Irc Gov in 090 2010

JRC:90-2010
GUIDELINES FOR
SELECTION, OPERATION AND
MAINTENANCE OF BITUMINOUS
HOT MIX PLANT

(FIRST REVISION)
INDIAN
ROADS CONGRESS
2010
Digitized by the Internet Arciiive

in
2014
https://archive.org/details/govlawircy201090
IRC:90-2010
GUIDELINES FOR
SELECTION, OPERATION AND
MAINTENANCE OF BITUMINOUS
HOT MIX PLANT
(FIRST REVISION)
Published by
INDIAN
ROADS CONGRESS
Kama
Sector
New
6,
Koti
Marg,
R.K. Puram,
Delhi-110022
NOVEMBER -2010
(
Price Rs. 300/-
(Packing & postage charges extra)
IRC:90-2010
First
Published
Repriented
2002
April, 2005
March, 2006
July, 2008
November, 2010
April,
Repriented
Repriented
Repnented
First
September, 1985
Revision
May, 2012
Reprinted
(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 Aravali Printers
& Publishers
Pvt. Ltd.,
(500 copies)
New
Delhi-110 020
IRC:90-2010
CONTENTS
Page No.
Personnel of General Specifications & Standards Committee (GSS)
Introduction
1
2.
3.
.;
Background
3|;
Purpose
Classification
3.1
Capacity of Hot Mix Plant
3.2
Methodology Adopted
3.3
3.4
4.
(i)
for Preparation of
Hot Mix
3.2.1
Hot mix plant (continuous type)
3.2.2
Hot mix plant (batch type)
Direction of Flow of Aggregates
and Hot Gases
3.3.1
Counter flow type dryer-mixer
3.3.2
Parallel flow type
drum mixer
Mobility of Hot Mix Plant
Components
Type Hot Mix Plant
Salient Features of Batch

4.1
'4
,
9
9
of Hot Mix Plant (Batch Type)
4.1.1
Cold bin feeder
10
4.1.2
Cold elevator or cold feed conveyor
11
4.1.3
Dryer drum
11
4.1.4
Primary pollution control device
4.1.5
Hoteievator
4.1.6
Screening
4.1.7
Hot bins
4.1.8
Weigh hopper
19
4.1.9
Bitumen
20
4.1.10
Mixing unit (pugmill)
4.1.11
Mineral
4.1.12
Control panel
13
14
unit
14
'
"
17
unit
filler/dust control
system
'
22
24
25
IRC:90-2010
Secondary
4.1.14
Hot mix surge
pollution control device (bag
house
silo
filter)
26
27
4.2
Selection of Site for Hot Mix Plant (Batch Type)
27
4.3
Advantages
28
4.4
4.5
5.
4.1.13
of
Hot Mix Plants (Batch Type)
Limitations of Hot Mix Plants (Batch Type)
RequirementofDG Set
Drum Mix
for
28
28
Hot Mix Plant (Batch Type)
28
Plant
5.1
Bnef
5.2
Components
28
Drum Mix
of Conventional
Plant (Parallel Flow Type)
29
29
5.2.1
Cold bin feeder
5.2.2
Aggregates over size
5.2.3
Cold feed conveyor
5.2.4
Automatic weighing system
5.2.5
Dryer
mixing drum
30
5.2.6
Exhaust control system
32
5.2.7
Bitumen
33
5.2.8
Primary pollution control device (dust
cum
29
rejection screen
30
30
unit
collection system)
34
5.2.9
Hot mix conveyor
34
5.2.10
Gob hopper
5.2.11
Control cabin
5.2.12
Mineral
5.2.13
Hot mix surge
5.2.14
Secondary
filler
34
'
34
34
system
34
silo
34
pollution control device
35
5.3
Advantages
5.4
Limitations of Hot Mix Plant (Drum-Mix Type)
36
5.5
Power Requirement
36
5.6
Double Barrel Drum Mix Plant
of Hot Mix Plant
for
5.6.1
Sequence
5.6.2
Components
5.6.3
Bitumen
(Drum-Mix Type)
Drum-Mix Plant
of
37
....
for preparation of hot
unit
mix
double barrel drum mix plant
37
39
41
IRC:90-2010
5.6.4
Drag conveyor
5.6.5
Gob hopper
5.6.6
Control cabin
5.6.7
Mineral
5.6.8
Secondary
6.
42
system
42
pollution control device (bag
house
42
42
silo
Hot Mix Plant (Double Barrel Drum-Mix Type)
Advantages
5.8
Limitations of Hot Mix Plant (Double Barrel
of
42
Drum-Mix Type)
42
43
Operation of Hot Mix Plants

6.1
Principles for Operation
43
6.2
General
43
6.3
Precaution During Operation of Plant
44
44
6.3.1
Cold aggregate feeder
6.3.2
Cold aggregate bucket elevator
44
6.3.3
Dryer unit
45
6.3.4
Burner
46
6.3.5
Hot elevator
46
6.3.6
Gradation unit
46
6.3.7
Mixerunit
6.3.8
Bitumen
'
r-
47
48
unit
Essential Activities while Starting, Operating and
Shutting
8.
.......
5.7
7.
41
Hot mix surge
5.6.9
41
..
system)
filter
filler
Down
the Plants
7.1
Check
7.2
Sequence
7.3
Upkeep
List
51
before Starting the Plant

of Operation for Starting
51
and Shutting Down the Plant
53
of the Plant During Idling
Maintenance and Upkeep of Hot Mix Plant

