SELECTION, OPERATION AND

MAINTENANCE OF BITUMINOUS
HOT MIX PLANT
(FIRST REVISION)

Published by

INDIAN ROADS CONGRESS

Kama Koti Marg,
Sector 6, R.K. Puram,
New Delt-ri-110022
NOVEMBER - 2010

Price Rs. 3001-

(Packing & postage charges extra)
First Published September, 1985
Repriented. April, 2002
Repriented April, 2005
Repr-ie&ed -. -March,_2000!5
Repriented July, 2008
First Revision November, 2010

(All Rights Reserved. No Part of this Publication shall be reproduced,

translated or transmited in any form or by any means without the
permission of the Indian Roads Congress)

Printed at : IG Printers & Publishers Pvt. Ltd., New Delhi

(500 Copies)
 CONTENTS

S.No. -- -

I Page No.

Personnel of General Specifications & Standards Committee (GSS) (0

Introduction
Background
2. Purpose
3. Classification
3.1 Capacity of Hot Mix Plant 4
3.2 Methodology Adopted for Preparation of Hot Mix
3.2.1 Hot mix plant (continuous type)
3.2.2 Hot mix plant (batch type)
3.3 Direction of Flow of Aggregates and Hot Gases
3.3.1 Counter flow type dryer-mixer
3.3.2 Parallel flow type drum mixer
3.4 Mobility of Hot Mix Plant
4. Salient Features of Batch Type Hot Mix Plant
4.1 Components of Hot Mix Plant (Batch Type)
4.1.1 Cold bin feeder
4.1.2 Cold elevator or cold feed conveyor
4.1.3 Dryer drum
4.1.4 Primary pollution control device
4.1.5 Hot elevat0.r.
4.1.6 screening unit
4.1.7 Hot bins
4.1.8 Weigh hopper
4.1.9 Bitumen unit
4.1.I
0 Mixing unit (pugmill)
4.1.11 Mineral fillerldust control system
4.1.12 Control panel
 4.1.13 Secondary pollution control device (bag house filter) 26 I

4.1.14 Hot niix surge silo 27

4.2 Selection of Site for Hot Mix Plant (Batch Type)
-
- - - -- - -- - -- - - - - - -- -

4.3 Advantages of Hot Mix Plants (Batch Type)

4.4 Limitations of Hot Mix Plants (Batch Type)
4.5 ~ e ~ u i r e m eof
n tDG Set for Hot Mix Plant (Batch Type) 28 I

5. Drum Mix Plant 28 1

I
5.1 Brief 28
5.2 Components of Conventional Drum Mix Plant (Parallel Flow Type) 29
5.2.1 Cold bin feeder 29
5.2.2 Aggregates over size rejection screen
5.2.3 Cold feed conveyor
5.2.4 Automatic weighing system
5.2.5 Dryer cum mixing drum
5.2.6. Exhaust control system
5.2.7- Bitumen unit
5.2.8 Primary pollution control device (dust
collection system)
5.2.9 Hot mix conveyor
5.2.10 Gob hopper
5.2.11 Control cabin
5.2.12 Mineral filler system
5.2.13 Hot mix surge silo
5.2.14 Secondary pollution control device 34 1
5.3 Advantages of Hot Mix Plant (Drurn-Mix Type) 35
5.4 Limitations OF Hot Mix Plant (Drum-Mix Type)
5.5 Power Requirement for Drum-Mix Plant
5.6 Double Barrel Drum Mix Plant
5.6.1 Sequence for preparation of hot mix
37
37
I
5.6.2 Coniponents of double barrel drum mix plant 39
5.6.3 Bitumen unit
 5i6.4 Drag conveyor 4I
5.6.5 Gob hopper 41
5.6.6 Control cabin
5.6.7 Mineral filler system
5.6.8 Secondary pollution control device (bag house
filter system) 42
5.6.9 Hot mix surge silo 42
5.7 Advantages of Hot Mix Plant (Double Barrel Drum-Mix Type) 42
5.8 Limitations of Hot Mix Plant (Double Barrel Drum-Mix Type) 42
6. Operation of Hot Mix Plants 43
6.1 Principles for Operation
6.2 General
6.3 Precaution During Operation of Plant
6.3.1 Cold aggregate feeder
6.3.2 Cold aggregate bucket elevator
6.3.3 Dryer unit
6.3.4 Burner
6.3.5 Hot elevator
6.3.6 Gradation unit
6.3.7 Mixer unit
6.3.8 Bitumen unit 48
7. Essential Activities while Starting, Operating and
Shutting Down the Plants
7.1 Check List before Starting the Plant 51
7.2 Sequence of Operation for Starting and Shutting Down the Plant 51
7.3 Upkeep of'the Plant During Idling 53
8. Maintenance and Upkeep of Hot Mix Plant
8.1 Maintenance Schedule
8.1 . I Daily maintenance schedule
8.2 Requirement of Tools and Plant for Maintenance
8.3 Requirement of Spare Parts and Lubricants for Repair and
Maintenance 58
9 Safety Aspect at Hot Mix Plant Site
9.1 Work Site
9.2 Plant and Equipment
9.3 . Loading and Transportation of Plant and Equipment
9.4 Maintenance of Plant and Equipment
10. Major Factors Affecting the Performance of Hot Mix Plant
10.1 Presence of Moisture Content in Aggregates
10.2 Dust Contents in Mix
10.3 Altitude
10.4 Insulation of Drum
11. Suggestions

ANNEXES
Annex- A - lnformation to be Furnished by the Purchaser While
Making an Enquiry with the Manufacturer

Annex- B - lnformation to be Supplied by the Manufacturer to the Purchaser

Annex- C - Typical Mot Mix Plant Emission and their Control

Annex- D - Typical Charts of Hot Mix Plant Output vs Different Parameters

Annex- E - Checklist for selection of Hot Mix Plant 70

Annex- F - Sample Prdcedure for Calculation of Rate of Usage Charges of 71

Hot Mix Plant.

Annex- G - Do's and Don'ts for Maintenance of Hot Mix Plants 74

Annex- H - Sample Calculation for Output Analysis of a Hot Mix Plant 77

Annex- I - Sample Calculation to Work Out Requirement of Hot Mix Plant 78

Annex -J - Calibration of Hot Mix Plant 79

 PERSONNEL OF THE GENERAL SPECIFICATIONS
AND STANDARDS COMMITTEE (GSS)
(As on 24 April, 2010 ) - --- -
--
- -
- - - -- - -

1
1. Sinha, A.V. Director General (RD) & Spl. Secretary, Ministry of
(Convenor) Road Transport & Highways, New Delhi
2. Puri, S.K. Addl. Director General, Ministry of Road Transport &
I (Co-Convenor) Highways, New Delhi
Kandasamy, C. Chief Engineer (R) (S&R), Miqistry of Road Transport
(Member-Secretary) and Highways, New Delhi
Members
Ram, R.D. Engineer-in-Chief-cum-Addl. Comm.-cum-Spl
Secy., Rural Construction Deptt., Patna
Shukla, Shailendra Engineer-in-Chief, M.P. P.W.D., Bhopal
Chahal, H.S. Vice Chancellor, ~eenbandhuChoturam University
of Science & Tech., Sonepat
Chakraborty, Prof. S.S. Managing Director, Consulting Engg. Services (I)
Pvt. Ltd., New Delhi
Datta, P.K. Executive Director, Consulting Engg. Services (I)
Pvt. Ltd., New Delhi
Vala, H.D. Ch~efEngineer (R&B) Deptt., Govt. of Gujarat,
Gandhinagar
Dhodapkar, A.N. Chief Engineer (Plg.), Ministry of Road Transport &
Highways, New Delhi
Gupta, D.P. Director General (RD) &AS (Retd.) MORTH, New Delhi
Jain, Vishwas Managing Director, Consulting Engineers Group Ltd,
Jaipur
Bordoloi, A.C. Chief Engineer (NH) Assam,Guwahati
Marathe, D.G. Chief Engineer, Nashik Public Works Region, Mumbai
Choudhury, Pinaki Roy Managing Director, Lea Associates (SA) Pvt. Ltd
New Delhi
Narain, A.D. Director General (RD) & A S (Retd.), MOST, Noida
Mahajan, Arun Kumar Engineer-in-Chief, H.P. PWD, Shimla
Pradhan, B.C. Chief Engineer, National Highways, Bhubaneshwar
Rajoria, K.B. Engineer-in-Chief (Retd.), Delhi PWD, New Delhi
Ravindranath, V. Chief Engineer (R&B) & Managing Director, APRDC,
Hyderabad
 IRC:90-2010

21. Das, S.N. Chief Engineer (Mech.), Ministry of Road Transport &
Highways, New Delhi
22. Chandra, Ramesh Chief Engineer (Rohini), Delhi Development Authority,
-- -
Delhi
-- ---

23. Sharma, Rama Shankar Past Secretary General, Indian Roads Congress,
New Delhi
24. Sharma, N.K. Chief Engineer (hlH), Rajasthan PWD, Jaipur
25. Singhal, K.B. Lal Engineer-in-Chief (Retd.), Haryana PWD, Panchkula ,

(Haryana)
26. Tamhankar, Dr. 1U.G Director-Grade Scientist (SERC-G) (Retd.),
Navi Mumbai
27. Tyagi, P.S. Chief Engineer (Retd.), U.P. PWD, Ghaziabad
28. Verma, Maj. V.C. Executive Director-Marketing, Oriental Structural
Engrs. Pvt. Ltd., New Delhi
29. Tiwar, Dr. A.R. Deputy Director General (WP), DGBR, New Delhi
30. Shrivastava, Col. O.P. Director (Design), E-in-C Branch, Kashmir House,
New Delhi
31. Kumar, Krishna Chief Engineer, U.P. PWD, Lucknow
32. Roy, Dr. B.C. Executive Director, Consulting Engg. Services (I)
Pvt. Ltd., New Delhi.
33. Tandon, Prof. Mahesh Managing Director, Tandon Consultants Pvt. Ltd.,
New Delhi
34. Sharma, D.D 1-1603, Chittaranjan Park, New Delhi
35. Banchor, Anil Head - Business Expansion, ACC Concrete Limited.
Mumbai
36. Bhasin. Col. A.K. Senior Joint President, Mls Jaypee Ganga Infrast.
Corp. Ltd., Noida
37. Kumar, Ashok Chief Engineer, Ministry of Road Transport &
Highways, New Delhi
Ex-Officio Members
1. President, IRC (Liansanga) Engineer-in-Chief & Secretary, PWD
Mizoram, Aizawl
2. Director General (RD) & (Sinha, A.V.) Ministry of Road Transport & Highways,
Spl. Secretary New Delhi
3. Secretary General (Indoria, R.P.) Indian Roads Congress, New Delhi
Corresponding Member
1. Merani, N.V. Principal Secretary (Retd.), Maharashtra PWD, Mumbai

(ii)

- -- - - . -
 There has been significant advancement in hot mix plant technology over the last
- two-decades. -Thishas-prompted-therevision of the document-titledJGuidelinesFor-
Selection, Operation and Maintenance of Bituminous Hot Mix Plants" (IRC:90-1985)
L
~
l
to update the same. With continued emphasis on mechanisation in road construction
it is necessary to familiarize the consultants, contractors, concessionaires, planning
and construction engineers with the technology aspects of hot mix plants and enable
them to select the appropriate type of hot mix plant, operate the plant in an optimum
manner with minimum downtime. It is hoped that this document will serve its intended
purpose. The changes in the design of hot mix plants at various spell of time have
been described in detail.

Scope

The Guidelines cover the following aspects :

a) Background
b) Purpose of ,Hot Mix Plant
c) Classification of hot mix plants, their salient, advantages and limitations.
d) lnformation to be furnished by the purchaser, while making an enquiry
with the manufacturer

I e)
f)
lnformation to be supplied by the manufacturer to the purchaser
Sample procedure for calculation or usages charges of Hot Mix Plant
g) Operation of Hot Mix Plant
h) Maintenance and upkeep of Hot Mix Plant
i) Major factors affecting the performance of Hot Mix Plant
j) Effect of moisture content, dust, altitude on output
k) Parmeters for the Selection
.. .
of Hot Mix Plant
I) Calibration of Hot Mix Plant

The Secretary General IRC and the Convenor of the Mechanisation Committee
(G-4), took a decision to revise the document and make it more contemporary and
relevant. Thus, the task of revision of document was assigned to Shri R.K. Saxena, SE
(Mech.) (Retd.), MORT&H. The document was revised with great painstaking efforts.
The document was then scrutinized by Shri S.N. Das, Convenor, Mechanisation
Committee (G-4) & CE (Mech), MORT&H along with the officers of the Mechanical
Wing of MORT&H and various important aspects were included in the document. The
 l
draft document was then circulated to the Members of the Mechanisation Committee
and tabled for discussion on 25.03.2010. 1
i

The Mechanisation Committee (personnel given below) in its meeting held on

--25-03-20-1--tized-the-Guidelines and recommended-its submission to the-General-
Specifications and Standards Committee (GSS) for their consideration.

Das, S.N. .......... Convenor

Verma, Maj. V.C. .......... Co-Convenor
Basu. Kaushik .......... Member-Secretary

Members

Balasubramanian, V. Raza, M.A.

Bharadwaj, R.S. Sachdev, V.K.
Gyani, P.S. Saxena, R.K.
Jain, Rajesh Kumar Sharma, K.C.
Kalita, N.K. Sharma, M.P.
Kumar, Niwas Shree Shankar, P. Ravi
Kumar, Sudhir Sharma, Rajesh
Lall, B.N. Singh, Mahendra
Paramanik, M.K. Singh, P.N.
Patwardhan, S.V. Singh, P.N.
Raj, Hans Rep., IOCL

Ex-Officio Member

President, IRC DG (RD) & SS, MORT&H

(Liansanga) (A.V. Sinha)

Secretary General, IRC

(R.P. Indoria)

The revised Guidelines were approved by the General Specifications and Standards
Committee (GSS) in its meeting held on 24.04.2010 and the Executive Committee in
its meeting held on 10.05.2010 and authorized the Secretary General, IRC to place
the same before Council. The document was approved by the IRC Council in its
19Istmeetingheld on 22.05.2010 at Munnar (Kerala). The Convenor, Mechanisation
Committee (G-4) &CE (Mech.) MORT&H was requested by DG (RD) & SS to incorporate
the comments offered by the Council members. The document after incorporation of
comments was approved by the Convenor, GSS Committee for printing.
 IRC:90-2010
1 BACKGROUND
The hot rr~ixplant technology came into existence around 1870, in which the basic
I -
r_e_qu_irementfor preparation of hot mix-that is-drying, screening, proportioning and-- -

I mixing were combined. These plants were crude and remained in that shape upto
the end of 1900. By 1900, the plants were improved by including aggregates bins,
cold elevators, rotary dryers, hot elevators, bitumen tanks and mixing platforms which
consisted of an aggregate measuring box, bitumen bucket, and pug mill mounted
at sufficient height to allow horse drawn carts pass underneath. The hot mix plants
up to 125 tonne per hour capacity were available by 1930. There was considerable
improvement in the design of hot mix plant during 1930 to 1940, when the conveyor
belts, better quality of gates, feeders in cold feeder system, large size of dryers,
cyclone type dust collectors, spring less scales and pyrometer recording system were
inducted. These plants were continuous as well as batch type.

In early 1950, higher capacity of plants with automatic burner control, automatic
proportioning and cycling function came into use. The hot mix plant continuous type
15120 tonne per hour capacity were imported and inducted in lndia during 1963
under International Development Agency project. During 1970's the most significant
development took place by emerging surge and storage bins, computerized control
system and improvement in noise and dust control system in hot mix plant, considering
health and safety aspect of operating staff. These plants were based on continuous
production process, were simpler in design and more portable. The hot mix plants
20130 tonne per hour capacity were indigenously developed in lndia during mid 70's
and a good fleet worked successfully upto 90's. During late 1970 and early 19801s,
there was sharp increase in petroleum price. Thus, further development took place
in the design of hot mix plant making it more fuel efficient, reusing milled bituminous
pavement known as "Reclaimed Bituminous Pavement" (REP) to preserve the natural
resources of aggregates and keep the environment free from pollutants. In Europe,
USA and other parts of the world, asphalt is used as binder. Therefore, the pavement
to be laid is known as asphalt pavement and reused milled asphalt pavement as
"Reclaimed Asphalt Pavement" (RAP). In lndia bitumen is used as binder. Therefore,
these terminologies are known as bituminous pavement and Reclaimed Bituminous
Pavement" (RBP). S~nce,heating, drying and mixing took place in the same drum,
these plants became popular with the name "Drum Mix Plant".

