Asphalt Plant Level II - July 2005 1 of 11

Appendix 3b
Slide 1
Construction
Training
Qualification
Program
Asphalt Plant
Level II
Appendix 3b
Batch Plants – Hot Bin
Calibration Practice Problems

This is the technique used to

Slide 2

Calibration of Hot Bins establish hot bin “pulls”, or the individual

Batch Plants bin weights, from a batching plant.

(Establishing Hot Bin Percentages and

Weights for Production Requirements)

July 2005 Appendix 3b - 2

These are the typical procedures

Slide 3

one goes through.

Batch Plant Calibration 1) Start the plant - run the cold feed, the
dryer, and the screens
• Start the plant - run the cold feed, the dryer,
and the screens
2) After stabilization - sample the
• After stabilization - sample the material from material from each hot bin
each hot bin 3) Washed gradations are preferred - but
• Washed gradation is preferred - but dry dry gradation is acceptable.
gradation is acceptable 4) Then blend the aggregates to
• Then blend the aggregates to determine the determine the percentages from each bin
percentages from each bin to meet the JMF.
to meet the JMF.
July 2005 Appendix 3b - 3
Asphalt Plant Level II - July 2005 2 of 11
Appendix 3b
Slide 4 Although the blending of
aggregates is shown here for hot bins, this
Blending of Aggregates same process is used in blending
materials for mix design as well as
• Batch Plant Hot Bins adjusting percentages on cold feeds based
• Other applications on stockpile gradations.
– Mix Design
– Cold Bins
• Methods
– Trial and Error
– Computer spread sheet

July 2005 Appendix 3b - 4

This is the formula used for the

Slide 5

procedure.
Blending of Aggregates
P = Aa + Bb + Cc + ….
– Where:
• P = % of material passing a given sieve for
the blended aggregates A, B, C, …
• A, B, C, … = % material passing a given
sieve for each aggregate A, B, C, …..
• a, b, c, …. = Proportions (decimal fractions)
of aggregates A, B, C, … to be
used in blend

July 2005 Appendix 3b - 5

Slide 6

Blending of Aggregates
P = Aa + Bb + Cc
Sieve BIN 1 a BIN 2 b BIN 3 c BIN 4 d Blend JMF

3/4 in

1/2 in

3/8 in

No. 4 A Aa B Bb C Cc D Dd P

No. 8

No. 16

No. 30

No. 50

No. 100

No. 200

July 2005 Appendix 3b - 6

Asphalt Plant Level II - July 2005 3 of 11
Appendix 3b
Slide 7 Start with the gradations of the
individual aggregates and list them based
Blending of Aggregates on the control sieves.
Sieve BIN 1 BIN 2 BIN 3 BIN 4 Blend JMF
You can determine the blend
3/4 in 100 100 100 100 100
proportions from each bin (or material)
1/2 in 100 100 100 77 96 by:
3/8 in

No. 4
100

100
100

87
98

4.1
19

3.1
87

63
1. Experience
No. 8 98 4.1 3.6 2.5 46
2. Computer program
No. 16 83 3.9 3.4 2.3 39

No. 30 65 3.0 2.5 2.0 31 3. By an empirical procedure

No. 50

No. 100
45

22
2.5

2.3
2.0

1.8
1.8

1.7
21

11
We will use the empirical
No. 200 8.0 2.0 1.0 1.1 4.4 procedure for this classroom problem.
July 2005 Appendix 3b - 7

Determine the amount to be

Slide 8

Blending of Aggregates pulled from Bin # 1 (0.45). Look for a

Bin # 1 sieve where there is a lot passing for the
Sieve BIN 1 0.45 BIN 2 BIN 3 BIN 4 Blend JMF No. 1 bin material and little passing for
3/4 in 100 100 100 100 100 the other bins. (No. 8 or No. 16 sieve)
1/2 in
3/8 in
100
100
100
100
100
98
77
19
96
87
then the equation reduces to P = Aa.
No. 4 100 87 4.1 3.1 63
No. 8 98 4.1 3.6 2.5 46
No. 16 83 3.9 3.4 2.3 39

