Hot Asphalt Mix Production and Quality Control

Construction of Hot Asphalt Mix
3th Year, Civil Engineering
By
Dr. Ashraf El_Shahat

Faculty of Engineering, Zagazig University
2011
3rd Year Civil Eng.
Construction of HMA.
Lecture 1
Production of Hot Mix Asphalt

(HMA)
FAE_ZUN
2011
FAE_ZUN
HMA Production
23/2/2011
Quality Control of Mix Production

Production
Placement
Compaction
FAE_ZUN
HMA Production
23/2/2011
3rd Year Civil Eng.
Production
FAE_ZUN
HMA Production
23/2/2011
Objectives
The production of good asphalt mix
using the appropriate percent of
aggregate and asphalt to achieve the
required specifications
FAE_ZUN
HMA Production
23/2/2011
3rd Year Civil Eng.
Hot Asphalt Mix Plant

Continuous
Batch
FAE_ZUN
HMA Production
23/2/2011
Batch versus Continuous Plants

No
1
2
3
4
5
Item
Calibration
Quality
Production
Projects
Cost
Batch
By weight
Low
Batch
Medium and Small
Low
Continuous
By volume
high
Continuous
Big
High
FAE_ZUN
HMA Production
23/2/2011
3rd Year Civil Eng.
Batch Plant
Asphalt
Cold Belt
Cold Bins
Mixing
Dryer
Flame
Hot Belt
Silo
FAE_ZUN
HMA Production
23/2/2011
Production
Fine Agg.
Bin 3
Bin 2
Bin 1
( 3/4
( 3/8
3/8 )
No.10 )
( Finer
No.10)
Coarse Agg.
FAE_ZUN
23/2/2011
HMA Production
3rd Year Civil Eng.
Batch Plant (Cold Bins)
FAE_ZUN
23/2/2011
HMA Production
Batch Plant (Dryer)
FAE_ZUN
HMA Production
23/2/2011
3rd Year Civil Eng.
Batch Plant (Dryer)
FAE_ZUN
HMA Production
23/2/2011
Batch Plant
Hot Bins
Mixing Chamber
FAE_ZUN
HMA Production
23/2/2011
3rd Year Civil Eng.
Sieves
Sieve 1
Sieve 3/8
Sieve No 10
Sieve No 40
Aggregate
Weighting
Over Size
FAE_ZUN
Bin 1 Bin 2 Bin 3 Bin 4
HBin 1
HBin 2
23/2/2011
HBin 3
HBin 4
FAE_ZUN
HMA Production
23/2/2011
3rd Year Civil Eng.
Mixing
Unit
FAE_ZUN
HMA Production
23/2/2011
Control Unite
FAE_ZUN
HMA Production
23/2/2011
3rd Year Civil Eng.
Continuous Plant
Asphalt
Cold Bins
Flame
Dryer
Silo
Conveying Belts
FAE_ZUN
HMA Production
23/2/2011
Continuous Plant
Aggregates
HMA Production
23/2/2011
FAE_ZUN
10
3rd Year Civil Eng.
Continuous Plant
FAE_ZUN
HMA Production
23/2/2011
Continuous Plant (Temperature)
FAE_ZUN
HMA Production
23/2/2011
11
3rd Year Civil Eng.
Lecture 2
Quality Control of
HMA Production
FAE_ZUN
2011
FAE_ZUN
HMA Production
23/2/2011
Objectives
The production of good asphalt mix
using the appropriate percent of
aggregate and asphalt to achieve the
required specifications
FAE_ZUN
HMA Production
23/2/2011
12
3rd Year Civil Eng.
Production
Fine Agg.
Bin 3
Bin 2
Bin 1
( 3/4
( 3/8
3/8 )
No.10 )
( Finer
No.10)
Coarse Agg.
FAE_ZUN
23/2/2011
HMA Production
Blending of Aggregates
B.No.1
65%
Sieve No. Av. 0.65
1.5
100
65
1
100
65
100
65
88
57
3/8
74
48
No. 4
49
32
29
19
No. 10
11
7
No. 40
No. 80
7
5
N0. 200
6
4
B. No.2
25%
Av. 0.25
100
25
100
25
100
25
100
25
100
25
100
25
56
14
19
5
12
3
9
2
B.No.3
10%
Av.
0.1
100
10
100
10
100
10
100
10
100
10
100
10
100
10
100
10
68
7
7
1
Combined
Aggregates
Specs (4C)
100
100
100
92
83
67
43
22
15
7
100
100
100
80 - 100
72 - 90
52 - 72
35 - 55
12 - 30
7 - 18
2-8
HMA Production
23/2/2011
13
3rd Year Civil Eng.
Quality Control
Dryer (Gradation , Temperature)