8.1
Maintenance Schedule
8.1.1
Daily
Requirement
of Tools
8.3
Requirement
Maintenance
of
and Plant
54
54
.54
maintenance schedule
8.2
51
for
Maintenance
Spare Parts and Lubricants
for
57
Repair and
58
IRC:90-2010
Safety Aspect at Hot Mix Plant Site
9.1
Work
9.2
Plant and Equipment
59
9.3
Loading and Transportation of Plant and Equipment
60
9.4
Maintenance of Plant and Equipment
Site
58
'
60
Major Factors Affecting the Performance of Hot Mix Plant
10.
11
58
:.:
10.1
Presence
10.2
Dust Contents
10.3
Altitude
10.4
Insulation of
of Moisture
in
Content
in
60
Aggregates
60
Mix
61
.
Drum
61
Suggestions
61
61
ANNEXES
Annex-
A-
Information to be Furnished by the Purchaser While
63
Making an Enquiry with the Manufacturer
Annex- B -
Information to be Supplied by the Manufacturer to the Purchaser
Annex- C - Typical Hot Mix Plant Emission and
66
their Control
Annex- D - Typical Charts of Hot Mix Plant Output vs
Different
65
Parameters
68
Annex- E -
Checklist for selection of Hot Mix Plant
70
Annex- F -
Sample Procedure
71
for Calculation of
Rate of Usage Charges of
Hot Mix Plant
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
Sample
Calculation to
Annex-
Annex-
Annex
-J
Work Out Requirement
Calibration of Hot Mix Plant
of Hot Mix Plant
78
79
IRC:90-2010
PERSONNEL OF THE GENERAL SPECIFICATIONS

AND STANDARDS COMMITTEE (GSS)
(As on 24 April, 2010
1.
2.
3.
&
Sinha,A.V.
Director Genera! (RD)
(Convenor)
Road Transport & Highways, New
Delhi
Puri, S.K.
Addl. Director General, Ministry of
Road Transport &
(Co-Convenor)
Highways,
Kandasamy,
Chief Engineer (R) (S&R), Mir)istry of
C.
( Member-Secretary)
New
Delhi
New
and Highways,
Spl. Secretary, Ministry of
Road Transport
Delhi
Members
4.
Ram, R.D.
Engineer-in-Chief-cum-Addi. Gomm.-cum-Spl.
Secy., Rural Construction Deptt., Patna
M.P PW.D., Bhopal
5.
Shukia, Shailendra
Engineer~in-Chief,
6.
Chahal, H.S.
Vice Chancellor, Deenbandhu Choturam University
&
of Science
7.
Chakraborty, Prof. S.S.
Managing
Engg. Services
(I)
Executive Director, Consulting Engg. Services
(I)
Pvt. Ltd.,
8.
Datta,
PK.
Pvt. Ltd.,
9.
Sonepat
Tech.,
Director, Consulting
New
New
Delhi
Delhi
Chief Engineer (R&B) Deptt., Govt, of Gujarat,
Vala, H.D.
Gandhinagar
10.
Dhodapkar, A.N.
Chief Engineer (Pig
New
Highways,
11.
Gupta, D.P
12.
Jain,
Vishwas
),
Road Transport &
Delhi
Director General (RD)
Managing
Ministry of
& AS
(Retd.)
Director, Consulting
MORTH, New
Delhi
Engineers Group
Ltd,
Jaipur
13.
Bordoloi,A.C.
Chief Engineer (NH) Assam, Guwahati
14.
Marathe, D.G.
Chief Engineer, Nashik Public
15.
Choudhury, Pinaki Roy
Managing
New
Director,
Works Region, Mumbai
Lea Associates (SA)
Pvt. Ltd.
Delhi
(RD) &
AS
MOST
16.
Narain,A.D.
Director General
17.
Mahajan, Arun Kumar
Engineer-in-Chief,
18.
Pradhan, B.C.
Chief Engineer, National Highways, Bhubaneshwar
19..
Rajoria,
20.
Ravindranath, V.
B.
(Retd.),
Chief Engineer (R&B)
(i)
H.P PWD, Shimla
Engineer-in-Chief (Retd.), Delhi
Hyderabad
Noida
PWD, New
& Managing
Director,
Delhi
APRDC,
IRC:90-2010
21.
Das, S.N.
New
Highways,
22.
Ramesh
Chandra,
Road Transport &
Chief Engineer (Mech.), Ministry of

Delhi
Chief Engineer (Rohini), Delhi Development Authority,

Delhi
23.
Sharma,
Rama Shankar
Past Secretary General, Indian Roads Congress,
New
Delhi
PWD,
24.
Sharma, N.K.
Chief Engineer (NH), Rajasthan
25.
Singhal, K.B. Lai
Engineer-in-Chief (Retd.), Haryana
Jaipur
PWD, Panchkula
(Haryana)
26.
Tamhankar,
Dr.
Director-Grade Scientist
G.
Navi
(SERC-G)
Mumbai
Chief Engineer (Retd.), U.P
RS.
27.
Tyagi,
28.
Verma, Maj. V.C.
(Retd.),
PWD, Ghaziabad
Executive Director-Marketing, Oriental Structural

Engrs. Pvt.
Ltd.,
New
Delhi
Deputy Director General (WP), DGBR,
29.
Tiwar, Dr. A.R.
30.
Shrivastava, Col.
OP.
Delhi
Kashmir House,
Director (Design), E-in-C Branch,
New
New
Delhi
PWD, Lucknow
31.
Kumar, Krishna
Chief Engineer, U.P.
32
Roy, Dr. B.C.
Executive Director, Consulting Engg. Services

Pvt. Ltd.,
33.
Tandon,
Prof.
Mahesh
New
Managing
New
Director,
Tandon Consultants
New
Sharma, D.D.
1-1603, Chittaranjan Park,
35.
Banchor, Anil
Head - Business Expansion,