No. 30 65 3.0 2.5 2.0 31

No. 50 45 2.5 2.0 1.8 21
No. 100 22 2.3 1.8 1.7 11

No. 200 8.0 2.0 1.0 1.1 4.4

a = JMF = ± 0.45
July 2005 A Appendix 3b - 8

Blending of Aggregates Determine the amount to be

Slide 9

pulled from Bin # 4 (0.15). This time

Bin # 4
Sieve BIN 1 (0.45) BIN 2 BIN 3 BIN 4 (0.15) Blend JMF look at the % retained = 100 – (%
3/4 in 100 45 100 100 100 100
passing), and find sieve where there is
1/2 in 100 45 100 100 77 11.6 96 some retained for Bin 4 material, and
3/8 in 100 45 100 98 19 87

No. 4 100 45 87 4.1 3.1 63

none for the other bins (1/2” sieve) then
No. 8
No. 16
98
83
44.1
37.4
4.1
3.9
3.6
3.4
2.5
2.3
46
39
the equation reduces to (100 - P) = (100 –
No. 30 65 29.3 3.0 2.5 2.0 31 D) d.
No. 50 45 20.3 2.5 2.0 1.8 21
No. 100 22 9.9 2.3 1.8 1.7 11

No. 200 8.0 3.60 2.0 1.0 1.1 4.4

d = 100 – JMF = ± 0.15

100 - D
July 2005 Appendix 3b - 9
Asphalt Plant Level II - July 2005 4 of 11
Appendix 3b
Slide 10 Blending of Aggregates Distribute the remaining amount
between bins 2 and 3 (0.20, 0.20).
Bin # 2 & # 3
Sieve BIN 1 (0.45) BIN 2 BIN 3 BIN 4 (0.15) Blend JMF

3/4 in 100 45 100 100 100 15 100

1/2 in 100 45 100 100 77 11.6 96

3/8 in 100 45 100 98 19 2.9 87

No. 4 100 45 87 4.1 3.1 0.5 63

No. 8 98 44.1 4.1 3.6 2.5 0.4 46
No. 16 83 37.4 3.9 3.4 2.3 0.3 39

No. 30 65 29.3 3.0 2.5 2.0 0.3 31

No. 50 45 20.3 2.5 2.0 1.8 0.3 21
No. 100 22 9.9 2.3 1.8 1.7 0.3 11

No. 200 8.0 3.60 2.0 1.0 1.1 0.17 4.4

July 2005 Appendix 3b - 10

Blending of Aggregates Finish all the calculations. We are

Slide 11

slightly out of spec on our target JMF.

Bin # 2 & # 3
So, we need to try the blend again.
3/4 in 100 45.0 100 20.0 100 20.0 100 15.0 100.0 100

1/2 in 100 45.0 100 20.0 100 20.0 77 11.6 96.6 96

3/8 in 100 45.0 100 20.0 98 20.0 19 2.9 87.5 87
No. 4 100 45.0 87 17.4 4.1 0.8 3.1 0.5 63.7 63

No. 8 98 44.1 4.1 0.8 3.6 0.7 2.5 0.4 46.0 46

No. 16 83 37.4 3.9 0.8 3.4 0.7 2.3 0.3 39.2 39

No. 30 65 29.3 3.0 0.6 2.5 0.5 2.0 0.3 30.7 31

No. 50 45 20.3 2.5 0.5 2.0 0.4 1.8 0.3 21.5 21
No. 100 22 9.9 2.3 0.5 1.8 0.4 1.7 0.3 11.1 11

No. 200 8.0 3.60 2.0 0.40 1.0 0.20 1.1 0.17 4.37 4.4

July 2005 Appendix 3b - 11

So we need to try the blend again.