By the end of year 2000, further development took place in the design of hot mix plant
for efficient utilization of heat produced in dryer drum and use of reclaimed biturr~inous
'pavement. This technology was known as double barrel technology. In this technology,
the concentric chambers of same drum are used to heat the virgin aggregates and mix
the same with molten bitumen, filler and reclaimed bituminous pavement.

Effort has been made in these Guidelines - - to

-- get the highway --
-- -- acquainted
- - - engineers - - - - -
-
1
with different type of hot mix available in international market. It will facilitate 1
selection of the hot mix plant in the region for preparation of hot mix depending upon
the quantum of work, availability of aggregates, fuel efficiency and use of reclaimed I
!
bituminous pavement.
I
2 PURPOSE
I
The purpose of hot mix plant is:
a) To blend different sizes of aggregates in specified proportion.
b) To dry the aggregates (reduce moisture content to below 0.5 percent)
and heat them to the specified temperature.
c) To heat the bitumen uniformly at specified temperature.
d) To feed controlled quantity of bitumen and filler in the specified
proportion.
e) To mix the aggregates with bitumen and filler thoroughly and ur~iformly
to produce homogenous mix at the specified temperature
f) To run in a safe, environment-friendly and reliable manner to carry out
the above tasks accurately and consistently.

3 CLASSIFICATION
The plant is classified based on its capacity, type of flow of aggregates and hot gases
in dryer drum, methodology adopted for preparation of hot mix.

3.1 Capacity of Hot Mix Plant

I
As per IS 3066-1965 and IS 5890-2004, the capacity of hot mix plant is given in
tonne per hour and is specified in the following manner for two different values of the
moisture content in the aggregates :
a) Output of plant at 6 percent moisture content in aggregates .
b) Output of plant at 2 percent moisture content in aggregates.

The hot mix plant 40160 tonne per hour capacity specifies that the output of plant
shall be 40 tonne per hour at 6 percent moisture content present in aggregates and
60 tonne per hour at 2 percent moisture content present in aggregates.
 3.2 Methbdology Adopted for Preparation of Hot Mix

Hot mix is prepared in hot mix plant either on continuous operation-basis

- - --
or in batch. -- -

I According to preparation of hot mix, hot mix plants are divided into two categories.
a) Continuous type
I
I b) Batch type

3.2.1 Hot mix plant (continuous type)

In continuous type of plant, aggregates, fines and bitumen are continuously inducted into
pugmillldrum mix in desired proportion and hot mix discharged without interruption.

3.2.2 Hot mix plant (batch type)

In batch type plant, hot bitumen is added with the batch of hot aggregates and filler
(if necessary) at desired temperature in desired proportion in mixing unit. The mix
prepared in batch is transferred either into silo for its storage or directly fed into tipper
for transportation. This process of batch transfer continues one after the other. The
batch type hot mix plant is classified based on capacity, type of flow of aggregates
and hot gases, screening system adopted for grading the aggregates, quantity of'hot
mix prepared per batch and number of batches prepared per hour.

The batch type hot mix plants upto 400 tonne per hour capacity are available
internationally.

Flow of material (aggregates, bitumen and fines) is similar for various designs of hot
mix plants except the method of screening, proportioning and mixing.

Plant capacity is specified in number of batches produced per hour. Normally, one
I
batch is prepared within 45 to 60 seconds.

3.3 Direction of Ftow of Aggregates and Hot Gases

The direction of flow of aggregates and hot gases in dryer drum specify the type of
flow in the plant. It may be of two types.
a) Counter flow type: In this type of plant, virgin aggregates enter the end
from where exhaust gases are discharged. The aggregates and hot
gases flow in opposite direction inside the dryer drum, which increases
efficiency of heat transfer process, lowers exit gas temperature, reduces
the plant emission and fuel consumption.
 b) Parallel flow type: In this type of plant, aggregates and hot gases flow
in same direction inside the dryer drum. This type of drum mixer has
certain limitations, which are given below:
A ) T h e thermalTfficiency of plant is on lower side due to low heat-
transfer inside the drum mixer. As a result, fuel consumption is on
the higher side.
2) The stack temperature is high, as most of the drying process of
aggregates takes place near the burner zone.
3) High blast of air from burner carries the dust from dry aggregates
through the exhaust, resulting in environmental hazards.

3.3.1 Counter flow type dryer-mixer

Three different types of dryer-mixers under this category are described below:

a) Counter Flow Drum Mix Coater (Fig. 1)

In this type of dryer-mixer, the virgin aggregates flow opposite to the hot gases in the
dryer and enter the coater. The reclaimed bituminous pavement may also enter into
the coater or mixing section along with the virgin aggregates in super heated condition,
which in turn heats the reclaimed material.

qrgin
Eshaust aggr~13ates
Burner

Fig. 1 Counter Flow Drum Mix Coater

The disadvantage of this type of drum mixer is that the hot virgin aggregates, liquid
bitumen and reclaimed bituminous pavement are injected at approximately the same
time in the coater, thus the rnixing time is short in the coater.

In case higher percentage of reclaimed bituminous pavement is used, the short mixing
time produces less homogeneous mixture.
 b) Counter Flow Drum Mixer with Embedded Burner (Fig. 2)

In this type of mixer, the burner is in inserted position inside the drum. The reclaimed
I
I
bituminous pavement is injected down stream of the burner, where itKiGi withvirgin-
aggregates and liquid bitumen. The disadvantage of this plant is that mixing time is
short and to maintain the burner is cumbersome process, since its key components

1 are not accessible. Thus, this type of drum mixer could not become popular.

HOT MIX AIR

COUNTERFLOW DRUM MIXER WITH EMBEDDED BURNER AND AIR -COOLED S H E U

Fig. 2 Counter Flow Drum Mixer with Embedded Burner

C) Double Barrel Drum Mixer (Fig. 3)

In this type of mixer, the transfer of heat from virgin aggregates to reclaimed bituminous
pavement is very effective due to sufficient mixing time. Thus, the mix produced is
homogenous.

RAP

LlOUlD
ASPHALT H O T MIX

Fig. 3 Double Barrel Drum Mixer

IRC:90-2010
3.3.2 Parallel flow type drum mixer

Three different type of mixers under this category are shown below.

Parallel Flow Plain Drum Mixer (Fig. 4)

Fig. 4 Parallel Flow Plain Drum Mixer

I
I

It is a common type of parallel flow drum mixer and is being widely used in different
road projects in India, since its induction in late eighties.

b) Drl-~mMixer with Centre Inlet for RBP (Fig. 5)

This type of drum mixer was developed in 1970's due to increase in crude oil prices.
It has resulted in the use of reclaimed bituminous pavement. It is similar in design to
plain drum mixer except a hole in the shell of drum to induct Reclaimed Bituminous
Pavement (RBP). This plant is suitable for use of reclaimed bituminous pavement up
to 30 percent.

Virgin
aggregates

1,iquid bitumen

Fig. 5 Parallel Flow Drl~rnMixer with Centre lnlet for RBP

 C) Drum Mixer with Coater (Fig. 6)

It is a parallel flow type drum mixer, in which hot gases and aggregates move in same
- - -

direction and reclgmed bituminous-pavement is added in cooler zone and mixed with
!
liquid bitumen in a mixer or coater located at the discharge end of the drum. It gives more
I time for mixing reclaimed bituminous pavement with virgin aggregates and liquid bitumen.
It produces good quality of homogenol~smix sing reclaimed bituminous pavement.

RBP % g i n aggregates

Burner

tllix coater bitumen

Fig. 6 Parallel Flow Type Drum Mixer with Coater

In this type of drum mixer approximately 70 percent of reclaimed material is heated by

virgin aggregates and 30 percent by hot gases.

3.4 Mobility o f Hot Mix Plant

The hot mix plant whether batch type or contin~~ous type may be categorized based
on two factors. a) Stationary type and b) Mobile type. Stationary type plants are more
rigid and normally used in construction of flexible pavement, where quantum of work is
more and frequently available to keep the plant engaged. In case quantum of work is
small and plant needs frequent shifting, mobile type of plant is preferred. Major units of
mobile type drum mix plant are fitted with pneumatic tyres, which make it convenient
to tow it from one place to another. Mobile batch type hot mix plant does not require
a crane of bigger capacity for its commissioning and dismantling. Nowadays a third
category of hot mix plant known as self-erecting or portable type is also in use. In this
case, the plants have an integrated foundation on which it can be erected.

4 SALIENT FEATURES OF BATCH TYPE HOT MIX PLANT

4.1 Components o f H o t Mix Plant.(Batch Type)

The essential components of hot mix plant (batch type) are given in Fig. 7. In addition.
Secondary pollution control device (Bag House Filter) and Hot mix surge silo are
optional components of batch type hot mix plant. The brief details of the components
are giver1 below:

1- Cold Bin Feeder, 2- Cold ElevatorlCold Feed Conveyor, 3- Dryer Drum, 4- Primary
Pollution Control Device, 5- Exhaust Stack, 6- Hot Elevator, 7- Screening Unit, 8- Hot Bins,
9- Weigh Box, 10- Bitumen Unit, 11- Mixing Unit (Pugmill), 12- Mineral Filler (Dust Collection
System), 13- Control Panel (Not shown)
Fig. 7 Different Components of Hot Mix Plant (Batch Type)
4.1 .I Cold bin feeder

a) It contains minimum 4 Nos. bins with separators between them, to

avoid inter mixing of aggregates being loaded in different bins.

b) The bin walls and bin gates are so designed as to prevent arching and
ensure smooth flow of aggregates.

c) Bin gates have a graded scale to control the amount of gate-opening.

d) The capacity of all four bins is sufficient to run the plant for minimum
30 minutes.
e) The first bin containing fines is provided with a bin vibrator (Fig. 8) to
avoid sticking of fines with the bin wall.

f) Variable speed motor (DCIAC) is provided below each bin, to control

the speed of conveyor belt, to vary aggregates proportion.

g) One gathering conveyor is provided to collect aggregates of different

sizes from the conveyors fitted under each bin.

h) Properly designed and calibrated bin gate are provided for smooth flow
of aggregates.
 i) Single deck vibratory screen is provided at discharge end of gathering
conveyor to remove over size aggregates.

Flow of material a
Fig. 8 Position of Bin Vibrator in 1st Bin
4.1.2 Coldelevatororcoldfeedconveyor

It feeds the aggregates received from gathering conveyor to dryer drum. The conveyor
used is known as slinger conveyor.

4.1.3 Dryer drum

It plays a vital role in the performance of hot mix plant. It is revolving cylindrical drum
normally ranging between 1.5 to 3.0 m in diameter and 6 to 12 m in length depending
upon the capacity of plant. The drum is in inclined position and its length to diameter
ratio is 4 to 6. It includes burner and blower fan, which provides primary air for
combustion of fuel and an exhaust fan to create a draft through the dryer. The drum is
fitted with longitudinal trough or channels called flights mounted with bolts and nuts.
The flights lift the aggregates and drop it in ve~lsthrough the burner flame and hot
gases. The dwell time (retention time for aggregates in dryer drum) will depend on the
slope of the dryer drum, its revolutions per minute, diameter, length, number of flights
and their arrangement, and efficiency of burner. The balance between fuel and air
supply should be maintained for complete combustion and efficient dryer operation.
Imbalance between draft air and blower air velocities can cause a back pressure
within the drum, which should be maintained.

Normally, dryers are designed to heat and dry the aggregates at 4 to 6 percent moisture
content for maximum efficiency. If moisture content present in aggregates increases,
the feeding of aggregates into dryer drum is reduced, resultirlg in drop in hourly
production capacity of plant.

The temperature of the aggregates controls the temperature of mix. The layer of
bitumen put on each particle of aggregates during mixing achieves the aggregates
 temperature instantaneously. The aggregates heated at high temperature can -
harden the bitumen during mixing wh~leunderheated aggregates cannot get a proper 1
I
coating of bitumen. Therefore, aggregates should be heated uniformly at appropriate
-temperature to achieve homogenou_s mix. The temperature of aggregatesshould be
measured with pyrometersl thermocouple or other suitable device by putting them at
appropriate location. !

4.1.3.1 Burner and fuel

The burner used in hot mix plant is based on gas or fuel oil or a combination of them. In
India, light diesel oil or furnace oil is used as fuel, hence burner shouldbe suitable for
such application. Burner should have a blower of adequate capacity to ensure efficient
fuel atomization with low noise, auto ignition and flame failure detection device. The
important components and the function of an efficient burner are as under:
a) Strainer - It removes contaminants in fuel oil and avoids
trouble during operation

b) Flow Meter - It registers total volume of fuel oil burnt by the

burner
c) Solenoid Valve - It opens or closes the fuel suction line based on the
signal received from burner control panel.
d) Fuel Feed Pump - It feeds the.fuel supply.
e) Relief Valve - It maintains the fuel pressure being fed to nozzle unit.
f) Control Valve - It regulates the return oil pressure from nozzle unit,
thus adjusting the quantity of fuel oil atomized at the
nozzle.
g) Blower - It supplies air for combustion including excess air.

h) Air Damper - It regulates the volume of air being supplied to

burner in proportion with fuel oil and is fitted at the
: outlet of blower. The damper closes when intensity
of flame is low and opens while it is high.
i) Blower and Fuel - These are low voltage, fully enclosed, fan cooled,
Pump Motor squirrel cage induction motors to drive blower and
fuel feed pump.
j) Control Motor - It is used to control opening of air damper and fuel
return line valve through automatic temperature
controller or manual switch.
 k) Ignition Transformer - It transmits more than 15,000 V emitting electric
and Electrodes spark in electrode gap to ignite fuel mist.

I) -Flame Detector-- -- - The photo seiiGFdef&Xthe glare ofoiflame andp

,
I connects1 breaks relay contacts.

I m) Automatic Temperature -
Indicator Controller
It is a microprocessor based digital indicating
controller, which operates based on the signals
received from a thermocouple or other sensing
device fitted to measure aggregates temperatl-re.
The output signal is transmitted to control motor
I which adjusts air damper and fuel supply.

n) Pre-Heater - Heats the furnace oil to a temperature of 100-110°C

to reduce its viscosity for efficient atomization1
combustion.

All controls, relays, indicators, switches, timers, pilot lamps, wiring for automatic or
manual control of dryer burner are located in control panel.

The fuel oil tank should be located close to the burner and bottom of tank should be at
same elevation as burner. The pipeline between burner and fuel tank should be clean,
of adequate diameter with minimum bends to reduce suction resistance.
I
I
The viscosity of furnace oil is more specially during cold weather. Therefore, pre- heater

i of suitable capacity is provided to keep uninterrupted supply of fuel into burner.

4.1.4 Primary pollution control device

It is the primary dust collection System (Fig. 9) of hot mix plant. Its function is to
remove undesirable amount of dust coming from the exhaust. It is cyclonic in shape, in
which dust is collected and removed1added to dry aggregates, if required. It consists

! of cyclonic separators and works on the principle of centrifugal separation. It is fitted

at the rear of dryer drum. The flue gases leaving the dryer drum pass through these
separators, Single cylinder cyclone basically consists of a large diameter cylindrical
shell having a conical base. Dust laden gas enters this shell tangentially, which gives
it spinning motion and makes it to travel ~ ~ p bottom
to of cylinder. After reaching the
I bottom, it spirals up and is sucked out (vacuum created by exhaust fan) through
coaxial cylinder fitted at the top. The larger size dust particles are thrown out towards
the wall of the cylinder due to spinning motion of gas. These particles slide down and
are collected in a hopper. These are removed through auger screw and sent to mixing
zone, if desired. Multiple units of cones having longer length of cyclones, smoo'thness
of inner wall are the main factors responsible for higher efficiency of cyclone. These
are capable of removing 60 to 90 percent of dust from the dryer exhaust. Hot Mix
-
Plant-Emission-arrdtheir Control are given in Annex-C.

Fig. 9 Primary Dust Collector

4.7.4. 7 Exhaust stack

The exhaust gases are eliminated through the plant exhaust stack. These gases
further pass through the secondary pollution contrbl device, that is bag house filter for
further filtration.