Mumbai
36.
Bhasin, Col. A.K.
Senior Joint President, M/s Jaypee
37.
1.
Kumar, Ashok
President,
IRC
Ltd.,
Highways,
New
Ex-Officio
Members
Delhi
ACC
Noida
Chief Engineer, Ministry of
Concrete Limited,
Ganga
Infrast.
4-
Road Transport &
Delhi
(Liansanga) Engineer-in-Chief
..'
Pvt. Ltd.,
Delhi
34.
Corp.
(I)
Delhi.
&
Secretary,
PWD
Mizoram, Aizawl
2.
Director General (RD)

Spl.
3.
Secretary
Secretary General
&
(Sinha, A.V.) Ministry of
New
Road Transport & Highways,
Delhi
(Indoria, R.P.) Indian
Roads Congress, New
Delhi
Corresponding Member
1.
Merani, N.V.
Principal Secretary (Retd.),
(ii)
Maharashtra
PWD, Mumbai
IRC:90-2010
INTRODUCTION
advancement in hot mix plant technology over the last
two decades. This has prompted the revision of the document titled "Guidelines For
Selection, Operation and Maintenance of Bituminous Hot Mix Plants" (IRC:90-1985)
to update the same. With continued emphasis on mechanisation in road construction
There has been
it
is
significant
necessary to familiarize the consultants, contractors, concessionaires, planning
and construction engineers with the technology aspects of hot mix plants and enable
them
mix
to select the appropriate type of hot
plant,
minimum downtime. It is hoped that

purpose. The changes in the design of hot mix
manner
with
been described
in detail.
this
operate the plant
document
will
in
serve
an optimum
its
intended
plants at various spell of time have
Scope
The Guidelines cover the
following aspects
a)
Background
b)
Purpose of Hot Mix Plant
c)
Classification of hot mix plants, their salient,
d)
Information to be furnished by the purchaser, while making an enquiry

with the manufacturer
"
,
^..
advantages and
limitations.
-r-' -^^---^:]-
e)
Information to be supplied by the manufacturer to the purchaser
f)
Sample procedure
g)
Operation of Hot Mix Plant
h)
Maintenance and upkeep of Hot Mix Plant
i)
Major factors affecting the performance of Hot Mix Plant
for calculation or
usages charges of Hot Mix Plant
j)
Effect of moisture content, dust, altitude
k)
Parmeters
I)
Calibration of Hot Mix Plant
for the Selection of
The Secretary General IRC and
on output
Hot Mix Plant
Convenor of the Mechanisation Committee

(G-4), took a decision to revise the document and make
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
the
it
IRC:90-2010
draft
document was then
and tabled
for
circulated to the
Members
of the Mechanisation
Committee
discussion on 25.03.2010.
The Mechanisation Committee (personnel given below) in its meeting held on

25.03.2010 finalized the Guidelines and recommended its submission to the General
Specifications and Standards Committee (GSS) for their consideration.
'
^
Convenor
Co-Convenor
Member-Secretary
Das, S.N.
Verma, Maj. V.C.

Basu, Kaushik
Members
Balasubramanian,
Raza, M.A.
V.
Bharadwaj, R.S.
Sachdev, V.K.
Gyani, PS.
Saxena, R.K.
Rajesh Kumar
Kalita, N.K.
Sharma, K.C.
Sharma, M.P.
Kumar, Niwas Shree
Shankar,
Kumar, Sudhir
Sharma, Rajesh
Jain,
Lall,
Singh,
Patwardhan, S.V.
Hans
Ex-Officio
President,
Ravi
Mahendra
Singh, RN.
Singh, RN.
Rep., lOCL
B.N.
Paramanik, M.K.
Raj,
P.
Member
DG
IRC
(Liansanga)
(RD) & SS,
MORT&H
(A.V. Sinha)
Secretary General, IRC
(R.R 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
191^^ meeting held 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
The
hot mix plant technology
BACKGROUND
came
existence around 1870,
into
requirement for preparation of hot mix that
is
in
which the basic
drying, screening, proportioning
mixing were combined. These plants were crude and remained
in
shape upto
that
the end of 1900. By 1900, the plants were improved by including aggregates
cold elevators, rotary dryers, hot elevators, bitumen tanks
mill
mounted
horse drawn carts pass underneath. The hot mix plants
at sufficient height to allow
up
bins,
and mixing platforms which
measuring box, bitumen bucket, and pug
consisted of an aggregate
and
125 tonne per hour capacity were available by 1930. There was considerable
to
improvement
in
the design of hot mix plant during 1930 to 1940,
better quality of gates, feeders
belts,
when
the conveyor
cold feeder system, large size of dryers,
in
cyclone type dust collectors, spring less scales and pyrometer recording system were
inducted.
In
These
plants
were continuous as
well as batch type.
early 1950, higher capacity of plants with automatic burner control, automatic
proportioning and cycling function
came
into use.
The
hot mix plant continuous type
15/20 tonne per hour capacity were imported and inducted
under International Development Agency
system and improvement

health
in
and safety aspect
noise and dust control system
bins;
in
hot mix plant, considering
These plants were based on continuous

design and more portable. The hot mix plants
in
20/30 tonne per hour capacity were indigenously developed
there
fleet
worked successfully upto
was sharp increase
computerized control
of operating staff.
production process, were simpler
and a good
1963
the most significant
project. During 1970's
development took place by emerging surge and storage
India during
in
in
petroleum
90's.
price.
in
India during mid 70's
During late 1970 and early 1980's,
Thus, further development took place
more fuel efficient, reusing milled bituminous

pavement known as "Reclaimed Bituminous Pavement" (RBP) to preserve the natural
in
the design of hot mix plant making
it
resources of aggregates and keep the environment free from pollutants.
USA and
other parts of the world, asphalt
is
In
Europe,
used as binder. Therefore, the pavement
known as asphalt pavement and reused milled asphalt pavement as

"Reclaimed Asphalt Pavement" (RAP). In India bitumen is used as binder. Therefore,
these terminologies are known as bituminous pavement and Reclaimed Bituminous
to
be
laid is
Pavement" (RBP). Since, heating, drying and mixing took place

these plants
By the end
became popular
with the
of year 2000, further
for efficient utilization of
name "Drum Mix
in
dryer
in
same drum,
the design of hot mix plant
drum and use
of reclaimed bituminous
pavement. This technology was known as double barrel technology.