Slide 12

Blending of Aggregates For our second trial we will use Bin # 1 –

Trial No. 2 45%; Bin # 2 – 19%; Bin # 3 – 20%; Bin
Sieve BIN 1 (0.45) BIN 2 (0.19) BIN 3 (0.20) BIN 4 (0.16) Blend JMF # 4 – 16%. We choose these percentages
3/4 in 100 100 100 100 100 based on experience and this gets us
1/2 in
3/8 in
100
100
100
100
100
98
77
19
96
87
closer to the JMF.
No. 4 100 87 4.1 3.1 63
No. 8 98 4.1 3.6 2.5 46
No. 16 83 3.9 3.4 2.3 39

No. 30 65 3.0 2.5 2.0 31

No. 50 45 2.5 2.0 1.8 21
No. 100 22 2.3 1.8 1.7 11

No. 200 8.0 2.0 1.0 1.1 4.4

July 2005 Appendix 3b - 12

Asphalt Plant Level II - July 2005 5 of 11
Appendix 3b
Slide 13 Once the individual bin
percentages are calculated, the individual
weights have to be established.
Determination of Bin
Weights or
How Much Aggregate
Should be Weighed out
from Each Bin

July 2005 Appendix 3b - 13

This slide summarizes the results

Slide 14

of the previous blend calculations. The

Example Problem mix will have 6% asphalt and will have
the aggregate proportions shown. The
• To summarize batch size will be three tons or 6000
– Batch Size 6000 lbs
pounds.
– % Asphalt 6%
– Bin # 1 45 %
– Bin # 2 19 %
– Bin # 3 20 %
– Bin # 4 16 %

July 2005 Appendix 3b - 14

The first step is to determine how

Slide 15

much aggregate will be in each batch.

Example Problem

• Calculate the amount of AC in the mix

6000 * 0.06 (6%) = 360 lb

• Total aggregate weight in the batch

6000 - 360 = 5640 lb

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Asphalt Plant Level II - July 2005 6 of 11
Appendix 3b
Slide 16 After the proportions of each
aggregate have been determined – it is
Example Problem easy to calculate the weight required from
each bin.
Bin Proportion Agg wt Req. Wt.
1 45 * 5640 2538

2 19 * 5640 1072

3 20 * 5640 1128

4 16 * 5640 902

July 2005 Appendix 3b - 16

Slide 17

Hot Bin Calibration

Practice Problem

July 2005 Appendix 3b - 17

Slide 18

Practice Problem
• Given:
– Batch size = 4000 lbs
– Asphalt content = 4.5 %
– Gradations shown on next sheet
• Required
– Blend the aggregates then
– Calculate the bin weights

July 2005 Appendix 3b - 18

Asphalt Plant Level II - July 2005 7 of 11
Appendix 3b
Slide 19
Practice problem gradation

Sieve Bin # 1 Bin # 2 Bin # 3 JMF

Size

3/4 inch 100 100 100 100

1/2 inch 100 100 100 100
3/8 inch 100 100 85 96
# 4 100 78 4.2 67
# 10 92.2 2.3 1.6 47
# 40 52.6 2 1.4 27
# 80 22.7 1.8 1.4 12
# 200 3.5 1.6 1.2 2.5

July 2005 Appendix 3b - 19

Slide 20

Blending of Aggregates
P = Aa + Bb + Cc
Sieve Bin # 1 Bin # 2 Bin # 3 Blend JMF

3/4 in 100 100 100 100

1/2 in 100 100 100 100
3/8 in 100 100 85.0 96.0
No. 4 100 78.0 4.2 67.0
No. 10 92.2 2.3 1.6 47.0
No. 40 52.6 2.0 1.4 27.0
No. 80 22.7 1.8 1.4 12.0
No. 200 3.50 1.60 1.20 2.50

July 2005 Appendix 3b - 20

Slide 21

Practice Problem

• Calculate the AC content in the mix

• Total aggregate weight in the batch

July 2005 Appendix 3b - 21

Asphalt Plant Level II - July 2005 8 of 11
Appendix 3b
Slide 22

Practice Problem
• To summarize
– Batch Size 4000 lbs
– % Asphalt 5.5 %
– Bin # 1 _____ %
– Bin # 2 _____ %
– Bin # 3 _____ %