4.1.5 Hot elevator

The aggregates after heating and drying are carried by a hot elevator (bucket conveyor
system) to the gradation unit. A stone box is provided at the edge of hot elevator
discharge chute, which lowers and smoothens the flow speed of aggregates falling on
screen sieves. However, in case of tower model where the dryer is at the top, there is
I
no need for any hot elevator.
I
4.1.6 Screening unit
!
The primary gradation of aggregates is done in cold bin feeder system. The secondary
gradation of aggregates, in hot condition, is carried out in screening unit. Thus it is I
known as second gradation control unit of hot mix plant batch type. The screening of
hot aggregates is essential in batch type hot mix plants to feed appropriate quantity
of graded hot aggregates in each batch. Normally, two designs of plants have been
adopted to separate different size of aggregates.
a) Through multi-deck vibratory screening
b) Through rotary screening
4.7.6.1 Hot mix plant (batch type) fitted with multi-deck vibratory sc

-The screening in multi deck vibrating

-
screen is--.d - -- -- -
-~~~ ~ - ~~ ~- ~ - ~ -
~ ~

~ ~ ~~

multi-deck vibratory screening, the aggregates . . ~.

elevator to vibrating screen for second gradation (Fig. 11 and 12).

Cold bins

Hot mix
discharge

Fig. 10 Hot Mix Plant (Batch Type) fitted with Multi Deck Vibratory Screen

Scrmn 1 I Over size 30 m m Cliute I

I I I rejection I

I I I

Fig.11 Different sizes of Screens in Fig.12 Screening the Aggregates to Achieve

Sequence one over another Specified Sizes through Reciprocating Motion

The hot aggregates received through hot elevator pass over a series of vibrating
screens of different sizes, which separates them into specific sizes and deposits into
hot bins.
IRC190-2010
4.1.6.2 Hot mix plant (batch type) fitted with rotary screen (Fig. 13)

In rotary screening, cold aggregates are taken into screening drum, where screening and
heating takes place simultaneously. In both cases, graded material iscollected in hot bins. -

Fig. 13 Hot Mix Plant (Batch Type) Fitted with Rotary Screen
The heat losses in screening and dryer drum are lesser, thus thermal efficiency of hot
mix plant (batch type) fitted with rotary motion is higher. Besides, the maintenance of
this type of plant is also less.

In rotary screening unit, cold aggregates received from cold bin feeder are fed into drum, in
which drying and screening of aggregates takes place in same drum via counter flow process
(Fig. 14). -The drum is inclined and mounted on two tire rings. The shovel flights are fitted
to the internal surface along the drum length to move the aggregates and form an efficient
drying curtain. Four sections of screens with screw flight plates on outer surface sieve the
various sized aggregates and deposit heated aggregates into different corr~partmentsof
hot bins. The over sized aggregates are removed for disposal. -The vacuum drum pressure
device fitted to control the rotary actuator at exhaust fan regulates the air flow.

cotnpartments

Fig,. 14 Screening of Aggregates through Rotary Motion

16
 IRC:90-2010
4. I . 6.3 Hot screens

For multi-deck vibratory screening unit, the screen provided at the top is a scalping
screen, which rejects and carries off oversized aggregates. It is
intermediate sized screens decreasing in size from tbp to bottom and last is fine screen.
For rotary screening unit, the screen configuration along the direction of aggregates
flow is reverse to that of multi-deck vibratory screening unit. That is, the first screen is
the fines screen, whereas the last screen is the scalping or oversized rejection screen.

The function of the screens is to separate the aggregates into specific sizes. The
screens must be clean, robust and their capacity matching with the capacity of dryer
drum and pugmill. Induction of finer aggregates into a bin intended to contain next
larger size fraction is called carry over. The carry over affects the mix design formula.
Carry over more than the prescribed limit can add the fines present in aggregates in
total mix, thus increasing the surface area to be covered with bitumen. To prevent
excessive carryover, screens should be checked daily for cleanliness.

4.1.7 Hot bins

These are used to store the .heated and screened aggregates of various sizes
temporarily (Fig. 15). Each bin is an individual compartment or a segment at large
compartment with division by partitions which are minimum 4 Nos. The capacity of
each hot bin should be sufficient enough to hold the aggregates of each size and
svoid their intermingling, when the plant is operating at f ~ ~capacity.
ll Normally, the
capacity of all hot bins should be of about ten batches production.

Each bin should be equipped with an overflow pipe to prevent the excess amount
of aggregates from backing up into other bins. The overl'low pipes should be
set to stop overfilling of the bins. Overflow vents should be checked frequently
to ensure that they are flowing. If a bin overfills, the screen above it rides on
the aggregates, resulting in heavy carryover and the possibility of damage to the
screen. Each compartment is equipped with pneumatically actuated two stage
discharge gates controlled by the computer system. It is fitted with a maximum
level indicator wired remotely to control the quantity of aggregates in bins and
warn the operator when bins are full. Hot bins should not be allowed to run empty1
starving also. Any shortage or excess of aggregates in the hot bins should be
 regularized, by adjusting the aggregates supply from respective bin of cold bin
feeder. Any leakage at the bottom of hot bins should be immediately repaired to
avoid improper mix gradation.
.-
- -- - - .

Fig. 15 Segregation of Aggregates in each Hot Bin

4. 1.7.1 Hot bin levelling indicator

It detects the quantity of aggregates stored in hot b ~ n sand indicates when it falls
below a certain level (Fig. 16). The indicators may be operated either electronically
or mechanically. Presently, electronic indicators mounted on the side of the bins
are used. Aggregates inside the bin apply pressure on the walls of the bin, which
controls the operation of diaphragm and indicator. In case aggregates drop to
a predetermined level, it is displayed through indicating larnpslwarning sign in
control panel.

Fig. 16 Hot Bin Levelling Indicator

18
4.7.7.2 Aggregates temperature measurement device ... ..,
.
. ...
.
.<

The temperature of aggregates is measured by providing thermocouple in first hot

-- - .--
. . - - -- - - -- - - -- - - -
bin, which contains fines.

4.7.7.3 Bin sampling device

-TI- is device (Fig. 17) is provided in the plant to take sample of hot aggregates from
bins and to check their segregation. It diverts the flow of aggregates from feeders or
gates under hot bins into sample containers. It is essential that sampling device be
located such, as to collect representative samples of material in bins. It is seen from
the flow of material over the screen in the plant that fine particles fall to one side of
each bin and coarse particles to other side. Therefore, the position of sampling device
in stream of material discharged from a bin determines whether the sample contains
a fine portion, a coarse portion or an accurate proportion of material in bin. It assists
in calibrating the grading of aggregates.

Fig. 17 Bin Sampling Device

...
4.1.8 Weigh hopper

The aggregates are withdrawn from hot bins in desired quantity through load cell
and accumulated in weigh hopper. The sequence of collection of aggregates in
weigh hopper is coarse aggregates first, intermediate sized aggregates next and fine
aggregates in the last. This sequence is designed to place the .fine fractions at the top
of weigh hopper, so that they cannot leak out through the gate at the bottom of weigh
hopper. This system allows the most efficient utilization of available volume in weigh
 hopper. Aggregates, thus collected in weigh hopper are transferred into pugmill where I
-1
these are blended with desired quantity of bitumen. The sequence of operations is I
I
-
shown in Fig. 18.
. - ..--

3 ,.',-. .
~ ~.- - -. - . ~
.- ~ ~ .- -

@Ii
I. Discharge gate of an aggregate bin 2. When scale reading reaches a
is opened and aggregates pour into preset weight, the discharge gate is
weigh hopper close

0 I 0
3 . Discharge gate of next aggregate 4. When scale reading reaches a
bin is opened and aggregates pour in preset weight, the discharge gate
to weigh hopper is closed.
5 . Repetition of ti~esesteps takes place for balance quantity of aggregate
sizes and mineral filler sizes also.

Fig. 18 Sequence of Operations used to Measure Aggregates

and Mineral Filler in Weigh Box
4 . I.8. I Weighing equipment

It is used to weigh aggregates, filler and bitumen separately to achieve specified mix
formula. Earlier, the weight of different constituents was being measured with spring
.I
balance system. Now, this system has been replaced with load cell which is lighter,
more reliable, easy to calibrate and low in maintenance cost. The weight of each weigh
hopper is measured through transducer, which sends electrical signal by a load cell.
Load cell is installed at weigh hoppers with ball rod-ends, rubber vibration dampers
and insulators. Following precautions are observed in this connection:
!
a) Lead wire of load cell may be tied 30 cm away from load cell.
I
b) Severe shock or excessive load more than 1.5 times the rated capacity
I
should not be applied on load cell which may cause damage to it.
Normally, load cell is designed to bear 20 to 30 percent of rated load
when respective weigh hopper is full of rated load.

4.1.9 Bitumen unit

The unit mainly consists of bitumen tank, heating system, bitumen pump and delivery
pipe.
 4.1.9.1 Bitumen weigh bucket

Bitumen is weighed separately in weigh bucket (Fig. 19) before being inducted into
pugnlIII. W h e r t heweigntofb-itu men -ad h- aprezdStSTEiWd-lEWl -in-t he-bucket,- -
a valve in delivery line closes it, which prevents its excess entry into bucket. The
bitumen is then pumped into pugmill through spray bar.
I Spray bar nI

PunlP
Fig. 19 System to Measure and Deliver desired
Quantity of Bitumen in Pugmill
4.1.9.2 Bitumen tank
I
It is an insulated tank, of adequate capacity (minimum one day storage) meeting to
the requirement of plant capacity. Minimum 2 Nos. bitumen tanks each of 45,000 litre
capacity should be provided for smooth running of 165 tonne per hour capacity hot
mix plant. Dial indicator type thermometer is provided outside the tank to indicate the
temperature of bitumen.

The heating system of bitumen should be efficient, having good fluidity of bitumen
for its easy pumping and spraying to get uniform coating on aggregates. The source
I
used for heating may be through direct heating, thermic oil heating or electric heating.
The viscosity of bitumen decreases with increase in temperature. Therefore, bitumen
heating will depend on its grade. The heating temperature of modified bitumen is kept
approximately 10°C above ordinary bitumen temperature. The heating may be done
in any of the following ways:
/
a) Direct heating system

In this system , flue tube along with burner is provided in bitumen tank. Burner operated
with light diesel oil1 furnace oil heats the bitumen around Ilue tube.
 IRC:90-2010
Thermic oil heating system (Fig. 20)

In this system, hot oil received from hot oil heater is circulated through the coils in I

- bitumen-tank7bttm-w-pumpyspray-pump, delivery-pipe;-bitumen-weighingtank, s p r a r 1 .
1
bar and pugmill; to keep the bitumen supply uniform and maintain the temperature.
It is provided with independent automatic control panel including oil temperature
indicating controller, low level switch, low circulation pressure switch, over temperature
cut off thermostat, burner control relays, burner operating circuits etc. Indicating type
thermometer to show the temperature of thermic oil and bitumen should be provided
at appropriate location for its visibility. It heats the bitumen and keeps bitumen tank,
piping and weighing hopper at constant temperature. Its operation is pollution free.
Oil heater

Spray pdnp

4.1 . I 0 Mixing unit (pugmill)

It is the chamber in which bitumen and aggregates are mixed thoroughly to achieve
I
homogenous mix. A lined mixing chamber with two horizontal shafts containing
several paddle arms and paddle tips are mounted. The paddle tips can be adjusted
and replaced easily. Paddles arms and tips are made of wear resistant high nickel 1
hardened cast alloy steel for longer service life and low maintenance cost. It has hot
oil jacketing system to avoid drop in mix temperature. -The paddles must be set such
that there are' no dead areas in the pugmill. The dead area is a place where material
can accum~~late out of reach of paddles and cannot be mixed thoroughly. Dead areas
can be avoided by assuring that clearance between paddle tip and the liner is less
than half the maximum aggregates size. -The quantity of material to be fed in pugmill
is very important to achieve the homogenous mix (Fig. 21). If material level is too high,
 the upper most material tends to float above the paddles and does not mix thoroughly.
Conversely, too little material in pug mill results in raking of tip paddles through the
m.at_terial withwt actually mixing-it --_ - -- --- - --.- . -

i Therefore, to achieve the maximum operating efficiency , the paddle tips should be
barely visible at the surface of material during mixing.

Over filled pugmill Under filled pugmill

Fig. 21 Effect of Feed Material in Pug Mill

4.1.10.1 Mixingcycle
1
It is the cycle during which bitumen, aggregates and mineral filler are blended in
pugmill of hot mix plant.

4.1.10.2 Batch mixing time

It IS the time between opening of weigh hopper gate and closing of pugmill discharge
gate During this period, the aggregates and bitumen are properly mixed and
I
homogenous mixture of thoroughly cooked particles achieved. The batch mixing
l
time should be minimum and such that homogenous mixture of evenly distributed
and uniformly coated aggregates particles is*achieved. The sequence of operations
in Pugmill is shown in Fig. 22. The improvement in design and techniques result
i in lowering the mixing time and achieve the mix as per specification. Longer mixing
time will adversely affect quality of mix, due to exposure of thin bitumen film to high
1 aggregates temperature in the presence of air, thus causing oxidation of bitumen.
It will also result in drop in the capacity of plant. Thus, the production cost will
increase
I
I

Normally, batch mixing time of the plant begins with 30 second mix cycle. The optimum
mixing time will depend upon type of aggregates, design of mix, presence of moisture
in aggregates, viscosity of bitumen, shape and size of pugmill; shape, size number of
paddle tips and their arrangement, peripheral speed of paddle tips, type and quantity
of bitumen flow, method adopted for adding aggregates and their sequence, size of
pugmill vls batch size, condition of pugmill, operator's efficiency.
 3. The aggregates and
bitumen are mixed. mis is discharged.

Fig. 22 Sequence of Operations in Pugmill

In batch type plant, mixing is a continuous process. Therefore, a hopper of smaller
capacity for temporary holding is provided at the discharge end of the mixer to store
the material until it can be delivered in a hauling truck.

If reclaimed material is to be processed in the plant, the reclaimed bitumen pavement

material is placed in a separate cold bin and transferred to the pug mill through a
charging conveyor. The reclaimed material is added in desired proportion to the
aggregates that has been superheated in dryer drum. The heat transfer and mixing of
two materials is done as they move through the pug mill.
I
4.1.1 1 Mineral filler/dust control system I
The mineral filler such as rock dust, hydrated lime or cement are used for the purpose
and stored in a separate chamber to protect it from dampness and to avoid its choking1
hardening from nioistures. The system consists of (a) a screw feeder which carries .filler
from f~llertank of adequate capacity (b) a screw feeder to carry dust collected from bag
filter and merge both of them into a common chute known as filler stock bin. Transportation
of filler from filler bin to weigh hopper is conducted either pneumatically or mechanically. In
pneumatic system, mineral filler is sent under air stream and handled as a fluid. It is more
accurate control system which eliminates the chances of plugging. The mechanical system
consists of a receiving hopper, screw conveyor, dust tight elevator to charge an elevated silo
 with a vane feeder to meter the fines into the plant. The rotary valve Is i n s b l l d - 3
of thefiller bin, wherein rotary plates equipped within the
. .
~
is
through the flapper gate, which._._ .driven
... -. . by air cylinder installed
~ . - at -lower
- .- p.a.fl_affthe_
opens/closes as per the requirement of filler into weigh hopper.

1 4.1.1 2 Control panel

I In batch type plant, aggregates and bitumen are mixed in batch, which is controlled by
opening and closing of weigh hopper, discharge gate, bitumen valve, pugmill discharge
gate with preset automatically controlled timing device. Automatic proportioning and
cycling control work together through preset interlockirlg devices. Automatic dryer
control regulates the temperature of aggregates discharged from dryer automatically
within a preset range. The control panel for batching console contains switches, circuits
for automatic batching including preset controls for weigh batch, interlock controls,
tolerance controls and limit switches.

The control panel consists of an air conditioned cabin to avoid the effect of heat,
dust and vibration; which can cause malfunctions in the system. It incorporates all
controllers, indicators including bin leveler, relays, switches, timers, pilot lamps, wiring
for operation of all components. The function of complete plant including operation of
different electric motors is controlled from control panel.

In addition to above, following controls of plant are exercised and the information
displayed in control panel:
a) Plant load (set as percent of plant capacity)
b) Composition of different materials:
1) Plant load
2) Moisture content
3) Aggregates bins
4) Bitumen
5) Mineral filler
c) Running weight of materials:
1) Quantity of aggregates in tonne per batch
2) Quantity of bitumen in kilogram per batch
3) Quantity of mineral filler in kilogram per batch
d) Total quantity of materials flow during specific period
1) Aggregates in tonne
 2) Bitumen in kilogram
3) Mineral filler in kilogram . .

~ - .- 4)
-- .-Total
.-..production
... --...-
- of mix -(1+2+3) in
.-...tonne
. . .~~ .-~.. . ..
~ . .. . .- ~ . .. . .. . ~.
..

e) Temperature of
1) Bitumen
2) Aggregates
3) Hotmix

4.1 .I 3 Secondary pollution control device (bag house filter)

It consists of a large metal housing containing hundreds of'inverted, tabular, synthetic.

heat resistant fabric filters. The function of a bag house filter (Fig. 23) is like a vacuum
cleaner. The housing is divided into two chambers.
a) Dirty gas chamber
b) Clean gas chamber.