3
the
Plant".
development took place
heat produced
in
In this
technology.
IRC;90-2010
the concentric
the
same
Effort
chambers
of
same drum
with molten bitumen,
has been made
in
are used to heat the virgin aggregates and mix
and reclaimed bituminous pavement.
filler
these Guidelines to get the highway engineers acquainted
with different type of hot mix plants available
selection of the hot mix plant
the
quantum
in
in
international market.
It
will facilitate
the region for preparation of hot mix depending upon
and use
of work, availability of aggregates, fuel efficiency
of reclaimed
bituminous pavement.
The purpose
of hot mix plant
PURPOSE
is:
a)
To blend
b)
To dry the aggregates (reduce moisture content
different sizes of
and heat them
aggregates
specified proportion.
to
below 0.5 percent)
to the specified temperature.
To heat the bitumen uniformly

d)
in
at specified
temperature.
To feed controlled quantity of bitumen and
filler
in
the specified
proportion.
e)
To mix the aggregates with bitumen and
filler
thoroughly and uniformly
produce homogenous mix
to
To run
in
at the specified
temperature
a safe, environment-friendly and reliable manner to carry out
the above tasks accurately and consistently.
The
in
CLASSIFICATION
based on its capacity, type of flow of aggregates and hot gases

dryer drum, methodology adopted for preparation of hot mix.
plant
is
classified
Capacity of Hot Mix Plant
3.1
As per
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
IS
moisture content
The
shall
in
the aggregates
a)
Output of plant
at 6 percent moisture content in
b)
Output of plant
at 2
percent moisture content
in
aggregates
aggregates.
hot mix plant 40/60 tonne per hour capacity specifies that the output of plant
be 40 tonne per hour
60 tonne per hour
at 2
at
6 percent moisture content present
percent moisture content present
in
in
aggregates and
aggregates.
IRC;90-2010
Methodology Adopted
3.2
Hot mix
is
According
prepared
in
for Preparation of
Hot Mix
hot mix plant either on continuous operation basis or
to preparation of hot mix, hot
a)
Continuous type
b)
Batch type
mix plants are divided
into
in
batch.
two categories.
'
Hot mix plant (continuous type)
3.2.1
in
continuous type of plant, aggregates, fines and bitumen are continuously inducted
pugmill/drum mix
in
desired proportion and hot mix discharged without interruption.
3.2.2
batch type plant, hot bitumen
(if
necessary) at desired temperature

in
batch
is
is
'
added
In
prepared
into
in
with the batch of hot aggregates
desired proportion
transferred either into silo for
its
in
mixing
unit.
storage or directly fed
and
filler
The mix
into tipper
This process of batch transfer continues one after the other. The
for transportation.
batch type hot mix plant
classified
is
based on capacity, type of flow
and hot gases, screening system adopted
for
grading the aggregates
of aggregates
quantity of hot
mix prepared per batch and number of batches prepared per hour.
The batch type
400 tonne per hour capacity are available
hot mix plants upto
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
batch
is
is
specified
prepared within 45
in
number
to
60 seconds.
of
batches produced per hour. Normally, one
Direction of Flow of Aggregates and Hot
3.3
The
direction of flow of
flow
in
the plant.
a)
It
aggregates and hot gases
may be
of
Counter flow
in
Gases
dryer
drum specify the type
two types.
type: In this type of plant, virgin
aggregates enter the end
from where exhaust gases are discharged. The aggregates
gases flow
in
of
and hot
opposite direction inside the dryer drum, which increases
efficiency of heat transfer process, lowers exit
the plant emission and fuel consumption.
gas temperature, reduces
IRC:90-2010
Parallel flow type: In this type of plant, aggregates
b)
in
same
and hot gases flow
direction inside the dryer drum. This type of
drum mixer has
certain limitations, which are given below:

1 )
The thermal
efficiency of plant
transfer inside the
drum
mixer.
is
As
on lower side due
to low heat
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.
Counter flow type dryer-mixer
3.3=1
Three
different types of dryer-mixers
under
Counter Flow Drum Mix Coater
a)
In this
this
category are described below:
(Fig. 1)
type of dryer-mixer, the virgin aggregates flow opposite to the hot gases
dryer and enter the coater.
The reclaimed bituminous pavement may
the coater or mixing section along with the virgin aggregates
which
in
in
in
the
also enter into
super heated condition,
turn heats the reclaimed material.
'
>
The disadvantage
Fig.
Counter Flow Drum Mix Coater
drum mixer is that the hot virgin aggregates, liquid

bitumen and reclaimed bituminous pavement are injected at approximately the same
time
In
in
of this type
of
the coater, thus the mixing time
is
short
in
the coater.
case higher percentage of reclaimed bituminous pavement
time produces less
homogeneous
mixture.
is
used, the short mixing
IRC:90-2010
Counter Flow Drum Mixer with Embedded Burner
b)
In this
type of mixer, the burner
is in
(Fig. 2)
inserted position inside the drum.
<;
The reclaimed
down stream of the burner, where mixes with virgin