Storage (Cold, Hot)
Sieves (Size)
Asphalt.
Mixing (Temperature, Time)
FAE_ZUN
HMA Production
23/2/2011
Dryer
FAE_ZUN
HMA Production
23/2/2011
14
3rd Year Civil Eng.
Dryer
- -
-
FAE_ZUN
23/2/2011
HMA Production
Sieves
No of hot bins depend on the
available no of sieves inside the
plant. The sketch show that
there are three sieves 1, 3/8
, No. 10 and No. 40
then there are three hot bins
HB1, HB2, HB3, HB4
Sieve 1
Sieve 3/8
Sieve No 10
Sieve No 40
Over Size
FAE_ZUN
23/2/2011
Bin 1 Bin 2 Bin 3 Bin 4
15
3rd Year Civil Eng.
Sieves

) (Bin
.
FAE_ZUN
HMA Production
23/2/2011
HB4
HB2
HB3
FAE_ZUN
23/2/2011
HB1
HMA Production
16
Aggregate
Weighting
3rd Year Civil Eng.
Mix
Blending
FAE_ZUN
HMA Production
23/2/2011
Blending of Aggregate
Sieve
Size
Inch
(65%)
3/8 Inch
(25%)
Fine Sand
(10%)
JMF
JMF
Tolr
JMF
Limits
SPECS
Limits
Inch
100
100
100
100
100
100
Inch
87.7
100
100
92
..
80-100
80-100
3/8 Inch
73.8
100
100
83
79-87
72-90
No. 4
49.4
96
100
66
62-70
52-72
No. 10
29.0
55.6
100
43
40-46
35-55
No. 40
10.5
18.8
100
22
19-25
12-30
No. 80
7.4
12
68.2
15
12-18
7-18
No. 200
5.7
8.5
7.4
4-8
2-8
FAE_ZUN
HMA Production
23/2/2011
17
3rd Year Civil Eng.
Cold
Bin
Cold
Bin
Cold
Bin
Bin 1
Bin 2
Bin 3
Minus
No10
3/8 No10
3/4 3/8
PUG
MILL
%
Passing
100
3/41/2
8%
8%
8%
8%
1/23/8
9%
9%
9%
9%
16 %
17 %
92
83
3/8No 4
17 %
17 %
1%
No 4
No10
66
13 %
23 %
23 %
23 %
10 %
43
19 %
Minus
No10
43 %
14 %
43 %
43 %
10 %
25 %
65 %
10 %
43 %
100 %
40 %
17 %
100 %
FAE_ZUN
HMA Production
23/2/2011
Example
Blending Percent is 17%, 40%, 43%

Batch Weight is 2000 kg/hr
OAC is 5.2%
Asphalt Weight = 2000* 0.052 = 104 kg
Aggregate Weight = 2000 104 = 1896 kg
%
Agg Wt
Accumulated Wt
Asphalt Wt
Bin 3
17
323
323
--
Bin 2
40
758
1081
--
Bin 1
43
815
1896
--
Asphalt
--
104
--
104
100
2000
1896
104
FAE_ZUN
HMA Production
23/2/2011
18
3rd Year Civil Eng.
Extracting Test of HMA

% Passing
JML
JMF
Sieve Size
100
92.4
100
80-100
100
92
3/4.
1/2.
)Bin 3 (17
83
65
79-87
62-70
83
66
3/8.
4
)Bin 2 (40
45
35
20
12
40-46
19-25
12-18
4-8
43
22
15
6
10
40
80
200
)Bin 1 (43
: ) (/ :./ ).(JMF
: ) :/ ( ).(JMF
: ))()( (
) (JMF .
FAE_ZUN
23/2/2011
HMA Production
Extracting Test of HMA

() ) (
:
= ) = * (/
) ( -:
Agg Wt
Accumulated Wt Asphalt Wt
--
323
323
17
Bin 3
--
1119
796
42
Bin 2
--
1896
777
41
Bin 1
104
--
104
--
Asphalt
104
1896
2000
100
Total
FAE_ZUN
HMA Production
23/2/2011
19
3rd Year Civil Eng.
QA of HMA
) ( ) ( ) ( ) ( ) ( - ) (
FAE_ZUN
HMA Production
23/2/2011
? Questions -
NCAT
HMA Production
FAE_ZUN
20
23/2/2011
3rd Year Civil Eng.
Placement of
Hot Mix Asphalt
FAE_ZUN
2011
FAE_ZUN
HMA Placement
25/2/2011
Placement of HMA
FAE_ZUN
HMA Placement
25/2/2011
21
3rd Year Civil Eng.
HMA Transfers
FAE_ZUN
25/2/2011
HMA Placement
HMA Transfers
) (Trucks
.
) (
.
.
:
.
FAE_ZUN
HMA Placement
25/2/2011
22
3rd Year Civil Eng.
HMA Placement
FAE_ZUN
HMA Placement
25/2/2011
Finisher
FAE_ZUN
HMA Placement
25/2/2011
23
3rd Year Civil Eng.
Finisher
: ,-.
:
: .
:
FAE_ZUN
25/2/2011
HMA Placement
Finisher
W
V
H
)(Sin
\
:
)(
g

lm .
%

FAE_ZUN
HMA Placement
25/2/2011
24
3rd Year Civil Eng.
Quality Control of HMA Placement