Dust laden flue gas enters the dirty gas chamber and subsequently to filter bags
through open mouth. This gas is sucked out of the filter bags by the effect of suction
pressure created by a vacuum pump. As the gas comes out of the filter bags, it gets
filtered and dust is left behind on the inner walls of filter bags . Shaker arrangement
(mechanical shaker or reverse air flow system) is provided to shake a portion of bags
at a time, to clean them of dirt particles. The dust shaken out of the bags drops into
a hopper at the bottom and is taken outlsent back to mixing chamber for its reuse, if
desired. It is a highly efficient fi~tkrarrangement capable to separate large size particles
up to 1 micron size with 99 percent efficiency. These filters are very expensive and
should be used with great care for their optimum utilization and highe.r efficiency.

Reverse air jets

/r

Fig. 23 Function of Bag House Filter

26
 4.1.14 Hotmixsurgesilo

The hot mix received from hot mix plant can be loaded directly into tipper. Alternatively,
-same-can-be-transferred-into-surge silo-(Fig. 24)-and-store-d-temp-orarilytill-itscontrolled
loading in tippers. It is a cylindrical shell with dual chamber, duly insulated with thermol
ceramic wool and can maintain hot mix temperature upto 3 hours approximately. A
combination of hot oil circulation and thermolceramic wool is capable to maintain hot
mix temperature upto 16 hours approximately depending upon ambient temperature,
quantity of bituminous mix and its temperature, hot oil temperature and its flow. Surge
silos are normally available in the range of 50 to 200 tonne capacity. Aweighing system
may be connected to the holding bin of the silo, to monitor the amount of hot mix
material being loaded in each tipper, which is controlled1indicated in control panel.

I Conveyor ~ omix
ant
t I
Surge
silo

- Hot mix
receiver

I I
Fig. 24 Transfer of Hot Mix into Surge Silo

4.2 Selection of Site for Hot Mix Plant (Batch Type)

Following points should be considered before commissioning the hot mix plant (batch
type) for its better efficiency:
a) The site should be at appropriate distance to ensure proper laying
, temperature.

b) The site ,should have sufficient space for stocking the aggregates
for minimum 5 days consumption, parking of vehicles1
equipments, shed for their repair, storage of spareslfuel, staff
residential sheds and other factors. Normally, 1351165 tonne
per hour capacity plant shall require minimum 10,000 m2 area.
c) Ground should be leveled and soil should have good bearing capacity
to construct the foundation.
d) Site should be neat and clean for free entry and exit of tippers at plant site.
 *
IRC190-2010 I I

e) The environmental effects that is noise, vibration, dust, water pollution;

should be considered in depth to prevent any harm to the residents or
farm location.
-- --
P-roper-water-drainage should-be provided for-smooth functioning-of-
plant.

4.3 Advantages of Hot Mix Plant (Batch Type)

The plant is fitted with secondary gradation control unit, thus the aggregates received
in pugmill are well graded. The aggregates and bitumen are measured in desired
quantity per batch and mixed in pugmill. Thus, homogenous mix is received in desired
proportion.

4.4 Limitations of Hot Mix Plant (Batch Type)

l
a) The cost of the plant is high.
b) The plant needs more space for commissioning.
c) Smaller capacity plants, less than 90 tonne per hour are not available
in the market, their operation being uneconomical and not feasible.

4.5 Requirement of DG Set for Hot Mix Plant (Batch Type)

Hot mix plants are commissioned in remote area, to keep the environment pollution
free. Power is not frequently available in remote areas, besides minimum fixed per
1
kilowatt charges are also to be paid on monthly basis to Electricity Board and cabling,
commissioniqg has also to be borne by consumer. The working period of plant is
also limited. Thus, it is a costly and time consuming factor. 'The diesel generating set
should be commissioned for economical and uninterrupted power supply to hot mix
plants. Normally 500 kVA diesel generating set is required for operation of 1351165
tonne per hour capacity plant.

5 DRUM MIX PLANT

I
5.1 Brief

The drum mix plant was adopted In India during late 19801s,for laying bit~~minous mix.
In drum mix plant, aggregates gradation is controlled at cold feed end and aggregates
heatiqg, drying and bitumen mixing are done in same drum. It has been adopted
widely due to its a) Portability b) Higher efficiency c) con om^in basic cost d) Lower
fuel consumption e) Reduction in man power and maintenance cost f) rouble free
 .- . - - --- - -
operation g) Ability to produce large quantity of mix at relatively low temperature and
h) environmental friendly.
.,.__ _. .. . . ....
_. .. . . . . -- .. .. ~ . -
'' ' ~

Thhe--dmm-.Ki~x plant may be e~therParall'el flow type or Counter flow type. In Parallel
~

flow type drum mix plant, aggregates and hot gases flow in same direction inside the
I same drum. This is conventional type of plant and is used in India.
1
1 In Counter flow type drum mix plant, the aggregates and hot gases flow in opposite
direction within the same drum. These may be of two types:
I
1

1) Drying and mixing of aggregates and bitumen takes place in same drum.

2) Drying of aggregates takes place in first drum and afterwards the dried
aggregatesare transferred to another drum where mixing of aggregates
and bitumen takes place. This is known as dual drum plant also. Afew
such type of plants are in operation in India.

5.2 Components o f Conventional Drum Mix Plant (Parallel Flow Type)

All the major components of drum mix plant (Parallel Flow ~ ~are ~shown
e in Fig.25.
)
In addition to these, it includes mineral' filler system. The hot mix surge silo and

1-Cold Bin Feeder (Mu~iin~m B i n d No.),2-Aggregate Over size Rejection Screen, 3-Cold Feed Conveyor, 4-Automatic
Weighing System, 5-Dryer cum Mixing Drum, &Exhaust Control System, 7-Bitumen Unit, 8-Pollution Control Device
jPrimar); Dust Collector), 9-Hot f i x Conveyor, 10-GobHopper, 11-Control Cabin
Fig. 25 Major Components of Drum Mix Plant (Parallel Flow Type)

secondary pollution control device are the optional components of the plant. The brief
details of the components are given below:

5.2.1 Cold bin feeder

The brief details have already been furnished in Para 4.1 . I .

;-5.2.2 Aggregates over size rejection screen

The brief details have already been furnished in Para 4.1 . I .

 5.2.3 Cold feed conveyor

It is known as slinger conveyor also. The brief details have already been furnished in
-
. Para 4.1.2. - _ _ - . - - ---
.. -
. . .-

5.2.4 Automatic weighing system

Load cell is provided at the center of slinger conveyor to measure the quantity of
material being fed in the drum.
i
5.2.5 Dryer cum mixing drum (Fig. 26)

It is a rotary shell made of heat resistance steel 1.0to 12 mm thick, supported on rings
and rollers. Its main function is:
a) To remove moisture from aggregates by heating it at appropriate
temperature.
b) To blend aggregates and bitumen in desired proportion to achieve
homogenous mix within 140°C to 160°C.
Aggregate

pipe

Fig. 26 Components of Dryer cum Mixing Drum

5.2.5.1 Design aspects
a) Dryer cum mixing drum.is divided into two zones:
1) Combustion zone: The heating and drying of aggregatestake place in this
zone.
2) Mixing zone: The mixing of aggregates, filler and bitumen takes
place in this zone.
b) The drum is provided with replaceable different shapes of flights,
which perform following fi~nctions:
1) Kicker flight - It pushes the aggregates inside the drum
 2) W flight - It eliminates showering of aggregates -

directly into flame

3) Notched flight - It allows the aggregates to fall scattered,
..- . - ~ .-.. .. so-~~.a.t-.aI.l-pa~ieles-a~e-7hea~ed-uniformly-----
- - --
. - ~

4) Cup flight - It forms a veil of aggregates so that flame

does not reach in mixing zone.
5) Aggregates rotation ring - It collects the aggregates received in
combustion zone and moves it to mixing
zone.
- It blends the aggregates , bitumen and
fillerlfines.

Quantity andarrangement of flights depends on the output of the plant.

c) Rate of drying the aggregates depend upon the moisture content present
in it. The dwell time in dryer cum mixing drum, can control the drying of
aggregates and achieve homogenous mix. It depends on following factors:
1) Length to diameter ratio of drum should be in the range of 4 to 6.
2) For drum mix plants up to 90 tonne per hour capacity; speed of
drum should be in the range of 10 to 12 revolutions per minute and
slope of drum not to exceed 9 cmlmetre.
d) Burner
1) The fuel used in the burner in drum mix plant is light diesel oil/
furnace oil. Preheater is essential for use of furnace oil.
2) Burner used in dryer cum mixing drum (Fig. 27) is based on forced
and induced draft principle, in which approximately 55 percent air
by exhaust fan and 45 percent by air blower is inducted in drum for
complete combustion of fuel.
3) The flame should be shorter, more intense and highly radiatory.

45 to SO percent through forced draft

Fig, 27 Burner used in Dryer cum Mixing Drum

 4 ) It should have auto flame failure detection system to avoid coating
.of aggregates with fuel. Photocell is used for detection of flame.
5 ) It should have auto ignition system to avoid explosion.
-- -- -.
- ---
.- - -6-)-There-should-be-dribbling-from-no-z-zle tip-when-bur-ner-is-in-shut- -

down position.
7) Excess air, approximately 25 percent should be supplied for
complete combustion of fuel. 1
e) ~ i t u m e line
n
1 ) Liquid bitumen is not sprayed into drum. It is pumped to a point with
such pressure, from where it discharges by gravity into drum.
2 ) It should be close to flights so that same niay not be picked up with
gas stream.
3) It should be more inside the drum but within mixing zone due to
longer dwell time for better miking.
f) Bitumen fines receiver
The dust received from dust collector or filler received from rr~ineral
filler system is inducted in desired proportion in mixing zone of drum
through bitumen fines receiver, (Fig. 28) which prevents the fines from
becoming rear borne.

Fig. 28 Bitumen Fines Receiver

5.2.6 Exhaust control system . ,

Its main function is to induce air in dryer cum mixing drum for complete combustion, to
remove evaporated moisture in aggregates and products of combustion. It consists of:
a) Exhaust fan: It is of centrifugal type and adequate capacity. In case it
is not of adequate capacity, the steam shall not be pulled out of drum
and complete combustion will not take place resulting in higher fuel
consumption and coating of aggregates with fuel. It should be fitted with
20 horse power motor for 40160 tonne per hour and 25 horse power with
60190 tonne per hour capacity plant to achieve optimum efficiency.
 b) ' Exhausf damper: It is provided at burner end to control automatic draft,
based upon vacuum pressure measured inside the dryer.
-- ........ 5.2.7..... E3jtWnen unit -.................................... _..._..
. ............

The bitumen unit mainly consists of:.

a> Bitumen tank

It is ins~~lated,
of adequate capacity (minimum one day storage) meeting to
the requirement of plant capacity. Minimum 2 Nos. bitumen tanks should
be provided along with the plant. Total 20 and 25 tonne capacity bitumen
tanks are adequate to run 40160 and 60190 tonne per hour capacity plants
respectively. It consists of a tank fitted with burner in flue tube. The fuel
used in burner is light diesel oillfurnace oil. Dial indicator type thermometer
is provided outside the tank to indicate bitumen temperature. The burner
should have thermostatic firing control for automatic control of bitumen
temperature within the specified range.

b) Bitumen pump
It is a positive displacement pump driven by variable speed motor to induct
bitumen in mixing zone of drum. The system ensures bitumen delivery in
desired proportion to dry weight of aggregates. In case modified bitumen is
being used in plant, provision for 1) one no. additional positive displacement
pump just below flue tube 2) adequate number of agitators in bitumen tank,
should be made for its proper circulation , mixing and maintaining uniform
temperature. It may be ensured that Guidelines for use of modified bitumen
are strictly followed to maintain the quality of mix.

c> Hot oil System

I t consists of hot oil tank, hot oil pump and bitumen line jacketing. It is
used to maintain uniform temperature -of bitumen and avoids its clogging
in bitumen line. The system may be used either as duct heating or indirect
heating as described here:
1) Direct heating:
An insulated tank approximately 125 litre capacity containing hot oil with
independent burner in flue tube is mounted on the chasis of bitumen
tank. Air and fuel from existing bitumen heating system are used for
heating hot oil. Hot oil in the range of 150°C-180°C is circulated through
bitumen pump and bitumen line jacketing with an independent pump.
2) Indirect heating:
Hot oil tank is installed at the top of bitumen tank, from where hot
oil passes by gravity into the pipe line passing through the bitumen
tank. Hot oil gets heated by bitumen tank temperature and circulated
in bitumen pump and bitumen line jacketing via independent pump.
This practice is normally used to heat hot oil in drum mix plant.
 5.2.8 Primary pollution control device (dust collection system)

The brief details have already been furnished in Para 4.1.4.

--
- S2:9---HeMx-con veyor -
- .-
. - -.
-- .- -
. --

The hot mix prepared in dryer cum niixing drum is taken to gob hopper through hot
mixlload out conveyor.

5.2.10 Gob hopper

Gob hopper collects the hot mix material and transfers it to tipper through hydraulic
arrangement. The blades of gob hopper should remain in closed position, while mix
material is being fed into it. These should open when gob hopper has completely filled
with mix material and the same is being transferred into tipper, to avoid segregation.
Scrapper blade is provided in gob hopper to avoid sticking of fines on conveyor belt
and achieve desired mix formula.

5.2.11 Controlcabin

-The brief details have been furnished in Para 4.1.12.

In drum mix plant, there is no system to measure the teniperature of aggregates.

Therefore, exhaust temperature is measured by putting thermocouple- in exhaust
chimney, which indicates temperature in control panel. It may be ensured that complete
fuel combustion takes place in dryer drum. and temperature is stable for fifteen
minutes before considering final exhaust gas temperature. Aggregates temperature
is approximately 12OC less than the exhaust gas temperature.

5.2.1 2 Mineral filler system

-The brief details have been furnished in Para 4.1.11.

5.2.13 Hotmixsurgesilo

The brief details have been furnished in Para 4.1.14.

.. .

5.2.1 4 Secondary pollution control device

It is of two types. a) Wet scrubber b) Bag house filter. Hot Mix Plant Emission and their
Control are given in Annex-C.

a) Wet scrubber type unit

In this type of unit, gases pass through the inlet and dust particles are trapped by
water showerlforced water spray, thus separating them from gas stream. It can
separate dust particles upto 5 micron size and eliminate certain amount of gases
also with varying efficiency. This system requires large quantity of water. The ponds
of adequate capacity are made to collect the slurry, reclaim and reuse the water. The
--
particles--settled-should-beyemoved frequently- preferably-within-2-to-3-days-forits -

better efficiency. These are of two types, the details of which are given below:

1) Open spray tower type (Fig. 29)

The dirty gases enter the chamber and pass through water spray under pressure. The
dust particles in the form of slurry settle down and are removed from the bottom. The
clean air passes out of the chamber.
Clean ait
out let

Water
- inlet
Dirty gases

Drain f o ~
-
I I
Fig. 29 Open Spray Tower Type Pollution Control Device

2) Venturi type (Fig. 30)

In venturiscrubber type, dust laden gases are made to pass through a venturi section
which is constantly wetted through stream of water at high pressure. The .flue gases
pass through this venturi section and atomize the liquid resulting in deposition of dust
particles with fine water droplets. In the complete process, clean air goes out and dust
particles in the form of slurry are removed from the bottom of the cylinder.

~ i s c h a r ~fore
slurry I
Fig. 30 Venturi Type Pollution Control Device
The efficiency of venturi type wet scrubber is higher than open spray tower type.
5.3 Advantages o f Hot Mix Plant (Drum-Mix Type)
a) The cost of the plant is less.
 b) The plant needs less space for commissioning and its transportation
is also easy.
c) The plants are available in different capacities ranging from 40160 to
. _- _-400tonnepe1ho-u r. . --. - -- - -- -- - - -- _ - -.. .

d) The operation and maintenance cost of plant is less, as compared to

other types of plants.

5.4 Limitations of Hot Mix Plant (Drum-Mix Type)

a) The plant does not have second gradation control unit i.e. only graded
material could be used to achieve desired mix quality.
b) The plant does not have any system to measure aggregates
temperature. Aggregates temperature is assessed by deducting 12OC
from exhaust gas temperature.
c) The quality of hot mix prepared is not as homogenous as in case of
batch type plant.