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
are not accessible. Thus, this type of drum mixer could not become popular.
bituminous pavement
is
injected
it
CCUNTERFLOW DRUftfi MIXER WITH EMBEDDED BURNER AND AiR COOLED SHiEL
-
Fig.
Drum Mixer with Embedded Burner
Double Barrel Drum Mixer
c)
In this
2 Counter Flow
(Fig. 3)
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
homogenous.
BAP
Fig.
3 Double Barrel
Drum Mixer
is
IRC:90-2010
3.3.2
Three
Parallel flow type

different type of
Parallel
a)
drum mixer
mixers under
..
..^
..
category are shown below,
this
Flow Plain Drum Mixer
(Fig. 4)
EXHAUST
0T
mx
Fig.
It
is
common
road projects
This type of
It
Parallel
Flow Plain Drum Mixer
type of parallel flow drum mixer and
in
India, since
Drum Mixer
b)
its
induction
with Centre Inlet for
drum mixer was developed
has resulted
in
in late
in
RBP
is
being widely used
in
different
eighties.
(Fig. 5)
1970's due to increase
the use of reclaimed bituminous pavement,
it
is
in
crude
similar
in
oil
prices.
design to
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
plain
to
30 percent.
IRC:90-2010
Drum Mixer with Coater
c)
It
is
a parallel flow type drum mixer,
direction
liquid
(Fig. 6)
in
which hot gases and aggregates move
and reclaimed bituminous pavement
bitumen
in
is
added
same
cooler zone and mixed with
in
a mixer or coater located at the discharge end of the drum.
time for mixing reclaimed bituminous pavement with virgin aggregates and
It
in
It
gives
liquid
more
bitumen.
produces good quality of homogenous mix using reclaimed bituminous pavement.
RBP
6 Parallel Flow Type
Fig.
In this
virgin
type of
drum mixer approximately 70 percent
of reclaimed material
is
heated by
Mobility of Hot Mix Plant

hot mix plant whether batch type or continuous type
on two
rigid
Drum Mixer with Coater
aggregates and 30 percent by hot gases.
3.4
The
Virgin aggregates
factors, a) Stationary type
and normally used
in
and
b)
may be
categorized based
Mobile type. Stationary type plants are more
where quantum of work

engaged. In case quantum of work
construction of flexible pavement,
is
more and frequently available to keep the plant

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
convenient
from one place to another. Mobile batch type hot mix plant does not require
to tow
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
it
it
case, the plants have an integrated foundation on which
4
4.1
The
it
can be erected.
SALIENT FEATURES OF BATCH TYPE HOT MIX PLANT

Components
essential
Secondary
components
of hot mix plant (batch type) are given in Fig. 7. in addition,
(Bag House
Filter)
and Hot mix surge
silo
are
IRC:90-2010
optional
components
of batch type hot mix plant.
The
brief details of the
components
are given below:
1-
Cold Bin Feeder 2- Cold Elevator/Cold Feed Conveyor, 3- Dryer Drum, 4- Primary
Exhaust Stack, 6- Hot Elevator, 7- Screening Unit, 8- Hot Bins,
Pollution Control Device, 59-
Weigh Box, 10- Bitumen
Mixing Unit (Pugmill), 12- Mineral
Unit, 11-
Filler
(Dust Collection
System), 13- Control Panel (Not shown)

Fig.
4.1.1
7 Different
Components
Cold bin feeder

a)
it
contains
minimum 4 Nos.
bins with separators
avoid inter mixing of aggregates being loaded

b)
The
bin wails
and
bin gates are
in
between them,
to
different bins.
so designed as to prevent arching and
ensure smooth flow of aggregates.

c)
Bin gates have a graded scale to control the
d)
The capacity
of
all
four bins
amount
of gate-opening.
sufficient to run the plant for
is
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 (DC/AC)
the speed of conveyor

g)
One
belt, to
gathering conveyor
sizes from the conveyors

h)
is
is
provided below each
bin, to control
vary aggregates proportion.
provided to collect aggregates of different
fitted
under each
bin.
Properly designed and calibrated bin gate are provided for smooth flow
of aggregates.
10
IRC:90-2010
Single deck vibratory screen
i)
conveyor
remove over
to
provided at discharge end of gathering
is
size aggregates.
Flow of material
Fig.
in
1st Bin
feeds the aggregates received from gathering conveyor to dryer drum. The conveyor
used
is
known as
slinger conveyor.
Dryer drum
4.1.3
It
8 Position of Bin Vibrator
Cold elevator or coJd feed conveyor
4.1.2
It
plays a
vital role in
the performance of hot mix plant.
normally ranging between
upon the capacity

ratio is
4 to
6.
It
of plant.
.5 to
3.0
The drum
The
inclined position
The
lift
revolving cylindrical
1
and
in
its
to create a draft
the aggregates
and drop
it
in veils
drum
length depending
length to diameter
includes burner and blower fan, which provides primary
with longitudinal trough or channels called flights

flights
is
diameter and 6 to
is in
combustion of fuel and an exhaust fan

fitted
in
It
air for
through the dryer. The drum
mounted
is
with bolts and nuts.
through the burner flame and hot
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
gases.
dwell time (retention time for aggregates
within the drum,
in
dryer drum)
will
which should be maintained.
Normally, dryers are designed to heat and dry the aggregates at 4 to 6 percent moisture
content for
maximum
efficiency.
the feeding of aggregates
If
moisture content present
into dryer
drum
is
in
aggregates increases,
reduced, resulting
in
drop
in
hourly
production capacity of plant.
The temperature
of the aggregates controls the temperature of mix.
bitumen put on each
particle of
The
layer of
aggregates during mixing achieves the aggregates
11
IRC;90-2010
temperature instantaneously. The aggregates heated at high temperature can
harden the bitumen during mixing while underheated aggregates cannot get a proper
coating of bitumen. Therefore, aggregates should be heated uniformly at approphate
achieve homogenous mix. The temperature of aggregates should be

