Asphalt Mix Production

and Placement

(Asphalt Plants, Paving Equipment, Compaction Equipment)

Presented by
Tika Wulandari | (22-2012-158)
Ratih D. Shima | (22-2012-167)

An asphalt plant is a high-tech group of machines capable of

uniformly blending, heating, and mixing the aggregates and asphalt
cement of asphalt concrete, while at the same time meeting strict
environmental regulations, particularly in the area of emissions.

Batch
Plants

Reclaiming
and
Recycling

Asphalt
Storage
and
Heating

Drum
Mix
Plants

Asphalt
Plants

Dust
Collect
ors

Asphalt Plants Common Various Type

Batch Plants
Primary Components :

Cold Feed System

Drum Dryer
Hot Elevator
Hot Screens
Hot Bins
Asphalt-Handling System
Pugmill Mixer
Surge Silo

Drum Mix Plants

Primary Components :

Cold feed system

Asphalt handling system
Drying and Mixing Drum
Elevator
Dust collector
Storage Silo

Batch Plants

Drum Mix

Batch Plants

Batch Plants Primary Component

1. COLD FEED SYSTEM

Cold feed bins provide aggregate surge storage and a uniform flow
of properly sized material for mixing.
Consists of three to six open-top bins mounted together as a single
unit. The size of the bins is balanced with the operating capacity of
the plant.
The individual bins have steep sidewalls to promote material flow,
they also provided with vibratory in case of sticky aggregates.
Each bin can be fed from sized aggregate stockpiles by front-end
loader, clamshell, or conveyor and has a gate for controlling material
at the bottom of it and a feeder unit for metering the flow.
The Plant operator adjusts the flow of the aggregates from each bin
to ensure a sufficient flow of material to keep an adequate charge of
aggregates in the hot binswhich these aggregates shall be
delivered by a belt conveyor below the gate.

Batch Plants Primary Component

COLD FEED SYSTEM
WITH FIVE BINS

COLD FEED SYSTEM

PARTS

Batch Plants Primary Component

2. Drum Dryer

To heat and dry aggregates

of the mix. Aggregates
temperature determine the
result temperature of the
mix. If aggregates has been
heated excessively, the
asphalt will harden during
the mixing, meanwhile if the
aggregate have not been
heated adequately, will
make the asphalt didnt
coat the aggregates
perfectly.

Batch Plants Primary Component

3. Hot Screening
The batch plant vibrating screen unit, which
enables gradation control of four aggregates
sizes into four different hot bins.
This screen will ejects oversized material out of
the production cycle.

Batch Plants Primary Component

4. Hot Bins

The aggregates from the hot screens are stored in the hot
bins, untul a batch of asphalt concrete is produced.
Ensure that the hot bins have sufficient material to feed the
pugmill for the production of a batch of asphalt concrete.
Compared to a drum plant, batches are individually blended
from the hot bins, this enables the aggregate blend of one
batch to be different from the blend of the next batch.

Batch Plants Primary Component

5. Weigh Hopper
Aggregate from the hot bins is dropped into a weigh
hopper situated below the bins and above the pugmill.
The weigh hopper is charged one hot bin at a time.
The aggregate weight in the hopper is cumulative, with
the mineral filler added last.
After charging, the weigh hopper gates are open to
discharge the aggregate into the pugmill

Batch Plants Primary Component

6 Asphalt-Handling System
The asphalt cement is stored at the plant in a
heated tank, and then pumped to the weigh tank
(or weigh bucket), ready for discharged into the
pugmill.
After the aggregates are added to the pugmll,
during the mixing process the asphat cement is
pumped and sprayed to coat the aggregates.

Batch Plants Primary Component

7. Pugmill Mixing

Pugmill mixing is the main part of the batch plant to mix aggregates
with asphalt that was stored in Asphalt-Handling System.
Most of batch plants use a twin-shift pugmill.
The mixing process generally takes about 1 min, 15 sec for loading with
the dry materials and 45 sec of mixing time with the asphalt cement.
Typical batch quantities range from 1.5 to 5 tons. A batch plant with a
5-ton pugmill can produce 300 tons of mix/hr if a continuous operation
can be maintained.
The plant is structured so that the discharge gate of the mixer is
sufficiently high to allow truck passage directly below for loading.

Batch Plants Primary Component

8. Surge Silos
Enable the plant to operate independent of
immediate truck availability. Surge silos are use as
alternative to transport mix from the pugmill.
Also enable the plant operator to premix and store
several batches of asphalt concrete to
accommodate an uneven distribution of truck
arrivals at the plant.

Drum Mix Plants

Drum Mix Plants Primary Component

1. Cold Feed System

In a drum plant, all of the drying and mixing is performed

within the drum and the asphalt concrete mix is
discharged directly from the drum into a storage silos in a
continuous manner. There is no weighing process such as
in the batch plant. Therefore, Drum Mix Plants also
refered as Continous Mixing Plants.
Compared to batch plants, the cold feed system of drum
mixing plants, the aggregates must be weighed prior to
feeding the material into the drum.

2. Mixing Drum

Consists of a long tube with flights for tumbling the

aggregates and the mix, a burner for heating the
aggregates, and a spray bar for applying the asphalt.
Aggregates are metered into one end of the drum, and there
is where the asphalt cement is sprayed onto the aggregates..
The aggregates spend times in the drum within 3 to 4 min.
Rotation speeds of the flights are normally 5 to 10 rpm, with
common diameters are from 3 to 12 ft and lengths between
15 to 60 ft.

3. Storage Silos
Since the drum plants produce a continuous flow of
asphalt concrete, the output must be stored in silos
for subsequent dispatch into the trucks.
These silos are typically insulated to retain heat
These silos also have a bottom dump for directly
discharging the asphalt concrete into the trucks.

Dust control system is

installed in asphalt
plants so that air
pollution can be
controlled.

Dust Collectors

Asphalt paver is a piece of construction equipment used

to lay asphalt on roads, bridges, parking lots and other
such places. It lays the asphalt flat and provides minor
compaction before it is compacted by a roller.

PAVING
EQUIPMENT

The Paving Equipment

Sweeper/broom, for removing dust from the surface to
be paved. This is done to ensure proper bonding
between the new asphalt and the old pavement.
Trucks for transporting the asphalt mix from the plant to
the construction site.
Asphalt distributor truck for applying the tack or sealing
coat. This is requires constant attention to produce a
uniform application. Factors that affect uniform
application are:

The Asphalt spraying temperature

The liquid pressure across the spray nozzles
The nozzle height above the surface
The distributor speed

Asphalt Paver

An asphalt paver consist of a

tractor, either track or rubbed-tired
and a screed. The tractor power
unit has a receiving hopper in the
front and a system of slat
conveyors to move the mix
through a tunnel under the power
plant to the rear of the tractor unit.
At the rear of the tractor unit, the
mix is deposited on the surface to
be paved, and augers are used to
spread the asphalt evenly across
the front of the trailing screed.
The screed controls the asphalt
placement width and epth, and
imparts the initial finish and
compaction to the hot mix
material.

Asphalt Paver

Because of the relationships between pavement air voids

and mechanical stability, durability, and water
permeabilitas, asphalt pavements are designed based
on the mix being compacted to a specified desity.

COMPACTION
EQUIPMENT

Rollers