5.5 Power Requirement for Drum-Mix Plant

Drum mix plant is fitted with electric motors for operation of different units.

Normally, drum mix plants of 40160 and 60190 tonne per hour capacity are being used
in India and total requirement of power for different units is approximately 105 and 130
horse power respectively, the details of which are given below:
Details of unit Horse power required
SI.No.
60190 t.p.h 40160 t.p.h
a) Auxiliary conveyors (410s.) 8.00 8.00
b) Gathering conveyor 5.00 5.00
C) Vibratory screen for oversize 3.00 3.00
rejection
d) Slinger conveyor 5.00 5.00
e) Dryer cum mixing drum 25.00 20.00
0 Exhauster 25.00 20.00
9) Dust collector conveyor screw 1.50 1.50
h) Load out conveyor ' 7.50 5.00
I) Hydraulic power pack 5.00 5.00
1) Asphalt pump 5.00 5.00
k) Air compressor for mineral filler 15.00 10.00
I) Burner air blower 15.00 10.00
m) Burner fuel pump 2.00 1.OO
n) Hot oil circulat~onpump 1.OO 1.OO
0) others 7.00 5.50
Total 130.00 105.00
 All the motors are not in operation at full load continuously. The generating set 82.5
kVA and 110 kVA are adequate to run 40160 and 60190 tonne per hour capacity drum
. .
. .. . ..mix
-. - ...pl_ant..re.s.p.e.ctiuely
-. .. . . . . - . .. -. -- - .- - -- -. -

5.6 Double Barrel Drum Mix Plant

In double barrel drum mix plant technology, the concentric chambers of same drum
are used to heat and mix the virgin aggregates with liquid bitumen, filler material
and reclaimed bituminous pavement (if required). The heat produced in dryer drum is
utilized more effectively in following manner:
a) The inner shell of the dryer drum de-moisturises and heats the virgin
aggregates upto required temperature and discharges it to outer shell.
b) The outer shell (annular portion) fitted with arms and tips is utilized
to mix the hot and dried virgin aggregates with reclaimed bituminous
pavement, filler material and liquid bitumen. It works as pugmill and
produces homogenous mix with use ofareclaimedbituminous pavement
upto 50 percent.

5.6.1 Sequence for preparation of hot mix

a) The aggregates in desired proportion are fed from cold bin feeder
to dryer drum (counter flow type) and shaken well with a vibratory
'
flap arrangement at the entry of dryer drum, which loosens the dust
particles sticking to the aggregates.
b) The dryer chamber consists of three sections fitted with different types
of flights for efficient drying of aggregates and effective heat utilization.
The arrangement of flights is shown in'the (Fig. 31). The function of
different types of flights is also shown below:

Fig. 31 Arrangement of Different Types of Flights in Double Barrel Plant

37
 IRC:90-2010

1) Conditioningflights: These are used to break up the lurr~psor sticky materials

as the aggregates enter the dryer chamber (Fig. 32).
C O N D I T I O N I N G FLIGHTS
...... - - . - -. - . . . . . . . . . . . . -- -- - -- .. - - - ..... -. .. . ........... - ..

Conditioning Aights break up any clumps or

sticky material when the aggregote first enters.

Fig. 32 Conditioning Flights

2) Showering flights: These are attached to the shell and arranged such as to
lift the aggregates and ensure their exposure evenly for effective drying (Fig. 33).
I SHOWERING FLIGHTS 1

1 Showering Ri h h make sure that the material

is veilnd evenYy through the hat gas stream.

Fig. 33 Showering Flights

3) Combustion flights: These are in the combustion zone and prevent

aggregates from impinging on the flame while spreading the material for maximum
radiant heat transfer. After completing the drying operation, the dried aggregates
- come out of the inner drum through the designated outlet near the burner (Fig. 34).
I COMBU.STlON
...
FUGHTS
I

Combustion :one Rights prevent aggregote

horn impinging on..the flame while spreading
Fig. 34 Combustion Flights
 c) The outer periphery of drying drum is fitted with paddles, arms and
tips. It is less than overall length of dryer drum, covered with another
-- stationary
.-- shell and
.-- - does the .function
- - of a mixing chamber.-. -- -

The drum rotates in inclined position. The aggregates, liquid bitumen,

0 reclaimed bituminous pavement and other ingredients as per job mix
formula present in mixing chamber (Fig. 35) are pushed upwards
1 against gravity by the paddleslarms fitted at the outer periphery of the
dryer drum. Due to slow material niovement in mixing chamber, the mix
gets sufficient time for proper mixing before the same is pushed to the
final outlet (towards the I-lpper end of mix chamber). It also utilizes the
radiant heat of dryer chamber, which reduces the fuel consumption.
In this section, the hot superheated virgin aggregates which come out
of the dryer chamber, mix with the reclaimed bituminous pavement
(RBP) being externally fed to mixing chamber (close to the outlet of
dried aggregates). The reclaimed bituminous pavement absorbs the
heat from virgin aggregates and evaporates the moisture content
present in it. Old bitumen present on reclaimed bituminous pavement
melts and coats the virgin aggregates thinly as the aggregates cool to
mixing temperature.

Fig. 35 Mixing Zone of Double Barrel Drum

d) The liquid bitumen is injected as per mix design, which coats both the
virgin and old aggregates with a thick film of bitumen. The fines1additives
are added at a later stage, which gets embedded into thick bitumen film
and mixing continues till hot mix exits in mixing chamber.

5.6.2 Components of double barrel drum mix plant

1) Cold bin feeder (minimum bins-4 nos.)
 2) Cold feed conveyor
3) Double barrel drum
4) RBP feeder
-- -. - -- -. - - ---
. - - -- - -- - - . -.

5) Primary dust collector

6) Bitumen unit
7) Drag conveyor
8) .Gob hopper
9) Control cabin
10) Mineral filler system
11) Secondary pollution control device (Bag house filter system)
12) Hot mix surgelstorage silo

5.6.2.1 Cold bin feeder

The brief details have already been furnished in Para 4.1.1. 1

1
5.6.2.2 Cold feed conveyor

It is known as slinger conveyor also. The brief details have already been furnished in
I
Para 4.1.2

5.6.2.3 Double barrel drum

A double barrel drum consists of two concentric chambers. 'The inner chamber acts
as dryer drum and outer chamber as mixing drum. It is fitted in inclined position and
rotates at slow speed through chain and sprocket mechanism. The drum shell is
supported by two steel tyres which rest on four trunion rollers and two guide rollers.
The process flow diagram is shown in Fig. 36.

Fig. 36 Process Flow Diagram for Double Barrel Drum Mix Plant
! -The dryer drum is fitted with low noise and high efficiency burner at one end. The
I
.-
dryer chamber is Titted with flights of three different configurations to ensure proper
-demoisturising
- and heating
-- ---of. -virgin aggregates upto
. required
--
-----.-- temperature.
- --. - .- -- --The
- heated
-
aggregates travel by gravity assisted by rotational movement of the drum (towards the - - -
burner side) and finally come out of the dryer chamber to the mixing chamber. The
annular portion of the dryer drum is fitted with mixing paddleslblades for churning the
hot virgin aggregates with externally added reclaimed bituminous pavement, liquid
bitumen and other additives for homogenous mixing as per job mix formula. The hot
mix inside the mixing chamber are pushed against gravity by the mixing blades and
finally come out of the'mixing chamber as final product.

5.6.2.4 RBP feeder

It consists of bin and conveyor, which feeds the reclaimed bituminous pavement
to double barrel drum. The reclaimed bituminous pavement feeding arrangement
may comprise of an impact crusher and close loop screening arrangement
as optional to ensure proper down sizing of milled reclaimed biturr~ilious
I
pavement.

5.6.2.5 Primary pollution control device (dust collection system)

The brief details have been given in Para 4.1.4.

5.6.3 Bitumen unif

The unit mainly consists of bitumen tank, bitumen heating system, bitumen pump
and delivery pipe. ~ i t u m e npump fitted with variable speed motor is used to feed the
liquid bitumen as per job mix formula through hot oil jacketed bitumen pipe line. In
addition to this, other controls like tachometer,Row meter etc. are provided to ensure
correct feeding of bitumen in mixing chamber.

5.6.4 Drag conveyor

The hot mix prepared is discharged from mixing chamber through drag slot conveyor
to the surge bin or hot mix storage silo.

5.6.5 Gob hopper

The brief details have already been furnished in Para 5.2.10.

IRC:90-2010
5.6.6 Control cabin

The entire operation of plant being run on automatic mode is controlled from a
centra Iized-control.. roorn, Th.e..-br~ef...d-e_tajl.s-b.aye a1.r.e-ady ....b-e.e.n..fu rnis-hed-in-Para. ..

4.1 .I2.

5.6.7 Mineral filler system

The brief details have been furnished in Para 4.1.11.

5.6.8 Secondary pollution control device (bag house filter system)

The brief details have been furnished in Paras 4.1.13 and 5.2.14.

5.6.9 Hot mix surge silo: The brief details have been furnished in Para 4.1.14.

5.7 Advantages of Hot Mix Plant (Double Barrel Drum-Mix type)

Double barrel drum mix plant has got following advantages over other type of plants:
a) The size of similar capacity of double barrel drum mix plant is less than
the hot mix plant (batch type) and its transportation is also easy and
economical.
b) The plant being of counter flow type and havirlg insulated mixing
chamber optimizes energy utilization.
c) The fuel consumption for heating the aggregates is on lower side.
d) Infrared sensors fitted at mixing chamber sense and control the desired
hot mix temperature and ensure even production.
e) The mixingtakes place in pugmill,thus more homogenous mix evenly coated
with uniform bitumen film thickness and negligible oxidation is achieved.
f) Higher percentage of reclaimed bituminous pavement upto 50 percent,
can be used to produce consistently high quality of hot p i x .

5.8 Limitation of Hot Mix Plant (Double Barrel Drum-Mix type)

The use of double barrel drum mix plant has following limitations:
a) Second gradation control unit is not provided in the plant, thus accurate
grading is not assured.
b) Only graded material is to be used.
c) The cost of double barrel drum mix plant is high in the category of.drum
mix plant.
 6 OPERAT-ION OF HOT MIX PLANTS
6.1 Principles for Operation
.-.-. - . . ..... . - ~. . . . ~. _ ~ . - - ... .

-The following principles govern the operation of modern hot mix plant:
a) The operation should be carefully planned, so that the final product is
of a high quality.
b) The operation should be run by a competent manager, who with his
supporting staff, are all fully conversant with the plant, its operation and
maintenance.
c) The aim should be continuity in operation, avoid break-down and
intermittent working.
d) The adequate stock of ingredients must be ensured.

6.2 General

The Guidelines given in plant manufacturer's operational manual should be strictly

followed. The points given below should also be taken care of before starting, shutting
down and running the plant.
a) The sample of aggregates, bitumen and mix material should be taken
at regular intervals of time and tested.
b) The stock piles of aggregates s h o ~ ~be
l d checked regularly.
c) The operation of cold feeders (setting of cold feeders) should be
checked twice daily and more frequently, if variation appears in the mix
and got calibrated, if required.
d) The operation of the dryer should be checked regularly.
e) The hot screens, hot bins and dust collector should be checked daily
for uninterrupted flow of aggregates.
f) The weigh hopper and bitumen bucket should be checked daily. The
accuracy of all scales should be checked at least once a week.
g) The operation of mixer unit should be checked regularly.
h) In drum mix plant and double barrel drurr~mix plant, the bitumen pump
should be checked for its accuracy and got calibrated, if required.
i) Carry out visual inspection of ,the mix, collect mix samples, do extraction
test on mix and bitumen penetration daily or as required, to ensure
compliance with specifications.
j) The records pertaining to quantity of aggregates, bitumen, mix being
laid and their temperature, be maintained.
 6.3 Precautions During Operation of Plant

The following precautions should be observed during various sequence of operations

- of the plant to achieve better performance and optimum utilization: _ _
. . - - - -

6.3.1 Cold aggregate feeder

a) Segregation of aggregates as well as intermixing should be prevented,
while loading aggregates into bins.
b) Bins should contain the aggregates of correct size and kept loaded
fully, to allow even ,Row through the feed gate in a particular set position.
The approximate tonnage per hour for gate openings is provided in the
form of calibration chart for each gate.
c) Arching of fineaggregates is prevented by placing a vibrator iri the.bin
containing fines.
d) Moisture on fine aggregates should be avoided, so that clogging may
not take place.
e) To avoid any damage of conveyor belt, by getting the aggregates stuck
between gate and belt, the discharge gate operings of bins be kept
1.5 times the maximum feed size of aggregates. If required, grizzly
may be kept over the bins to prevent large pieces of stone coming in
the bins, which may clog the gate.
f) After completing the work for day, bins should be left with minimum
material especially during rainy season. It will ensure less strain on
belts and drives while starting four bin feeder next day and their longer
life.
g) The material build I,I~should be checked periodically to prevent rollers
from turning and remove the same.

6.3.2 Cold aggregate bucket elevator

., .

a) In order to reduce the feeding height of four bin feeder, a pit of

approximately one meter depth should be dug, to place cold elevator
mounting frame.
b) Ensure the buckets receive the material from gathering conveyor,
eliminating digging, although the edges are hard faced to give long life.
c) Ensure aggregates are not accumulated in pit.
d) In case of rains during previous night, ensure the water logging in pit of
cold elevator is removed.
 e) Don't start the feeder, until the dryer burner has been incited.

6.3.3 Dryer unit

..~
.. - . . h.eeedve.r;-e -n-s"-rg, h.feeed-bOXbO~-ddmm--door-is o-pwd.,-.
.-a.)-. ...B.efore.-sta.rti.n.g..t - - --- - - --

dust removed and cleaned.

b) Before starting the plant, the nozzle and burner should be cleaned with
kerosene oil.
c) Don't allow the aggregates to flow through the dryer drum, when the
vertical hot elevator bucket is not working.
d) Before starting the dryer drum, the aggregates should not be inside it;
since a very high torque is required to start the dryer drum filled with
aggregates.
e) If furnace oil is used in the burner, it should be pre-heated to bring
down its viscosity, before passing it through burner. The furnace oil to
be preheated between 1OO°C-110°C.
f) Before starting a new installation, ensure that combustion chamber of dryer
drum and bitumen boiler are completely dry. Refractory lining of combustion
chamber should be dried with low wood fire and not by oil firing.
g) Don't permit open fire around fuel oil tanks.
h) Always stand and hold torch at desired length, to prevent getting burnt
in case burner puffs back.
i) While lighting burner, never allow excessive fuel to be sprayed into
combustion chamber of drum.
j) Don't keep the burner lighted for a long time preferably more than five
minutes, without aggregates inside the dryer drum, as the dryer drum
may bulge. Operate the burner on low flame, when it is not loaded
fully.
k) Shape of the flame is regulated by means of air swirling action.
IWaximum swirl will produce a short wide flame and minimum swirl a
long cigar shaped flame.
I) If fuel pump delivery is irregular or negligible, prime the pump and see
the pump does not suck air through joints on suction side.
m) Observe the exhaust smoke during operation. If it is found black, it
means incomplete combustion of fuel and feeding of excess fuel.
In case of white smoke, it shows the presence of moisture in fuel.
Necessary action may be taken accordingly.
 n) Ensure no holes are formed in the cyclone unit, which may add to
excess dusty conditions at site.
o) The flow of material in dryer drum should be uniform. It should not
-- _b.eeo~-ehadeLb~passing_more_quantity-otaggr_egates fr_om-fo-ucbin
feeder to dryer drum. It should be checked by measuring hot aggregates
temperature, to be maintained at about 180°C and moisture content
not to exceed 0.5 percent.
p) The heat loss of aggregates from dryer to mixer and hot mix from mixer
to laying site should be checked at regular intervals of time.
q) At the end of day, put off the dryer druni burner by stopping fuel oil
supply and then the motor.

6.3.4 Burner

The burner fitted on dryer unit should be adjusted properly to maintain uniform
and desired aggregates temperature. Shorter and longer flame length will heat the
aggregates and dryer ends properly.

6.3.5 . Hot elevator

a) Before starting the plant, the material at the foot of elevator should be
removed through flap door.
b) Don't allow the aggregates to flow from dryer drum, when vertical
bucket elevator is not working.
c) Hot elevator discharge chute is provided with liners and to be checked
weekly to determine the extent of wear.
d) Hot aggregates from dryer drum should be delivered to vertical elevator
only when the motor of elevator picks up the speed and runs at rated
revolutions per minute.
e) Care should be taken to see that buckets receive the material directly
with out digging.