measured with pyrometers/ thermocouple or other suitable device by putting them at
temperature
to
appropriate location.
Burner and
4.1.3.1
The burner used
fuel
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 should be 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)
in
hot mix plant
Strainer
is
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
e)
f)
Pump
It
feeds the
Relief Valve
It
maintains the fuel pressure being fed to nozzle
unit.
Control Valve
It
regulates the return
pressure from nozzle
unit,
fuel supply.
oil
thus adjusting the quantity of fuel
oil
atomized
at the
nozzle.
g)
Blower
h)
Air
Damper
combustion including excess
It
supplies
It
regulates the volume of air being supplied to
burner
air for
proportion with fuel
in
oil
and
The damper closes when

low and opens while is high.
outlet of blower.
of flame
i)
j)
is
is fitted
air.
at the
intensity
it
Pump Motor
These are low voltage, fully enclosed, fan cooled,

squirrel cage induction motors to drive blower and
fuel feed pump.
Control Motor
It
Blower and Fuel
is
used
to control
opening of
air
damper and
fuel
return line valve through automatic temperature

controller or
12
manual
switch.
IRC:90-2010
Ignition
k)
Transformer
It
and Electrodes
spark
Flame Detector
I)
more than 15,000 V emitting electric

electrode gap to ignite fuel mist.
transmits
in
The photo sensor detects the
glare of
flame and
oil
connects/ breaks relay contacts.
m) Automatic Temperature
It
Indicator Controller
Pre-Heater
>
fuel
same
signal
adjusts
reduce
its
transmitted to control motor
is
air
oil
damper
to a
and
fuel
supply.
temperature of 100-1 10C

atomization/
viscosity for efficient
combustion.
switches, timers, pilot lamps, wiring for automatic or
All controls, relays, indicators,
The
measure aggregates temperature.
Heats the furnace
to
manual
to
fitted
The output
n)
indicating
from a thermocouple or other sensing
received
which
digital
which operates based on the signals
controller,
device
based
microprocessor
is
control of dryer burner are located in control panel.
oil
tank should be located close to the burner and bottom of tank should be at
The pipeline between burner and fuel tank should be

of adequate diameter with minimum bends to reduce suction resistance.
elevation as burner.
The viscosity of furnace oil

of suitable capacity
is
more specially during
cold weather. Therefore, preheater
provided to keep uninterrupted supply of fuel into burner.
4.1.4
It
is
is
clean,
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 removed/ added 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
it
having a conical base. Dust laden gas enters
spinning motion and
bottom,
it
spirals
makes
up and
is
it
to travel upto
The
bottom of cylinder. After reaching the
larger size dust particles are thrown out towards
due to spinning motion of gas. These particles slide down and

a hopper. These are removed through auger screw and sent to mixing
the wall of the cylinder

in
which gives
sucked out (vacuum created by exhaust fan) through
coaxial cylinder fitted at the top.
are collected
this shell tangentially,
13
IRC 90-2010
zone,
if
desired. Multiple units of cones having longer length of cyclones,
of inner wall are the
main factors responsible
removing 60
are capable of
to
smoothness
for higher efficiency of cyclone.
These
90 percent of dust from the dryer exhaust. Hot Mix
Plant Emission and their Control are given
in
Annex-C.
Gases out through exhaust
Inlet for tlue
gases
Collected fines
Fig.
9 Primary Dust Collector
Exhaust stack
4.1.4.1
The exhaust gases are eliminated through the

further
pass through the secondary
plant exhaust stack.
pollution control device, that
is
These gases
bag house
filter
for
further filtration.
Hot elevator
4.1.5
The aggregates
after heating
system) to the gradation
and drying are carried by a hot elevator (bucket conveyor
unit.
stone box
is
provided at the edge of hot elevator
discharge chute, which lowers and smoothens the flow speed of aggregates
screen sieves. However,
no need
for
any hot
in
case of tower model where the dryer
is
falling
on
at the top, there
is
elevator.
Screening unit
4.1.6
The secondary
is
gradation of aggregates, in hot condition, is carried out in screening unit. Thus
known as second gradation control unit of hot mix plant batch type. The screening of
The primary gradation
of aggregates
is
done
in
cold bin feeder system.
it
hot aggregates
of
is
essential
graded hot aggregates
adopted
to
in
in
batch type hot mix plants to feed appropriate quantity
each batch. Normally, two designs of plants have been
separate different size of aggregates.

a)
Through multi-deck vibratory screening
b)
Through
rotary screening
14
IRC:90-2010
4. 1.6. 1
The screening
in
multi decl< vibrating
fitted with
screen
multi-deck vibratory screen (Fig. 10)
done through reciprocating motion.
is
multi-deck vibratory screening, the aggregates
after heating are
elevator to vibrating screen for second gradation (Fig. 11
and
In
taken through hot
12).
Vibrating
screens
Cold bins
Hot bins
Pugmill
Dryer
Hot mix
drum
discharge
Fig.
10 Hot Mix Plant (Batch Type)
fitted
Over
with Multi
mm
size
Deck Vibratory Screen
CImIe
Over
si/e 3(i
mm rcjcclion
rejectio?!
Chute
Vibrating
screen
2.5 lo
13 to
30
mm
Ou)2.5min
mm
\
30 nim
2.5 to
5 10
mm
5 to 13
Fig. 11 Different sizes of
Screens
Sequence one over another
The
hot aggregates
in
Fig. 12
^'
to 2.5
mm
5mm
mm
Screening the Aggregates to Achieve
Specified Sizes through Reciprocating Motion
received through hot elevator pass
screens of different sizes, which separates them

hot bins.
15
over a series of vibrating
into specific sizes
and deposits
into
IRC:90-2010
4.1.6.2
In rotary
The heat losses
in
both cases, graded material
is
collected
in
hot bins.
screening and dryer drum are lesser, thus thermal efficiency of hot
mix plant (batch type)