:
)(.
)(.
)(.
FAE_ZUN
HMA Placement
25/2/2011
QC of HMA Placement
Placement Continuity
g

-:

FAE_ZUN
HMA Placement
25/2/2011
25
3rd Year Civil Eng.
Placement Continuity

:
= ) (
) /(
)/(
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . .
FAE_ZUN
25/2/2011
HMA Placement
Example
/
./ .
.
= ) (
= . = ( .) ./
FAE_ZUN
HMA Placement
25/2/2011
26
3rd Year Civil Eng.
Placement Temperature

)(
<
FAE_ZUN
25/2/2011
<
HMA Placement

FAE_ZUN
HMA Placement
25/2/2011
27
3rd Year Civil Eng.

% .
/ :
)/ = ( )/ ( )(/
\ g
.\
m .
/....................................
FAE_ZUN
HMA Placement
25/2/2011

lm m-:
.
.
:
= lm = = . = . = /. lm = . = . FAE_ZUN
HMA Placement
25/2/2011
28
3rd Year Civil Eng.

:
= / = , = = = // - lm = ]). = *[/(-
25/2/2011
HMA Placement

lg \ .
./ )(IRI
> ) (,
> ./ ) (,
- ) (.- .
-./ ) (-.
- ) (-.
-/ ) (-
- ) (.-
.-/ ) (.-
< ) (.
< ./ ) (.
FAE_ZUN
HMA Placement
25/2/2011
29
3rd Year Civil Eng.
Pavement Compaction
GOOD COMPACTION LEADS

TO GOOD PERFORMANCE
FAE_ZUN
HMA Compaction
26/2/2011

.
.(Shear Strength)
.(Waterproofing)
.(Oxidation)
FAE_ZUN
HMA Compaction
26/2/2011
30

3rd Year Civil Eng.

.

.
FAE_ZUN
26/2/2011
HMA Compaction

%
.

.
FAE_ZUN
HMA Compaction
26/2/2011
31
3rd Year Civil Eng.

: .

.

FAE_ZUN
HMA Compaction
26/2/2011

)
( )(
).(Kneading Action

.

.
FAE_ZUN
HMA Compaction
26/2/2011
32
3rd Year Civil Eng.

-

)/( )
FAE_ZUN
HMA Compaction
26/2/2011

)
( .
)
(
.

FAE_ZUN
HMA Compaction
26/2/2011
33
3rd Year Civil Eng.
FAE_ZUN
26/2/2011
HMA Compaction
FAE_ZUN
HMA Compaction
26/2/2011
34
3rd Year Civil Eng.

\ .

FAE_ZUN
HMA Compaction
26/2/2011

l
g
.
l g
.
.
\
\ .
FAE_ZUN
HMA Compaction
26/2/2011
35
3rd Year Civil Eng.

)/(

FAE_ZUN
26/2/2011
-----
HMA Compaction

)
(
.
.

-
-
-/
-
-
-/
-/
-/
-
-/
-/
-
-
-
-
-
-
-
-
-
-
-
-
--
FAE_ZUN
HMA Compaction
26/2/2011
36
3rd Year Civil Eng.

:
:
.
:
.
FAE_ZUN
HMA Compaction
26/2/2011
FAE_ZUN
HMA Compaction
26/2/2011
37
3rd Year Civil Eng.

-:
. =
= ) ( ) /
. = /
. .%
FAE_ZUN
HMA Compaction
26/2/2011

? Questions -
FAE_ZUN
HMA Compaction
26/2/2011
38

Hot Asphalt Mix Production and Quality Control

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Hot Asphalt Mix Production and Quality Control

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Construction of Hot Asphalt Mix

3th Year, Civil Engineering

Dr. Ashraf El_Shahat

3rd Year Civil Eng.

Production of Hot Mix Asphalt

Quality Control of Mix Production

3rd Year Civil Eng.

3rd Year Civil Eng.

Hot Asphalt Mix Plant

Batch versus Continuous Plants

3rd Year Civil Eng.

3rd Year Civil Eng.

Batch Plant (Cold Bins)

Batch Plant (Dryer)

3rd Year Civil Eng.

Batch Plant (Dryer)

3rd Year Civil Eng.

Bin 1 Bin 2 Bin 3 Bin 4

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

Continuous Plant (Temperature)

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

Dryer (Gradation , Temperature)

3rd Year Civil Eng.

Bin 1 Bin 2 Bin 3 Bin 4

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

Blending Percent is 17%, 40%, 43%

3rd Year Civil Eng.

Extracting Test of HMA

Extracting Test of HMA

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

Quality Control of HMA Placement

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

GOOD COMPACTION LEADS

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

3rd Year Civil Eng.

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