement is pumped through spray bars into the
pugmill to coat the aggregates.
Pugmill Mixing
 Most plants use a twin shaft pugmill for mixing the batch. To
achieve uniform mixing, a pugmill’s live zone should be
completely filled with mix
 PAVING EQUIPMENT
A paving operation requires several pieces of equipment. These
include;

– Sweeper/brooms for removing dust from the surface to be paved.

– Trucks for transporting the asphalt from the plant to the construction

site.

– Asphalt distributor truck for applying the prime tack, or seal coats.

– Asphalt Paver.

– Material transfer vehicle (optional).

– Rollers.
Material transfer device

 A material transfer device can receive

multiple truckloads of asphalt concrete,
remix the asphalt concrete, and deliver
it to the paver hopper
Asphalt distributor
 When applying an asphalt prime, tack, Asphalt distributor
or seal coat, a specially designed
distributor truck is utilized

Asphalt paver

 This equipment that is used to pave the

asphalt on the road
Asphalt Paver
 3.2.3 Concrete Batching Plants
 Concrete consists of cement, water, and aggregate that are
mixed together, placed, consolidated, and allowed to solidify
and harden.

 Concrete batching plant consists the equipments used for

batching, mixing and placing,

 Batch control (controls the proportion of ingredients )

– The ingredients are introduced into a concrete mixer and

mixed for a suitable period of time until all the ingredients
are adequately blended together
• Ready-mix concrete is a type of concrete that is
manufactured in a factory or batching plant, according to a set
recipe, and then delivered to a work site, by truck mounted
transit mixers . This results in a precise mixture, allowing
specialty concrete mixtures to be developed and
implemented on construction sites. The first ready-mix factory
was built in the 1930s, but the industry did not begin to
expand significantly until the 1960s, and it has continued to
grow since then.
• Ready-mix concrete is preferred over on-site concrete mixing
because of the precision of the mixture and reduced work site
confusion. However, using a pre-determined concrete mixture
reduces flexibility, both in the supply chain and in the actual
components of the concrete.

• Ready Mixed Concrete is also referred as the customized

concrete products for commercial purpose. the Ready-mix
Concrete Company offer different concrete according to user's
mix design or industrial standard.
• Ready Mixed Concrete, or RMC as it is popularly called, refers
to concrete that is specifically manufactured for delivery to
the customer's construction site in a freshly mixed and plastic
or unhardened state.

• Concrete itself is a mixture of Portland cement, water and

aggregates comprising sand and gravel or crushed stone.

• In traditional work sites, each of these materials is procured

separately and mixed in specified proportions at site to make
concrete.
• Ready Mixed Concrete is bought and sold by volume - usually
expressed in cubic meters. RMC can be custom-made to suit
different applications.

• Ready Mixed Concrete is manufactured under computer-

controlled operations and transported and placed at site using
sophisticated equipment and methods. RMC assures its
customers numerous benefits.
Concrete batching plant
Mixing

 There are two types of

concrete‐mixing operations in use:

(1) transit mixing and

(2) central mixing Central – mixed concrete plant

Transit – mix truck

Equipment for transporting (placing) concrete
Placing of concrete
Once the concrete arrives at the project
Concrete buggy
site, it must be moved to its final position
without segregation and before it has
achieved an initial set.

Concrete pump
(through pipe)

Chute
Bucket
(Concrete (Large & massive
transported to lower construction. Handled by
level) crane) Wheelbarrow
Transporting concrete with concrete
pumps
Transporting concrete with chutes
Transporting concrete with various
means
Thank you