type of plant
In
where screening and
13 Hot Mix Plant (Batch Type) Fitted with Rotary Screen
Fig.
In rotary
screen (Fig. 13)
screening, cold aggregates are taken into screening drum,
heating takes place simultaneously.
this
fitted with rotary
is
screening
fitted
with rotary motion
is
higher. Besides, the
maintenance of
also less.
unit,
cold aggregates received from cold bin feeder are fed into drum,
in
which drying and screening of aggregates takes place in same dnjm via counter flow process
(Fig. 14).
The drum
is
inclined
and nx)unted on two
to the internal surface along the
dmm
length to
tire rings.
move
The shovel
flights
are
fitted
the aggregates and form an efficient
saew flight
on outer surface sieve the

various sized aggregates and deposit heated aggregates into different compartments of
hot bins. The over sized aggregates are removed for disposal. The vacuum drum pressure
drying curtain. Four sections of screens with
device
fitted to control
Fig.
plates
the rotary actuator at exhaust fan regulates the air flow.
Screens
14 Screening of Aggregates through Rotary Motion
16
IRC;90-2010
Hot screens
4.1.6.3
For multi-deck vibratory screening
unit,
the screen provided at the top
screen, which rejects and carries off oversized aggregates.
intermediate sized screens decreasing
For rotary screening

flow
is
size from top to bottom
whereas the
function of the screens
screen
last
to
is
their capacity
called carry over.
is
Carry over more than the prescribed

total mix,
The
limit
first
screen
is
into specific sizes.
The
into a bin
intended to contain next
carry over affects the mix design formula.
can add the fines present
in
aggregates
in
thus increasing the surface area to be covered with bitumen. To prevent
These are used
to store the
temporarily (Fig. 15).
compartment with
each hot
Each
bin should
capacity of
all
for cleanliness.
heated and screened aggregates of various sizes
bin
is
an individual compartment or a segment
division by partitions
be
when
the plant
to hold the
is
aggregates
operating at
full
each size and
of
capacity. Normally, the
hot bins should be of about ten batches production.
bin should
aggregates
be equipped with an overflow pipe

from backing up
into other bins.
prevent the excess amount
to
The overflow pipes should be
set to stop overfilling of the bins. Overflow vents should be
ensure that they are flowing.
the aggregates, resulting
in
screen. Each compartment
If
heavy carryover and the

is
level indicator
checked frequently
a bin overfills, the screen
above
possibility of
warn the operator when bins are

or
rides on
damage
It
is fitted
with a
wired remotely to control the quantity of aggregates
Any shortage
it
to the
equipped with pneumatically actuated two stage
discharge gates controlled by the computer system.
starving also.
at large
which are minimum 4 Nos. The capacity of
enough
sufficient
avoid their intermingling,
to
the
is,
Hotbins
4.1.7
of
That
matching with the capacity of dryer
excessive carryover, screens should be checked daily
Each
last is fine screen.
the scalping or oversized rejection screen.
is
pugmill. Induction of finer aggregates
larger size fraction
unit.
separate the aggregates
screens must be clean, robust and
drum and
and
the screen configuration along the direction of aggregates
reverse to that of multi-deck vibratory screening
the fines screen,
The
unit,
in
followed by two
is
It
a scalping
is
full.
Hot bins should not be allowed
excess
of
17
aggregates
in
in
maximum
bins and
to run
empty/
the hot bins should be
IRC:90-2010
regularized, by adjusting the aggregates
feeder.
Any leakage
at the
supply from respective bin of cold bin
bottom of hot bins should be immediately repaired
to
avoid improper mix gradation.
Fig.
4.1.7.1
It
Hot bin
15 Segregation of Aggregates
each Hot Bin
levelling indicator
detects the quantity of aggregates stored
below a certain
in
level (Fig. 16).
The
in
indicators
hot bins and indicates
may be operated
or mechanically. Presently, electronic indicators
when
it
falls
either electronically
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
a predetermined level,
is
it
case aggregates drop

displayed through indicating lamps/warning sign
indicator.
In
control panel.
Fig.
16 Hot Bin Levelling Indicator
18
to
in
IRC:90-2010
4.1.7.2
Aggregates temperature measurement device
The temperature
bin,
of aggregates
which contains
4.1.7.3
is
measured by providing thermocouple
fines.
Bin sampling device
This device (Fig. 17)
is
provided
in
bins and to check their segregation.
gates under hot bins
into
the plant to take sample of hot aggregates from

It
diverts the flow of
sample containers.
It
is
aggregates from feeders or
essential that sampling device be
located such, as to collect representative samples of material
the flow of material over the screen
each
in
bin
and coarse
in
in
bins.
the plant that fine particles
fall
particles to other side. Therefore, the position of
is
to
seen from
one side
of
sampling device
in bin.
It
assists
calibrating the grading of aggregates.
Fig.
4.1.8
17 Bin Sampling Device
Weigh hopper
The aggregates are withdrawn from hot

and accumulated
weigh hopper
is
aggregates
the
of
It
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
hot
in first
in
in
bins
in
desired quantity through load
weigh hopper. The sequence of
coarse aggregates
last.
first,
This sequence
is
collection of
cell
aggregates
in
intermediate sized aggregates next and fine
designed
to place the fine fractions at the top
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
19
in
weigh
IRC:90-2010
hopper. Aggregates, thus collected
in
weigh hopper are transferred
into pugmill
where
these are blended with desired quantity of bitumen. The sequence of operations
shown
in
Fig. 18.
3.
Discharge gate of next ;iggregate

to
4.
openal and aggregates pour

w eigh hopper
bin
is
When scale reading

preset weight,
in
sizes
Fig.
of these steps takes place for balance

and mineral filler sizes also
used
formula.
to
weigh aggregates,
Earlier,
Load
and
Filler in
reliable,
is
filler
and bitumen separately
easy
this
to calibrate
and low
in
maintenance
weigh hoppers with
insulators. Following precautions are
ball
unit
Bitumen
cell is
designed
respective weigh hopper
30
cell
to
The weight
of
is lighter,
each weigh
by a load
cell.
connection:
cm away
Severe shock or excessive load more than

