2

The Production and Testing

of Bituminous Materials

2.1 Mixing Plants for Bituminous Highway Materials

The operation of proportioning the various aggregate sizes, adding binder and
mixing the whole to produce as far as possible a homogeneous mass is a relatively
simple process if a soft binder is employed; quality control is not important and only
a small amount of mixed material is required. All that is required is a heated tray and
several men with shovels.
Production of large quantities of material with highly viscous binders to exacting
specifications is a much more complex task, however, and various specialised items
of plant have been evolved to meet these needs.

1.1.1 Coated-macadam Mixing Plants

Traditionally, mixing plants developed in two separate ways: one type of plant for
the production of coated macadam and another for producing asphalts. Because
coated macadams frequently have binders of low viscosity and contain a relatively
low proportion of fine material these plants are often sited close to the aggregate·
source, making it necessary to haul the mixed material for considerable distances
to the laying site.
In a typical coated-macadam plant a range of aggregate sizes appropriate to the
grading of the material being produced is placed in storage bins that have at their
lowest points devices allowing a weighed quantity of each aggregate size to be
discharged onto a conveyor. A batch of aggregate is then heated in an oil-fired batch
heater before being discharged into a mixer, the binder and the filler being added
separately before the mixing process commences. After mixing, the coated macadam
is discharged directly into road transport or else conveyed to insulated storage bins.
An outline diagram of a typical plant is shown in figure 2.1.

32
R. J. Salter, Highway Design and Construction
© R.J. Salter 1988
 THE PRODUCTION AND TESTING OF BITUMINOUS MATERIALS 33

batch
heater

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feed

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Figure 2.1 Outline of the arrangement of a coated-macadam plant

2.1. 2 Asphalt Mixing Plants

Rolled asphalt is delivered to the laying site at high temperatures and for this
reason it is frequently necessary for the mixing plant to be sited within a reasonable
hauling distance of the laying site. For this reason asphalt mixing plants are
commonly made in a form allowing them to be moved closer to the site of construc-
tion operations. Even in industrial areas where there is likely to be a reasonably
constant demand for asphalt the plant may still be designed for portability.
In addition to the high mixing temperature of rolled asphalt it frequently
contains 35 per cent or more of sand, which may be damp or saturated, requiring
large amounts of heat to dry it and to complete the heating process. For this reason
the layout of an asphalt mixing plant differs from a coated-macadam mixing plant.
As can be seen in figure 2.2 the coarse and fine aggregate is dried and heated in a
continuous oil-fired rotary dryer. From the dryer the mixed aggregate is conveyed
to the screens and after screening discharged into heated aggregate storage hoppers,
which then feed the twin-shaft rotary mixer. The capacity of the hoppers is small
compared with a coated-macadam plant, usually not containing more than the
aggregate required for half an hour's production.
While a coated-macadam plant cannot be used to produce asphalt it is possible
for an asphalt plant to produce coated macadams.

2.1.3 Drum-mixing Plants

A range of plants in which the binder is added to the aggregate during the drying
and heating process and referred to as drum mixers is gaining increasing popularity