S_04 ECET-06

CONTINUOUS PAVING PLANT & PROCESS

1.0 PURPOSE

This procedure outline the use of continuous paving plant and processes (PPP),
Drum plant model 20:104 to produce the asphalt hot mixes.

2.0 SCOPE

Basically all raw materials input are controlled by using the weighing method,
where a load cell is located at all raw material’s input conveyor to supply weight
information directly to the computer system. A temperature gauge is located at the
out let of the plant and it is also connected to the computer for determine the
mixture’s temperature. The details of the drum plant and the operation procedure
are attached: “The Paving Plant and Processes Drum Mixer Manual”.

3.0 REFERENCES

ASTM D 979-87 Standard Test Methods for Sampling Bituminous Paving

Mixtures;
ASTM D 2172-88 Standard Test Methods for Quantitative Extraction of Bitumen
from Bituminous Paving Mixtures;
ASTM D 2726-88 Standard Test Methods for Bulk Specific Gravity and Density of
Compacted Bituminous Mixtures Using Saturated surface-dry
specimens;
ASTM D 1559-82 Standard Test Methods for Resistance to Plastic Flow of
Bituminous Mixtures Using Marshall Apparatus;
BS 812:Part 1:75 Methods for Sampling and Testing of Mineral Aggregates,
Sands and Fillers;

4.0 DEFINITION

4.1 Premix: Premix is asphaltic concrete commonly used in the

construction industry Premix is a general term describing a mixture of
various stones sizes held Together by a bitumen binder.
Premix is produced as a hot, dry material, which requires careful handling.
The material is applied to a surface whilst it is in the hot state. This is usually
done through a paver/finisher machine. As the material cools its ultimate
strength is achieved. Premix is often known by other common names such
as Hotmix or Asphalt.

4.2 Drum Mixer The drum mixer process is an example of continuous method
of making premix. The drum mixer process combines the heating and drying
of the aggregate and it’s mixing with liquid asphalt, bitumen or tar.

4.3 PPP: Paving Plant & Process.

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5.0 RESPONSIBILITIES

5.1 The operation and control of paving plant & process (PPP) is under the
responsibility of MTD CONSTRUCTION Sdn.Bhd.

5.2 Hierarchy of the plant management and operation are as follow:

Name Position Experience Contact

6.0 MATERIALS

6.1 The compliance of raw materials for hot mixes shall be checked and tested
prior use into the
Plant. Required raw materials are as follow:

6.1.1 37.5 mm nominal size granite crusher run;

6.1.2 25.0 mm granite aggregate;
6.1.3 20.0 mm granite aggregate;
6.1.4 10.0 mm granite aggregate;
6.1.5 Quarry dust;
6.1.6 Bitumen 80/100 penetration;

6.2 Material Quality Requirements:

6.2.1 Sieve analysis test shall be carrying out to determine the consistency
of the sizes.
6.2.2 The test shall be conducted every 5,000 ton of raw materials
delivered.
6.2.3 If the grading is found deviated, the supplier shall be informed and
immediate action should be carrying out to correct the mistake.
6.2.4 If necessary the technician will adjust the mixture’s combine
percentage at the hot mix plant in order to ensure the good quality of
final mixture.
6.2.5 Material shall be tested in advance and shown compliance before
delivery.

7.0 EQUIPMENT’S

7.1 Hot Mix Plant

7.2 Laboratory Equipment.

The Q.C Laboratory were equipped with necessary instrument and as listed
below:

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7.2.1 Weighing instrument:

 1 no of 5,000 grams electronic balance;
 1 no of 25 Kg mechanical balance;
 1 no of 2.6 Kg mechanical balance;

7.2.2 300 mm diameter test sieve:

 50 mm, 37.5 mm, 28 mm, 20 mm, 14 mm, 10 mm, 6.3 mm, 5 mm,
3.35 mm,
 1.18 mm, 425 m, 300 m, 150 m, 75 m and pan.

7.2.3 1 no of rifle box with 50 mm aperture.

7.2.4 1 no of 150 liter fan forced laboratory oven.
7.2.5 Marshall set.

 1 set of Marshall mechanical compactor completes with mould and

extractor.
 1 set of Marshall testing machine for determining stability and flow.

7.2.6 1 no of bitumen extraction machine.

7.2.7 2 no of 6” length thermometers range from 20c to 250c.

7.3 Calibration of the Hot Mix Plant.

In house calibration for the hot mix plant will be carried out twice a year. The
calibration will be carried out by the individual motor for raw material and
load the material to a lorry for weight verification. Using a weight bridge,
which was calibrated by the weight bridge supplier in advance, does the
weighing. If the plant’s desired weight is tally to the Weight Bridge’s tonnage,
the calibration processes consider completed other wises the motor speed
and the load cell shall be readjusted.

7.4 Calibration for laboratory equipment.

Independent Testing Company conducts the calibrations for Marshall

machine and electronic balance. The calibration interval is every year per
calibration.

8.0 SAFETY CONDITION

Refer to Safety Booklet

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9.0 ACTIVITY PROCESS

The mixing procedures for hot mix plant are as follow and will be monitored by the
Q.C team

9.1 Moisture content for all the raw materials shall be ascertained twice a day by
using the pan frying method. The moisture contents for aggregates are
directly transmitted to the computer system for adjustments of materials
weight.
9.2 Upon receiving an order from the construction site, the plant operator shall
recall the mixture number that was installed in the computers in advance.
9.3 After the mixture information has been retrieved, other relevant information
will be keyed into the computer and the production of hot mix shall begin.
9.4 Prior to loading all lorries shall have their bucket cleaned and freed from
water or others materials.
9.5 Once the truck is loaded, the mix shall be covered with tarpaulin and then
the lorry will move to the Weight Bridge for weighing.
9.6 On site, prior to the discharge of hot mixes, the site supervisor will check the
docket to ensure correct material.
9.7 If the hot mix’s control parameter such as bitumen content, grading, Marshall
properties are found deviated the engineer will be informed and immediate
action will be carrying out to correct the mistake.
9.8 If necessary the technician shall decide the adjustment to be made in order
to produce the proper final product.
9.9 For field density control,a core sample will be abstracted from every 2000
m^2 of area laid. The test will be conducted by using water replacement
method.
9.10 The entire test shall be conducted in contractor’s supervision.
9.11 The above procedures will be repeated for all production.

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