6.3.6 Gradation unit

6.3.6.1 Screening unit:

a) The screen must be of adequate area, having correct size of openings
and arranged in sequence.
b) The screen must be set at proper slope for smooth flow of aggregates.
 c) The screen should not have holes. The clogging of screen will not
allow the aggregates to pass through. Therefore, the screens must be
inspected and cleaned frequently.

6.3.6.2 Weighing hopper:

a) Ensure that sufficient material is always stored in all four hopper bins.
b) The automatic'leveling control device to maintain minimum level of
aggregates in any bin stops the plant, if aggregate level drops to
predetermined level; should be checked periodically. It may also be
ensured that over Row from any bin should not occur. The cold feed
should be controlled accordingly.
c) The sample of aggregates sho~,lldbe taken from each hot bin at regular
intervals to check for proper grade.
d) The proper gate openings should be ensured, since the output and
proportioning of aggregates depends upon the same.

6.3.6.3 Proportioning the aggregates:

a) Ensure that aggregate feeder gates are set as per calibration chart
provided on each gate.
b) Gradation tests may be carried out on each sample, collected at regular
intervals.
c) Check up the scales for zero error at no load every day.
d) The aggregates should be discharged from hot bins into weigh hoppers,
starting with coarse and progressing down to the finest, in the batch
plant.
e) The aggregates, filler.and bitumen weighing scales should be calibrated
correctly and checked periodically preferably once in two weeks.

6.3.7 Mixer unit

a) The pugmill does the job of proper mixing, if the tips of paddle arms are
found clearly above the mix. An under filled pugmill does not allow the
paddles to work properly. In an over filled pugmlll, the material floats
above the paddles and is not fully mixed.
b) The mixing should be done in shortest possible time, to produce
uniform mix. If the mixing time is too short, the particles would
not have a uniform coating of bitumen. If the time is too long, the
bitumen coating will harden because of long exposure of bitumen
to heat and air. An average time for dry 'mixing could be about
 15 seconds followed by 30 to 45 seconds of mixing, after bitumen
is added.
Over size aggregates entering the mixer, tend the mixer arms to bend.
-+-.e-cl.earance-b.etwe.en-th.e.-p.add-l.e..tips.-..a n-s.i.d-e--l-i-n~n-g--of-mixe-r
,.-.d--i -b-ox--
..

should not be more than 2 cm.

Check aggregates h0ppe.r gates and bitumen feed valve to see that
they close tightly and no leakage takes place into mixer after the feed
is stopped.
Ensure sequence of feeding the material. Therefore, coarse aggregates
first, followed with smaller sizes progressively in order of size.
See that the paddles and tips are set to ensure proper mixing action.
See that the lining and tips are not worn. The tips have a tendency to
wear faster in macadam work compared to seal coat.
Check distribution of bitumen uniformly over entire width of mixer
covering all parts.
Check the temperature of mix frequently, as soon as it is dumped into
tippers. Ensure that the temperatures of aggregates and bitumen are
within the specified range.
Check the mix temperature frequently for laying and rolling.

6.3.8 Bitumen unit

a) Ensure before filling the bitumen tank, it does not contain water. Even
a small amount of water will cause hot bitumen to foam up several
times its normal volume, resulting in its over flow.
b) Fill up the bitumen tank to its 80 percent capacity only, since the volume
of bitumen increases while raising the temperature. The over flow of
bitumen can be fire hazardous.
c) The boiler should be located nearest to the plant to ensure safety,
reduce the straih on the bitumen pump and prevent the clogging of
bitumen line. The lead pipes should be insulated against risk to the
work man and maintain the bitumen temperature. It should always
be at inclined position to enable the hot bitumen to run down to the
bitumen boiler when not in use. The boiler should also be erected with
slight downward inclination towards the hottest firing end. Cold bitumen
under the flue tubes will then drain down the inclination towards the
firing end and can be drained without choking.
 d) The top lids of the bitumen tank should be kept closed, since the water,
dust are the deterrents to good and clean bitumen. Clean the external
sides of barrels, before charging to prevent foreign matter going into - - -
-. -- . .
t h T - b 5 i l e T - T h e - d u s t a n d - f i n e particles settle down around the flue
tubes, which results in poor heat transfer, local heating of flue tubes
and cracks are produced in welding resulting in l,eakage, which can be
fire hazardous.
e) In case excess fuel has been fed into flue tubes, shut off the fuel
supply and allow air to blow off the fuel and again start the procedure
for lighting the burner. It is always safe to start the blower first before
turning on the fuel.
f) Bitumen must be maintained at specified temperature. Overheating
may cause cracking and it may be difficult to pump.
g) Whenever there is a change in type of bitumen to be used, the bitumen
tank should be drained and cleaned thoroughly with solvent before
further use.
h) Certain solvents like diesel oil to be used for cleaning are highly
inflammable and must be thorougt~ly drained before bitumen is
circulated. If the traces of such solvents reach the mixer and come ir
contact with the heated aggregates, risk of fire cannot be ruled out,
i) Bitumen tank burner may be lighted, only when the level of bitumer
inside the tank is higher than the heating tubes.
j) Circulate the hot oil for about fifteen minutes to melt the bitumen sticking
to the walls of the bitumen line.
k) While inducting hot oil into a cold line, open the valve very slowly, to
allow piping and jackets heat up gradually. Rapid induction of hot oil
into cold lines will result in uneven expansion of lines and may damage
the connecting points in line.
I) The hot oil level shoukfbe checked regularly in the hot oil tank. If the level
falls, check for any leakage in hot oil or jacketed bitumen pipe lines.
m) Ensure that the dust does not enter the meter relay box and dial head.

6.3.8.1 Bitumen pump

a) It is a rotary gear type of pump in which while working, suction develops
on the kettle side and pressure on the delivery side of the pump.
b) The gear pump should be thoroughly drained at the end of each
operating period. The failure toclean the pump results in solidifying the
 bitumen around the rotor and may break the gear teeth or driving shaft,
when the power is applied. The only means of. relieving the clogged
rotor is by heating the pump, which is troublesome.

d) . When "Weeping" becomes apparent at the bottom pump gland, tighten

the gland nuts carefully, one flat at a time. If "Weeping" is allowed to
persist, it soon becomes a leak and gland packing is to be replaced.
e) It should be made a practice to disengage the pump drive at the end of
operation. Otherwise, if the plant is started next day, before the bitumen
is sufficiently heated for circulation, the pump drive, if still engaged will
place excessive strain on the driving shaft and might cause the shaft or
rotors to break. The pump rotor should also be reversed for about four
to five minutes, as soon as the plant is stopped, to empty the bitumen
pipe lines. Always observe that the pump rotors are free by applying
the V-belt drive gradually. Slipping of the belt over the pump driving
pulley indicates that the rotors are clogged and need heating to relieve
them. Never apply the drive quickly, as it may cause damage to the
pump rotors or shaft.
In case chain drive is being used, engage the clutch slowly and ensure
that the pump gears are not clogged, which is indicated by excessive
slipping of the clutch.
f) If the rate of flow of pump falls during operation, the cause may be
slipping of clutch. In case it is not so, it would mean that pump rotors
have worn out and need renewal.
g) It has been practically found in the field that clogged bitumen pump is
relieved by heating the case, either by using a blow pump or igniting
the oil soaked waste. These methods destroy the pump gland and
should not be used.
h) Boiling water may also be poured continuously over the pump housing
to relieve the clogged rotar.
i) When a new pump or pump with new rotor is fitted, the pump at times
may fail to lift the bitumen. To overcome this, uncouple the pipe from
delivery side and pour a small quantity of heated bitumen approximately
ten litres and at same time reverse the pump rotor by means of hand
wheel. Reconnect the pipe and start up. This difficulty would not occur,
once the pump has been operating satisfactorily.
j) Bitumen to be used in ,the rrlix should be heated to ensure its fluidity,
before the pump is started. The bitumen must be allowed to circulate
 for atleast fifteen minutes before the mixing commences, so as to
keep the meter, spray bar warm and also relieve the solidified deposits
- --
_ _ _ throughout
_- -___ A-
the circuit. test-cock
-_ in return line close
- - - to- the kettle is-_-. - .-

provided to ensure that bitumen has,completely circulated.

7 ESSENTIAL ACTIVITIES WHILE STARTING, OPERATING

AND SHUTTING DOWN PLANTS
7.1 Check List Before Starting the Plant

The following items covered in the check list should be verified by the operator and
ticked before starting the plant. The date and time should be mentioned inthe check
list and kept as record:
a) Have you carried out daily maintenance schedule as per instructions.
b) Have you topped up all oil tanks and gear boxes with proper grade of
oil and fuels. .

c) Have you checked the oil level in the air cleaner and topped it up.
d) Haue you checked the tension of "V" belts, flat belts and chains.
e) Have you checked all grease points.
f) Have you checked all guards and covers fitted in the plant complying
the safety norms.
g) Have you heated the bitumen pipe line through hot oil system for
uninterrupted supply of bitumen.
h) Have'you cleared the accumulated stones before starting the bucket
elevator.
i) Have you checked the conveyor belts for any damage or wear.
j) Have you checked the conveyor rollers for free turning.
k) Have you checked too much fuel is not sprayed into the combustion
chamber of dryer.
I) Have you checked there is no water in the bitumen tank before pouring
the bitumen in the tank.

7.2 Sequence of Operation for Starting and Shutting Down the Plant

The starting and shutting down the plant should be done in chronological order for its
smooth running. The sequence for starting various components of plant is as under:
a) Exhaust fan
3'

IRC190-2010
b) Dust cleaning system
c) Filler feeding system
d) Vibrating screen
-. -- - . .- - - -.
. .- - - - ---

e) Hot elevator
9 Dryer
g) Inclined belt
h) Collecting belt
i) Cold aggregate feeder
j) Burner
k) Mixing unit
I) Cold bin feeder

During shutting down the plant, the first component to be stopped is the input of
aggregate system. The material trapped inside the drum should be then flushed out
from the system in the sequence shown below:
a) Cold bin feeder
b) Collecting belt
c) Inclined belt
d) Burner
e) Hot elevator
f) Vibrating screen
g) Mixing unit
h) Drying drum
i) Cleaning system and filler system
j) Exhaust fan

The following points should also be considered, while starting arid shutting down the
plant:
a) After ten minutes before seizing the production of plant or two to three
batches short of desired number of batches; the feeder unit should be
stopped.
b) As soon the last portion of aggregates Leaves the dryer, the burner
should be shut off from the cock provided close to the burner, which
 cuts off the fuel supply. Now shut off the dryer. motor. When the final
batch has been mixed and discharged, both ends of paddle shafts
- - .--. .
should
-- ---
be cleaned with light diesel oil or high speed-
diesel to ensure - - --

that they are free torotate at the time of starting the plant next day.
c) The plant should not be stopped, in case the material is in transit. The
plantmay be stopped if dryer, elevator, screens, bins, mixer are empty.
d) Now, put off the bitumen tank burner by stopping the fuel supply. Stop
the bitumen pump and reverse its drive immediately, either by hand
wheel or reversing the motor rotation. Move the lever on pressure
regulator (metering system only) to draining position. Fix the discharge
of weigh1 spray system hopper in open position. The bitumen system
must be drained thoroughly to ensure its easy operation the next day.
All bitumen piping should have slope downwards to the kettles to assist
drainage, and a tap fitted in the delivery line just after the pump, which
may be left open over night to prevent the clogging of the pump. If
cleaning solvents are used, these should be thoroughly drained off,
before re-circulating the bitumen.
e) The fuel tank should be filled.
f) Defects, if any or unusual sound should be reported to the'concerned
engineer and got rectified.
g) Check and rectify any leakage, especially in bitumen and hot oil
system.
h) Check all bolts, nuts for tightness and tension in the chain.
i) Inspect the blower of exhaust fan for balancing and play of bearings.
j) Weld the cracks in the sheets, if found.
k) Clean the plant, specially dusvaggregates collected underneath the
belt/ chain conveyors and lubricate all points.
I) Keep the motors and exhaust pipes covered to avoid rain or dew
entering 'inside.

7.3 Upkeep of the Plant During Idling

If the plant is left in open for more than six weeks, certain precautions should be observed,
especially on mobile plants and in extreme climatic conditions, which are as under:
a) Isolate ,the mains supply to electrically driven plant to prevent
unauthorized starting.
 Cover the exposed.starter panels.
Wrap all V-belts including pulleys with a strong, self-adhesive paper
and lubricate exposed chain drives.
- -. . .. . - . -.

Grease all adjusting screws, dryer swiveling support rollers, motorslide

rail adjusting screws, jacks to prevent rusting.
Protect the dryer burner nozzle.
Remove the pneumatic tyred wheels of a mobile plant and keep them
safely. Protect the hubs of axles also.
If roller shutters are fitted on the mixer housing, lower and lock them up.
Close the windows of the control cabin and keep the doors locked.
Cover the top of the exhaust fan to prevent ingress of water.
j) Cover the inlet of the burner air blower.
k) If the door is fitted in the dryer feed end box, pin it in the closed position.
I) The plant may be painted, if required to prevent corrosion.

8 MAINTENANCE AND UPKEEP OF HOT MIX PLANT

Proper maintenance and upkeep of hot mix plant is required for its long life, control on
frequent breakdowns, maintaining quality of output and controlling the operating cost.

The sched~~les for maintenance of hot mix plants are prescribed by the manufacturers
and given in their maintenance manuals. Sometimes the working conditions of particular
site need frequent checking of specific items due to their premature failure. These items
are added in the maintenance schedules as per requirement.The maintenance schedule
forms daily, weekly, fortnightly, monthly, quarterly, half yearly should be got printed, the
items checked as per format, signed by the maintenance staff and kept in records. The
history sheet of plant should also be maintained properly and transferred along with the
plant to assess the requirement of critical coniponents at particular spell of time. It may
be ensured during maintenance that recommended type and grade of oil, lubricants are
used in the plant. The Do's and Don'ts for maintenance of hot mix plant are mentioned
at Annexure-G. A brief of normal maintenance schedule is given below:

8.1 Maintenance Schedule

8.1 .I Daily maintenance schedule

a) Lubricate all parts as given in daily lubrication chart.
 b) Check the gear box oil level atleast one hour after the shut down of
plant, when the oil will settle down and indicate the correct level. If
nece~sarytopfhe~up-.. - - _ _ - _ -_. - - -- -
-.
.. -- - .

c) Top up all drip feed lubricators.

d) Tighten all bolts after completing day's operation, especially mixer
arms, tips, liners, elevator buckets, dryer lifters, roller paths etc.
e) The following points should also be attended to during operation of the
plant:
i) Bitumen cocks are operated for production of every batch of mix
material. These should be lubricated at an interval of every two
hours. Other cocks need lubrication daily.
ii) Check the bearings and ensure that over heating does not occur.
iii) Turn on all chain drive drip feed lubricators.
iv) Turn ,the key on the filter, in the burner fuel supply pipe line
periodically during the day, to remove water and sediments.
v) Open the tap of moisture separators of air receiver twice daily.
.J

vi) Check the gland of bitumen pump. Tighten if "Weeping" is evident.

vii) Be alert for undue noises, which may be due to loose bolts.
viii) Tighten the bucket bolts on hot elevator.
ix) Recheck the angle of dryer drum under frame to ensure that no
local sinkage has occurred.

1) Weekly Maintenance Schedule (Fifty to sixty hours):

In hot mix plants the trouble does not happen momentarily. It takes place slowly due
to slackness of beltslchains, loose bearings and other factors. The plant has open
gearing, open chain driveslflat belt/ V-belt drives, anti-friction metallic bearings due
to its low revolutions drive. The grease used for gear lubrication becomes a grinding
material, when it absorbs the dust and fine sand. These should be cleaned at least
once a week and new grease applied.
a) Lubricate all components as instructed in weekly lubrication chart.
b) Clean the filters on suction side of the burner fuel and bitumen pump.
c) If filters are fitted on the blower, remove the element, wash it in paraffin,
soak lightly in fresh oil and refit.
 d) Check all V-belts and chain drives and do necessary adjustments
accordingly.
e) lnspect feeder and conveyor belts for wear and tear and broken
.~ ...... . .
.. -- .......- . ... ... .
fasteners.
f) Checkthe belt scrapers on feed unit and in gob hopper. Ensure they
are in good condition and effective. If necessary,.replacethem.
g) Check the conveyor belts; in case of holes or cuts, repair them
immediately by lacing or vulcanizing.
h) Clean the cyclone of dust collection.
i) Periodic inspection of flue tube is essential to prevent a fire accident
resulting out of punctured tube.