July 2005 Appendix 3b - 22

Slide 23

Practice Problem
Bin Proportion Agg wt Req. Wt.
1

July 2005 Appendix 3b - 23

Slide 24

ANSWERS

Batch Plants – Hot Bin Calibration

Practice Problem

July 2005 Appendix 3b - 24

Asphalt Plant Level II - July 2005 9 of 11
Appendix 3b
Slide 25

Hot Bin Calibration

Practice Problem

July 2005 Appendix 3b - 25

Slide 26

Practice Problem
• Given:
– Batch size = 4000 lbs
– Asphalt content = 5.5 %
– Gradations shown on next sheet
• Required
– Blend the aggregates then
– Calculate the bin weights

July 2005 Appendix 3b - 26

Slide 27

Practice problem gradation

Sieve Bin # 1 (.50) Bin # 2 (0.20) Bin # 3 (0.30) Blend JMF

3/4 in 100 50 100 20 100 30 100 100

1/2 in 100 50 100 20 100 30 100 100
3/8 in 100 50 100 20 85.0 26.0 96.0 96.0
No. 4 100 50 78.0 15.6 4.2 1.3 66.9 67.0
No. 10 92.2 46.1 2.3 0.5 1.6 0.5 47.0 47.0
No. 40 52.6 26.3 2.0 0.4 1.4 0.4 27.1 27.0
No. 80 22.7 11.4 1.8 0.4 1.4 0.4 12.1 12.0
No. 200 3.50 1.75 1.60 0.32 1.20 0.36 2.43 2.50

July 2005 Appendix 3b - 27

Asphalt Plant Level II - July 2005 10 of 11
Appendix 3b
Slide 28

Example Problem

• Calculate the AC content in the mix

4000 * 0.055 (5.5%) = 220 lb

• Total aggregate weight in the batch

4000 - 220 = 3780 lb

July 2005 Appendix 3b - 28

Slide 29

Example Problem
• To summarize
– Batch Size 4000 lbs
– % Asphalt 5.5 %
– Bin # 1 50 %
– Bin # 2 20 %
– Bin # 3 30 %

July 2005 Appendix 3b - 29

Slide 30

Example Problem
Bin Proportion Agg wt Req. Wt.
1 50 * 3780 1890

2 20 * 3780 756

3 30 * 3780 1134

July 2005 Appendix 3b - 30

Asphalt Plant Level II - July 2005 11 of 11
Appendix 3b
Slide 31

Additional Gradation
Problem

July 2005 Appendix 3b - 31

Slide 32

Gradation
Sieve BIN 1 BIN 2 BIN 3 BIN 4 Blend JMF

3/4 in 100 100 100 100 100

1/2 in 100 100 100 89.7 97

3/8 in 100 100 96.7 84.5 95

No. 4 100 82 3.4 3.6 60

No. 8 87 4.8 2.6 2.8 45

No. 16 66 4.0 2.5 1.9 34

No. 30 49 3.5 2.3 1.7 25

No. 50 34 2.1 1.9 1.5 18

No. 100 15 2.0 1.8 1.4 8

No. 200 6.0 1.8 1.6 1.3 3.7

July 2005 Appendix 3b - 32

Slide 33

Gradation Answer
Sieve BIN 1 (0.50) BIN 2 (0.10) BIN 3 (0.10) BIN 4 (0.30) Blend JMF

3/4 in 100 50 100 10 100 10 100 30 100 100

1/2 in 100 50 100 10 100 10 89.7 26.9 96.9 97

3/8 in 100 50 100 10 96.7 9.7 84.5 25.4 95.0 95

No. 4 100 50 82 8.0 3.4 0.3 3.6 1.1 59.6 60

No. 8 87 43.5 4.8 0.5 2.6 0.3 2.8 0.8 45.1 45

No. 16 66 33.0 4.0 0.4 2.5 0.3 1.9 0.6 34.2 34

No. 30 49 24.5 3.5 0.4 2.3 0.2 1.7 0.5 25.6 25

No. 50 34 17.0 2.1 0.2 1.9 0.2 1.5 0.5 17.9 18

No. 100 15 7.5 2.0 0.2 1.8 0.2 1.4 0.4 8.3 8
No. 200 6.0 3.00 1.8 0.18 1.60 0.16 1.3 0.39 3.73 3.7

July 2005 Appendix 3b - 33