MonthlyMaintenance Schedule (Two hundred to Two hundred fifty hours):

a) Clean the burner nozzles as per instructions.
b) Check all electrical wiring ,and cables for loss of insulation or corrosion
and replace, if required.
c) Check the screen cloth, screen meshes and repair1 replace, if ,

required.
d) Check the elevator pins, links and replace, if worn out.
e) Check the load cell and replace, if required.

Quarterly Maintenance Schedule (Eight hundred to One tliousand hours):

a) Drain the oil of gear boxes, flush them and refill to correct level with
recommended gear oil.
b) lnspect the dryer chain ring for worn out or broken pins. Remove the
affected segments of the rirlglpins and replace them.
c) Check the oil level in exhaust fan bearings and top up, if required.
d) lnspect the liner plates in dryer feed ring, discharge chute, elevator
discharge chute and interior of paddle mixer and replace, if
required.
e) Check the burner combustion chamber refractory for earbanization,
clean it and repair, if required.
f) Clean electric contact and relays in control panel.
g) Do the calibration of load cell and weigh bucket.
 4) Maintenance of Electric motors:
a) Isolate the mains supply to prevent unauthorized starting.
-
. ~ b)...-Cover-~l-l-~ke-e-xposed-~o~or-s~a~er-paneIsand-eon~pols--with-tappauIin----
-

'

or plastic sheet to prevent their damage during rains.

c) Always place the proper size.of fuse, while replacing it. Never put a
substitute of different size.
d) Do earthing of entire electric s~.~pply
line properly.
e) Keep the motors and contacts always clean, by blowing away the
dust.
f) Test check no-volt coils and over load protection devices for their proper
function.
g) All the wiring should be placed under insulated cabling and properly
covered trench.

8.2 Requirement of Tools and Plant for Maintenance

The hot mix plants are located in remote area, where repair facilities are not available.
It is essential to have a small workshop for the repair and maintenance of hot mix plant
and allied equipments for their upkeep and effective utilization. The following tools and
plants should be available in the workshop at site.
a) Diesel welding set
b) Small electrical tools for drilling, grinding etc.
c) Pillar drill machine 25 mm capacity.
d) Gas welding set.
e) Chain pulley block (three tonne capacity).
f) Hydraulic jack of adequate capacity for erection of plant.
g) 25 mm Manila rope length 50 m, 100 mm wire rope about 70 m in
length, Wire rope clan~ps,Packing timber like railway sleepers.
h) One set of hand tools such as spanner, screw drivers, hammers, chain
spanners, screw spanner, chain and pipe wrench.
i) Grease guns, oil cans, trays.
j) General items of store like bolts, nuts, washers, pins, fasteners, fan
belt, jitter, cotton waste and other fast moving items.
 8.3 Requirement of Spare Parts and Lubricants for Repair and Maintenance

It is essential that adequate inventory of fast moving spare parts and recommended
lubricants should be available for repair and maintenance of hot mix plant. The
r r r a n u f a c t u r e r ' s - r ~ ~ n s - f o r i a s t - m o v i n g - s p r e a r t s - - m a y be
- followed,--It--
would be appropriate to place the order for fast moving spare parts along with the
plant, so that the work does not suffer during operation. Normally, the procurement
of-spare parts @ 10 percent cost of plant is adequate. The bulk purchase of spare
parts and lubricants should not be carried out, which involves space, blockage of
investment, chances of pilferage and fire hazard. In case the procurement is to be
done through import, time factor for placement of purchase order, opening of letter of
credit, shipping period, custom clearance, inland transportation should also be taken
into consideration.

9 SAFETY ASPECTS AT HOT MIX PLANT SITE

The safety of equipments, operating and maintenance staff should be the prime criteria
at hot mix plant site. Efforts should be made to make the plant site as accident free
zone. In this connection, following precautions should be'strictly followed:

9.1 Work Site

a) Create awareness regarding safety among staff.
There should be no slip-shot and short cuts.
Provide proper training to staff on safety.
Always employ a skilled and trained worker for the job.
Every worker should be medically fit for the job assigned.
Prywide first-aid boxes with adequate supplies.
Keep fire fighting equipments
- in operational condition.
Ensure that workers wear helmets, safety belts, goggles, gloves and
other items as necessary.
Use proper tools and tackles.
Ensure proper and clean platformlpathways for the work men to pass
througj-r.
Provide adequate illumination.
Provide guards and railings wherever necessary.
m) Blow siren before start of plant every time.
n) There should be an emergency switch located at a short distance from the
plant, which will stop all plant operations in the event of an emergency.
o) A First Aid Box s h o ~ ~always
ld be available, in the control room.
p) Smoking should be prohibited near binder or fuel storage tanks.

Keep the equipment in good running condition.

Never operate unsafe equipment.
Be familiar with all controls, gauges, instruments.
Look around before starting the plant and equipment.
Never leave the equipment unattended with its engine running.
Keep operator's platform clean and free from oil and grease.
Operate the equipment only from operator's seattplatform.
Never carry out serviciqg, adjustment and repairs, when the equipment
is running.
Never permit unauthorized persons to handle the equipment.
The operator must have maximum unrestricted view of the operating
area.
Avoid loose connections in electrical system.
Ensure that engine is switched off and immobilized against unauthorized
use.
m) Don't leave the control, when the equipment is working.
n) Be careful in removing the radiator cap, after engine has been
running.
o) Avoid leakage and over heating of bitumen.
p) Take precautions against backfire from burner.
q) Store fuel and lubricants away from plant.
r) Keep away from hot bitumen.
s) Be careful while attending to lighted burner.
t) Inspect all cables of plant periodically.
u) Shut down procedure:
1) Put all the controls in neutral.
2) Shut off the engine after allowing it to idle and gradually cooled
down.
v) No open fire should be allowed around bitumen or fuel storage tanks.
 9.3 Loading and Tansportation of Plant and Equipment
a) Load and unload the plant and equipment on the leveled ground.
b) Use the indicated lifting points, while lifting the plant and equipment
- . - -- - - - - --.-- - - - - --. -.- -.
w i t h a crane.
c) Ensure correct loading and unloading procedure for different type of
equipments.
d) Use ramp of adequate strength.
e) Block transport vehicle, so that it cannot move.
f) Tie and block the equipment securely for transport.

9.4 Maintenance of Plant and Equipment

a) Avoid fire hazards. Close fuel shut off valve.
b) Carry out repair and servicing in accordance with manufacturers'
recommendations.
c) Before working on hydraulic system, make sure that hydraulic pressure
is released.
d) While installing the electrical system, the supply battery must be
disconnected.
e) Protect the eyes with safety glasses, while striking the metal parts and
during welding.
f) Wear gloves, while handling bitumen, parts of sharp edges and during
welding.

10 MAJOR FACTORS AFFECTING THE PERFORMANCE

OF HOT MIX PLANT
The performance of hot mix plant depends on its design criteria, operational efficiency,
maintenance and availability-of allied machines. The following are the major factors
which affect the performance of drum n-~ixplant:

10.1 Presence of Moisture Content in Aggregates

The presence of moisture content in aggregates plays a vital role in preparation,

production of hot mix and fuel consumption of hot mix plant.

If moisture content is very high say '8-10 percent, the aggregates shall not fall out
of flights in a uniform veil, thus there shall not be ur~iformand adequate heating of
 IRC:90-2010
.?,>, -->
~

.:s@
<
.:

aggregates. Thus, the increase in moisture content results in drop of production and :..

increase in fuel consumption also.

10.2 Dust Content in Mix

With increase in dust content in mix, output falls because there is more surface area
to be coated by bitumen which requires greater mixing time. The indicative relation
between dust content and output is given in Annex-D.

10.3 Altitude

The output of plant is derated approximately @ 3.5 percent every 300 m rise in elevation
above sea level. The requirement of plant in specific area should be assessed based on
this factor also. The variation of output with altitude is attached in the Annex-D.

10.4 - Insulation of Drum

The output of plant can be increased by 2.5 percent and fuel consumption decreased
by 4 percent by maintaining temperature difference between outer and inner shell
of drum approximately 60°C. The drum shell s h o ~ ~be
l d insulated with glass wool or
aluminium painted to avoid heat losses.

11. I Following suggestions are made for selection of hot mix plant, .its trouble
free operation, efficient running and to achieve qualitative mix:
a) The hot mix plant should be of reputed make and proven design.
b) The capacity of plant should be selected based on availability of
space for its commissioning, quantum of work and time period for its
completion.
c) The Guidelines, instructions, maintenance schedules prescribed in
manufacturers' manual should be strictly followed.
d) History sheetsllog books should be maintained properly. It shall give an
assessment for the requirement of spare parts needed for replacement
at particular spell of time and their stocking for future use. It will reduce
the inventory of spare parts in stock.
e) Fast moving spare parts should be kept in store at plant site to avoid
idling of the plant.
 Pyrometers/thermocouples are very sensitive instruments. These
should be shielded from the heat of dryer drum, vibrations of the plant
and got calibrated frequently; atleast once during the working period.
-The-vibrating-screen-cover-should-be-opened-regularly;-checked-for---
sieves wear and tensioning conditions and adjusted accordingly.
Control panel of hot mix plant should be got calibrated regularly to
ensure accuracy of hot mix and output of plant.
In case of break down of plant, instructions given for trouble shooting
in operational manual should be followed.
Genuine spares to be procured from plant manufacturer, to avoid break
down and keep their interchangeability.
Skilled operators, technicians duly trained by plant manufacturer or
otherwise, should be deployed for smooth operation / maintenance of
plant.
control Panel should have provision to store real time process data for
reference and review.
High speed drives should be properly guarded, electrical wiring shou'ld
have proper insulation and should be properly earthed and all relevant
safety codes should be fully complied in design, erection and operation
of the hot mix plant.

11.2 Information to be furnished by the purchaser is given at Annex-A.

11.3 Information to be supplied by the manufacturer to the purchaser is given at

Annex-B.

A1.4 The Parameters for the selection of Hot Mix Plant are given at Annex-E.

11.5 The Sample Calculation to ascertain the rate of usage charges of Hot Mix
Plant is given at Annex-F.

11.6 The Sample Calculation for the output analysis.of Hot Mix Plant is mentioned
at Annex-H.
. .:-
'

11.7. The Sample Calculation to work out requirement of Hot Mix -Plant is
mentioned at Annex-I. .

11.8 Some inputs regading calibration of Hot Mix Plants are given at AnnexJ.
 ANNEX-A
(Clause 11.2)
...~.

.- ... .
- -BE--F-u-R-N-I-S-H-ED--B-YYf HEPuRccHHAAERWHLE
IN F.o.R.M-AT I-O-N-T(3 MAKI AN
ENQUIRY WITH THE MANUFACTURER

There are different types of Hot Mix Plants available with their salient features. It is
suggested that following information in respect to Hot Mix Plant may be furnished
by the manufacturer while making the purchase, so 'that appropriate type, make and
model could be offered by the manufacturer.

1) Site Conditions:
a) Space available for commissioning the plant.
b) Altitude above mean sea level
c) Temperature and climate
d) Any other special conditions under which hot mix plant is to be used

2) Type o f Hot Mix Plant:

Drum mix coater1Drum niix with embedded burnerlplain drum mixer1Drum

mixer with centre inlet for RBPIHot mix plant (Batch type)/Double barrel
drum mix plant

3) Type of flow:

Counter flow1Parallel flow

4) Methodology adopted for preparation of hot mix:

Continuous type1Batch type

5) Mobility o f Hot Mix Plant:

Stationary type1Mobile type

6) Essential and optional units of Hot Mix Plant:

The components shown below may be selected based on the type of

requirement of plant.
a) Cold bin feeder (Minimum- 4 No.)
b) Aggregates over size rejection screen
c) ' Cold etevatorlcold feed conveyor

63
IRC:90-2010
d) Automatic weighing system
e) Dryer drum
- K) Drllercummix~~g.drurn-- -- - -. . -
g) Primary pollution control device
h) Hot elevator
i) Screening unit
j) Hot bins
k) Weigh box
I) Bitumen unit
m) Mixing unit (Pugmill)
n) Mineral filler1 dust collection system
o) Control panel
p) Secondary pollution control device (Essential component as Bag house
filter in batch type plant and optional as wet scrubber type in drum mix
plant)
q) Hot mix surge silo (Optional component)
 ANNEX-B
(Clause 11.3)
- INF-o-RMA1'I~o~N-TO~~B~E-SSCJ
PC, E-M-A--W RER - - - -- . - ..-

TO THE PURCHASER

he manufacturer should furnish the information to the purchaser as shown in

ANNEX-A. In addition to that, following information should also be supplied to the
purchaser to get him acquainted with the product and assist him in selection of
plant.

1) Model and type of Hot mix plant offered

2) Brief description of the plant along with its units and their capacity

3 Specific features of the plant, if any

Type and No. of flights in DryerIDryer cum mixing drum

Capacity of electric motors fitted with different ur~itsof plant

Capacity of DG set required for operation of plant

Overall dimensions and weight.of different units of the plant for transportation
purpose

After sales-service, nearest to the commissioning site

Supply of spare parts catalogue, operation and maintenance nianual

assured

List of fast moving components assured

Details of similar model of plants supplied so far, year wise

Provision of training facilities

 ANNEX-C
(Clause 4.1.4 & 5.2.1 4)

--
-- W-P-X-PLANT- EMISSIONS-AN D-THE1R-CONTROL-

The pollution norms are fixed by the respective State Pollution Control Board which
are binding on plants where they are in use. The following information are merely
guiding factor.

Emission Factors for Particulate Matter (PM,,), CO, Nox,SO, and VOCs :

Emission Factor ( k g l t ~ n n e )-~

Process
co NOx so2 vocs

Batch mix asphalt plants :-

0.17 0.013 0.0025 0.0072
Natural gas-fired dryer
0.035 0.084 0.1 2 0.02
Oil-fired dryer

Drum asphalt plantsb:-

0.028 0.015 0.0017 0.022
Natural gas-fired dryer
0.0018 0.038 0.028 0.03
Oil-fired dryer

Batch Mix Asphalt Plants Drum Mix Asphalt Plantsb

Process
~ ~ (~gltonne)
1 0 ~ ~ ~ (~gltonne)
1 0 ~

Natural gas-fired dryer:

Uncontrolled 22 22
Fabric filter 0.0098 0.004 1
Oil-fired dryer:
Uncontrolled 2.2 2.2
Fabric filter 0.03 0.015

Source: USEPA document AP-42 (1995)," Factor u n i t s are kg of PM,, emitted per
tonne of asphalt produced, includes both parallel and counter flow asphalt p l a n t s .
 IRC:90-2010

Typical Hot Mix Asphalt Plant Emission Control Technologies : -

Emission
I I
Pollwtani-.- .- _ -

Cyclones 50 - 75

Multiple cyclones 90

Settling chamber < 50

Baghouse 99 - 99.7
Process
Venturi scrubber 90 - 99.5

Dryer and combustion process modifications 37 - 86

vocs
Limestone 50
so,
Low sulfur fuel 80

Paving maintenance 60 - 99

Fugitive dust p"40 Wetting & crusting agents 70 - 80

Crushed reclaimed Asphalt Pavement Material 70

Adapted from : Gunke., Kathryn. OO'C. 1992. Hot-Mix Asphalt Mixing Facilities.
Buonicore, Anthony J., and Wayner T. Davis, Editors. Air Pollution Engineering
Manual. Van Nostrand Reinhold, New York, NY; USA.
 ANNEX-D
(Clause 10.1, 10.2, 10.3)

_TIY_P_(CAI_m-=QFcl QFM].X-pLA N F Q M'~P.M~-V-S..- -

.-.- - - - -. . --

DIFFERENT PARAMETERS

DEPENDENCY OF-OUTPUT WITH SALIENT PARAMETERS

Moisture-vs-Output
120.00%
g
1000
.0?0'
Y
3 /
P '
3
0
-
IC
0
g3
p!
80.00%

60.00%
q -:
$ 40.00%

-
&
P
5 20.00"
P
CI

5 0.00%
'-'-\o &Q& ."" 88
&\Q
5- P. $.
&\o
8. 4.
\
,Q~
s\o
.\, 0 ,$'
s\o

Moisture (%)

Output Oh
content
40 %
 Output vls Dust Content

-. j --.-,oo------,,.- .- ----'
I--- -

88

( Output %

Dust.Content

EFFECT OF ALTITUDE ON PRODUCTION OF MIX

Effect of altitude on the production of mix in a Hot Mix Plant on a 7' diameter drum with
300° F (148.g°C) mix, 310° F (154.44OC) stack temperature and 5 percent moisture
removed.

Factor Production Rate

TPH
0 1.OO 267
-1 500 0 98 262
W
5
-1
1.000 0.96 257
4 1,500 0.94 252
V)
W
> 2,000 0.92 247
a 2,500 0.91 243
I-
W 3,000 0.89 238
W
LL
Z 4,000 0.86 230
W
n 5,000 0.83 222
3
k
3 6,000 0.80 214
a
7,000 0.77 205
8,000 0.74 197
9.000 0.71 191
10,000 0 69 184
 ANN EX-E
(Clause 11.6)

SELECTION PARAMETERS FOR HOT MIX PLANT

Selection item Options available Selection Criteria I

1) Capacity 3 TPH - ,650TPH i) Volume of work
ii) Completion time
I
iii) Availability of site area
iv) Quantity required to b produced per day

a) Batch typelContinuous i) Purchase cost

tY Pe ii) Maintenance cost
iii) Position of availability and after sales service
iv) Gradation
v) Useof RBP
vi) Emission norms
vii) Noise restriction
viiilvariation of Mixes
i) Size of the Plant
ii) Volume of mix to be produced and the period
thereof to meet local requirement
iii) Cost of erection vis-a-vis trans~ortation
c) Conventional layout1 i) Site area available
Tower type layout ii) Ease of erection
d) Parallel FlowlCounter i) Purchase cost vis-a-vis fuel saving
FlowlDouble Barrel ii) Position of ava~lab~lity
and after sales service
iii) Use of RBP
3) Bitumen Tank a) Plain tanklspecialized i) Requirement of using straight nJn or modified
tank for modified bitumen bitumen
I I ii) Position of availability and after sales service
b) Direct HeatinglHot Oil
Heater
i) Ease of maintenance \
ii) Local fire safetylemission control norms
4) Pollution Control MulticyclonelBag House Filter i) Need to use recuperated fines
System M e t Scn~bber iil Local emission control norms I
 ANN EX-F
(Clause 11.7)
SAMPLE
- -- PROCEDURE
--- --- - FOR CALCULATDN OF RATE OF USAGE -- - - -.-

CHARGES OF HOT MIX PLANT

Assumptions

a > Salvage value = 15 percent of the cost of equipment at site

b) Storage charges = 1 percent of total investment to be.depreciated, spread

over the economic life

c > Repair and maintenance charges per hour including replacement of

tyres = 150 percent of total investment to be depreciated spread over the
economic life

d) Over head charges @ 5 percent of the sum of wages per hour + Servicing
charges (Manpower and material cost)
1. For Equipments Used Departmentally
1.I Ownership charges
A) Total investment at site of work (This includes AIT cost, sales tax,
excise/custom and other duties, transport expenses consisting of
freight by ocean or rail, insurance, loading1 unloading charges,
erection and commissioning on receipt) = Rs. X (say)
6 ) Deduct salvage value @ 15 percent of total investment = 0.15X
C) Total investment to be depreciated = 0.85X
D) Economic life of machine in hours = Y hours
E) Depreciation per hour =- Rs. 0.85 X N
per hour
F) Storage charges per hour ( I percent of "C" spread over = 0 . 0 1 Rs.0.85
~
the economic life) X/Y
Total ownership charges = (E) + (F) ---- I

1.2 Operation charges

G) Repair and maintenance charges per hour (including maintenance and
replacement of tyres) is 150 percent of "C" spread over the economic
life = I.5x(C)/(D) -T-----I I
 IRC190-2010
1.3 Overhead charges

5 percent of ownership and operation charges = 0 . 0 5 ~(1+11) ------- III

- ---Qwner-shi-qjephour -- - ----- =--Rs--. ---- -- . - -

Operation charges per hour = Rs.

Overhead charges per hour = Rs.

1.4 Running charges

Operating staffllabour wages
Designation No. Unit wage per month Wages per month
i) Operator
ii) Helper
iii) Cleaner
iv) Misc. Expenses
Total wages required for Operating staff and labour per month = Sum of wages per
month

H) Total wages required for Operating staff and labour per hour = Total wages
required for Operating staff and labour per monthlHours per month
I) Servicing charges
Servicing charges includes man power cost
Designation No. Unit wage per month Wages per month

i) Mechanic
ii) Cleaner
Total wages required for servicing staff per month = Rs.
Total wages required for servicing staff per hour = Total wages required for
servicing staff per monthlHours per month
J) Servicing charges (Material cost)
Fuelllubricant Rate per litre Consumption (In litrelkg) Expenditure
per month per month
i) Fuel
ii) Lubricants
 iii) Grease
iv) Hydraulic oil
..-v-)--&ar-oil---.. - .~ _ .~ ~

vi) Cotton waste

vii) Furnace oil (In case of hot mix plant)
Total expenditure per month = Rs
Total servicing charges (material cost) = Total expenditure per monthrrotal hours
per month

K) Cost of lubricating oil, fuel consumed per hour

Over head charges @ 5 percent of total = 0.05x(L) .............................. V

Hire charges = I+II+III+IV+V
2. For Equipments Given to Contractor and Outside Agencies

When the equipments are issued to contractors, interest and insurance charges
@ 10 percent of the average investment per year will be calculated as under and
added.

* on 5 years life

= Rs.

M) Interest and insurance charges per hour

Therefore the total charges in that case would be as follows:
3wnership charges (E+F+M) = I
Operational charges = II
Running charges
Overhead charges @ 5 percent of total
charges per hour (I+II+I'V)
Hence hire charges per hour = I+II+IV+V
 ANNEX-G
(Clause 8)
DO'S AND DON'TS FOR MAINTENANCE OF HOT MIX PLANTS

Maintain proper gap between Skirt rubber and Auxiliary belt

~ n s u r 'belt
e center run position
Gate opening of all bins should be as per requirement
Greasing of bearing and oil checking in all gear boxes
Rubber guard should be fitted properly and greasing ofbearing.
Slinger belt should be center run and greasing of bearing and oil checking in gear
box.
Load cell frame should be free during operation and locked when plant is not
working
Check the oil level in all gear boxes.
Proper setting of thrust wheel of drum
Greasing of all bearings.
Ensure the trunion wheel adjustments.
Tighten the nuts and adjustments bolts.
Ensure proper adjustmentsttighten of drum drive gear Motor chain .
Ensure proper lubrication of drum drive chain.
Pre-heat the Drum before feeding of aggregates
Start burner with zero darnper position
Before starting burner, clean both the ignition electrode
Observe the smoke of burner during operation to ensure that the burner operates
properly.
Ensure leakage free operation of pump and solenoid and pressure relief valve
Ensure photocell working for auto mode of burner
Start the exhauster with close position of exhauster
Belt tightening of exhauster belt.
Watch out for any black smoke at chimney outlet
Monitor the differential pressure during operation.
Monitor the smoke temperature while running.
 Ensure continuous operating of the cascading ring.
Grease the vibrating screen daily before the start up of the plant
Check all the cylinders before start
--_________.-.- _-- up of the plant . -- - .. . -

Clean the air filter and oil fiter daily.

Check the Compressor pressure daily
Ensure clean air inlet to the air compressor.
Carry out maintenance at regular intervals
Water earth pits regularly
Follow safety rules.
Maintain Generator, monitor Voltage and Frequency
Keep the control room clean and remove all unwanted. materials
Keep panel power off while carrying out any welding work in the plant
Keep all panels under shelter, water should not enter the panels.
Remove all material from the plant before shut down
Check the calibration at regular intervals. Also it is advised'to undertake calibration
of load cells for the measurement of flow rate of aggregates, bitumen and filler on
regular intervals (say one month)
Operate the bitumen transfer pump only after the bitumen temperature reaches
beyond the 120"
Check alignmentltighten,at regular intervals
Close the main valve at .the fuel tank before servicing fuel pipeline; prepare and
place suitable container or vat under pipe joint before loosening it.
Disconnect the load cell, invertors and other electrical devices when the welding
work is carried out in the plant.
Stop the operation of the plant when you see the lighting near by or hear clap of
thunder and also shut off the electrical lightning.
Adjust all the vibrator weights to the same phase and the same mass.
Do the checking of the Level of the Hot oil in hot oil tank
Don'ts:
Do not operate Bin Vibrator when bin is empty
Do not allow the level of bitumen in the Bitumen tank to fall below safety level
Don't close bin gate when Plant is in operation:
Don't operate Vibratiqg Screen in idle mode.
 Don't feed the higher size of Aggregates in Drum
Don't stop the drum till it reaches the ambient temperature.
Don't disturb the burner working pressure during operation
-- ---- - -- - --- -- -.
Do not operate the Burner without operating exhauster and Drum
Do not fully open the Damper gate while running.
Do not operate Exhauster with Full open Exhaust Damper
Don't touch the hot oil pipe line by hand directly
Do not operate the plant without proper knowledge. This could be dangerous.
Do not start Drum moto'r directly on load try to remove load or give momentum to
druni before power is switched ON
Do not start or stop the bigger motor frequently on load
Never use wires instead of fuse links. Spare fuse links are provided in the panel
Do not power the panel without proper earthing
Do not run the plant at more than rated capacity
Do not run without proper earthing
Do not run the panel without proper supply power condition
Do not touch the panel without wearing shoes
Do not close the breaker on load without cover or arc chutes ;the flash may
damage your eyes
Do not try to carry out the maintenance with power ON
Do not bypass safety of any equipment with power ON
Do not use under size cables or motors .This can result in fire hazards.
Never touch the metal parts of terminal with your finger
Do not smoke in the vicinity of the HMP and certainly not within 5 meters of fuel
tank and fuel pipe line
 ANN EX-H
(Clause 11.6)

. S.A.Mp.~E..~.-I;~I;JL+-~lON-FO~OU-~pU-T.-A.N.A.I;~.SI.S .

OF A HOT MIX PLANT

Time period for completion of 1 Km (2 lane) Bituminous Pavement Construction

by 60-90 TPH Drum Mix Plant

SI.No. Type of Pavement Quantum of work involved Quantity of aggregate

in 2 lane (7.00 m) NH Road in TonnesIKm.
~ncum assuming density 2.2

1) 75 mm BM 7 mx0.075 mx1x1000 m = 525~2.2

= 525 cum = 1155 Tonnes
2) 25 mm SDBC 7 mx0.025 mx1x1000 m = 175~2.2
= 175 cum = 385 Tonnes

3) Total tonnes of aggregates to be prepared in Hot Mix Plant: 1155+385 = 1540

Tonnes

4) Average output of Plant : 60-90 TPH Plant ( Say) 75 TPH

5) Assume Plant working hours per day - 7.5 Hrs

6) Total Tonnage produced in a day 75x7.5 = 562.5 Tonnes

7) Time required for producing 1540 tonnes aggregates.

-1540
- - 2.73 days (Say) 3 days
562.5
 ANNEX-I
(Clause 11.7)

SAMPLE CALCULATION TO WORK OUT REQUIREMENT

... -- -- uF-HO T-MIX-PL-A-N T - - - - - - - - - -- -- -- -

Assumption

200 Km of 2 lane road (7.00 m width) to be strengthened with 50 mm BM and 25 mm

SDBC in a year.

i) Quantity of aggregates for 50 mm BM for 200 Km = 7 m x 0.050 m x 200 x 1000

= 70,000 cum.

Assume density of aggregates : 2.2

Quantity of BM : 70,000 x 2.2 = 1,54,000 Tonnes.

ii) Quantity of aggregates for 25 mm SDBC for 200 Km. = 7 m x 0.025 x 200 x 1000
= 35.000 cum.

Assume density of aggregate : 2.2

Quantity of SDBC = 35,000 x 2.2 = 77,000 Tonnes

iii) Total quantity of aggregate to be prepared in Hot Mix Plant : 1.54.000 + 77.000
= 2,31,000 Tonnes

iv) Suppose the work will be executed with 60-90 TPH Drum Mix Plant, Average
output = 75 TPH

v) Total working hours of Plant in 1 year : 1500 Hrs.( assuming 200 working days
@ 7.5 working hours per day)

vi) No. of Plant required to produce.mix 2,31,000 in a year

- 2,31,000
= 1.71 = 2 Plants
75 x 1500
 ANN EX-J
(Clause 11.8)

Calibration is the process of adjusting the settings for known levels of accuracy. Every
time a measurement is made or a process is performed, there is an actual result and
an expected result. Because of random and variability with a definite pattern, the actual
result usually differs from the expected result. Calibration is done to either identify1
rectify the non-random variability or account for it in such a way that the difference
between the actual and expected results is negligible.

Calibration is done for the Cold bin feeders, Temperature measuring devices and
load cells to measure the flow rate of aggregates and the Bitumen. The details of the
procedure of calibration vary with the type of plant and the manufacturer.

Calibration, for example, o f a load cell in a drum mix plant is undertaken for three to
four control settings covering the production range anticipated for the material.

Calibration of the Load Cell

The load cell in a Drum Mix Plant is used to measure the flow rate of aggregates and the
Bitumen. The calibration is initially done in the static mode and then in dynamic mode.
a) The default settings (factory settings) of the load cells are to be checked.
If there is any change, there is a requirement to calibrate. The speed
of the slinger conveyor is checked which is LN160 where L is the length
of the slinger conveyor and N is the RPM.
b) Thereafterthestaticcalibrationoftheloadcell(beneaththeslingerconveyor)
needs to be done with the help of a standard weight .-Thereforetheoretical
value of the TPH is equal to Weight (Kg) x Speed of the slinger conveyor
(mlsec) x (360011000) TPH
c ) To undertake the dynamic calibration of the load cell the Slinger
conveyor, gathering conveyor, load out conveyor and thermodrum
have to be started..-The gate opening of the cold bin feeder is set as per
the manufacturer's recommendation. Only one feeder is kept in open
position. Also a trolley or a truck with known tare weight is selected and
is kept under the loadout conveyor.

The plant IS allowed to run for a fixed time duration and the output is collected on the
trolleyltruck. -The weight of the material is calculated after calculating the weight of the
loaded truck. The actual -TPH is calculated from the weight of the material output from a
given feeder, time of output and percentage of this aggregate (from the job Mix formula).
This process is followed for at least 'three control settings. The Load cell constant
(Actual TPHrrheoretical TPH) is then calculated.

Calibration of the Bitumen Flow Rate

-- - -- . - .- - . --- - . . - - -

The Plant is allowed to run at 100 percent load and 3 percent (say) of Bitumen .
The arrangement to collect the discharge of bitumen pump in a vessel is made. The
system is allowed to run for duration of 30 seconds. The actual weight of the output
is calculated by subtracting the difference between the empty vessel and the vessel
filled with bitumen. The theoretical weight of the output for a Plant with output of 45
Tons per Hour is (TPH*(1000/3600)*30*(3/100)). This process is repeated for at least
three observations. If the actual weight is less than the theoretical weight then the
speed of the pump js increased.

In the case of Batch Mix Plant the load cell is calibrated for Aggregates, Filler, and
Bitumen. The details have to be followed as per the manufacturer's recommendations
Manuals.

For the sake of illustration, Manufacturers prepare a calibration chart for each of the
aggregates to be used in the hot mix.

An example of determining the control settings for each cold feed using the calibration
chart is as follows:

1) Mix Design Criteria

Coarse Aggregate 20 percent (Cold Feed # I )

Intermediate Coarse Aggregate 40 percent (Cold Feed #2)

Fine Aggregate 30 percent (Cold Feed #3)

Filler 10 percent (Cold Feed #4)

Binder Content .. . 5.0 percent

2) Flow Rate Per Cold Feed

Q = Required Flow Rate per Bin (tlh)

T = Plant's Mix Production Rate (.llh)

B = Percent of Aggregates in Mix (as decimal)

 P = Percent by Weight of Total Mix (as decimal)

Plant Production of 350 tlh

-
Q (cold Feed #I) = 350 x .95 x .20 = 66.5 tlh

Q (Cold Feed #2) = 350 x .95 x .40 = 133 tlh

Q (Cold Feed #3) = 350 x .95 x .30 = 99.8 tlh

Q (Cold Feed #4) = 350 x .95 x . I 0 = 33.2 tlh

The calibration chart to determine the control settings for each cold feed is
used by locating the production rate for each cold feed on the vertical scale,
moving horizontally to the appropriate control line and then vertically down
to locate the control setting. The approximate bin settings are:

Bin 1 = 23 percent
Bin 2 = 53 percent
Bin 3 = 43 percent
Bin 4 = 18 percent

By making these determinations, the discharge rate of each cold feed supplies a balanced
flow of material. This balance is critical as it provides a uniform flow of material.

Percent Max. RPM

 (The Official amendments to this document would be
published by the IRC in its periodical, 'Indian Highways' which
shall be considered as effective and as part of the
codelguidelineslmanual, etc. from the date specified therein)