Normally, load
4.1.9
in this
b)
tied
which
electrical signal
Lead wire
of load cell
cell
with spring
rod-ends, rubber vibration dampers
observed
may be
cost.
a)
when
achieve specified mix
was being measured
measured through transducer, which sends
cell is installed at
to
system has been replaced with load
should not be applied on load
The
of aggregate
Weigh Box
the weight of different constituents
balance system. Now,
hopper
quantitx'
Weighing equipment
4.1.8.1
more
reaches a
discharge gate
18 Sequence of Operations used to Measure Aggregates
and Mineral
is
tlie
is closed.
5 Repetition
It
is
which
.5
from load
cell.
times the rated capacity
may cause damage
to
it.
bear 20 to 30 percent of rated load
is full
of rated load.
unit
mainly consists of bitumen tank, heating system, bitumen
pipe.
20
pump and
delivery
IRC:90-2010
Bitumen weigh bucket
4.1.9.1
Bitumen
is
weighed separately
pugmill.
When
a valve
in
delivery line closes
bitumen
is
then
in
weigh bucket
(Fig. 19) before being inducted into
the weight of bitumen reaches a pre-determined level
pumped
it,
which prevents
into pugmill
Pug
mill
through spray
its
excess entry
in
the bucket,
into bucket.
The
bar.
Spray
pump
Fig.
4.1.9.2
It
is
19 System to Measure and Deliver desired

Quantity of Bitumen in Pugmill
Bitumen tank
an insulated tank, of adequate capacity (minimum one day storage) meeting
the requirement of plant capacity.
Minimum 2 Nos. bitumen tanks each
of
45,000
to
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
used
The
for heating
may be
viscosity of bitumen
through direct heating, thermic
decreases with increase
in
oil
heating or electric heating.
temperature. Therefore, bitumen
depend on its grade. The heating temperature of modified bitumen is kept

approximately 10C above ordinary bitumen temperature. The heating may be done
heating
in
will
any of the following ways:
a)
In this
Direct heating
system
flue
with light diesel
oil/
system
tube along with burner

furnace
oil
is
provided
in
bitumen tank. Burner operated
heats the bitumen around flue tube.
21
iRC:90-2010
^
Thermic
oii
heating system (Fig. 20)
system, hot
in this
received from hot
oi!
oil
heater
is
circulated through the coils
in
bitumen tank, bitumen pump, spray pump, delivery pipe, bitumen weighing tank, spray
bar and pugmiil; 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
at
to
show
the temperature of thermic
appropnate location
piping
for
its visibility.
and weighing hopper
at
and bitumen should be provided

heats the bitumen and keeps bitumen tank,
It
oil
constant temperatu'ê.
Its
operation
Bi lumen
"tank
is
pollution free.
lot Oil
Hitmnen
.racket
J2ii2e_
..J
Weigh
h.^'n
;i
bucket
Ijitiuncn
li
Pug
ii
mill
Spray
Fig.
4.1.10
pump
20 Heating of Bitumen through Thermic
Oil
System
Mixing unit (pugmiil)
chamber in which bitumen and aggregates are mixed thoroughly to achieve

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
It
is
the
hardened cast
oil
alloy steel for longer service
jacketing system to avoid drop
that there are
no dead areas
in
in
life
and low maintenance
cost.
It
has hot
mix temperature. The paddles must be set such
the pugmiil.
The dead area
is
a place where material
can accumulate out of reach of paddles and cannot be mixed thoroughly. Dead areas
can be avoided by assuring that clearance between paddle
than half the
is
maximum aggregates
very important to
tip
and the
liner is less
The quantity of material to be fed in pugmiil

achieve the homogenous mix (Fig. 21). If material level is too high,
size.
22
IRC:90-2010
the upper
most material tends
Conversely, too
little
material
to float
material without actually mixing
Therefore, to achieve the
pug
in
^bove the paddles and does not mix thoroughly.

mill results
in
raking of
tip
paddles through the
it.
maximum
operating efficiency
the paddle tips should be
barely visible at the surface of material during mixing.
Over
filled pugniill
Under
filled
Fig. 21 Effect of
Feed Material
in
Pug
Mill
Mixing cycle
4.1.10.1
It
Piigmill live zone
pugmill
the cycle during which bitumen, aggregates and mineral
is
filler
are blended
in
pugmill of hot mix plant.
Batch mixing time
4.1.10.2
It
is
the time
between opening
of
weigh hopper gate and closing of pugmill discharge
During this period, the aggregates and bitumen are properly mixed and
gate.
homogenous mixture of thoroughly cooked particles achieved. The batch mixing

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
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
aggregates temperature
It
will
also result
in
in
drop
the presence of
in
air,
film to
high
thus causing oxidation of bitumen.
the capacity of plant. Thus, the production cost
will
increase.
Normally, batch mixing time of the plant begins with 30 second mix cycle.
mixing time
in
depend upon type
of aggregates, design of mix,
presence of moisture
aggregates, viscosity of bitumen, shape and size of pugmill; shape, size number of
paddle
of
will
The optimum
tips
bitumen
and
flow,
their
arrangement, peripheral speed of paddle
method adopted
for
adding aggregates and
tips,
their
pugmill v/s batch size, condition of pugmill, operator's efficiency.
23
type and quantity
sequence, size
of
IRC;90-2010
Spray, bar
Weigh
box
-Pug
mil
2. The
The gates of weigh box

are opetied and diseharged
into
3.
pug
pug mill gate

opens and finished
bitumen are mixed.
5.
batch type plant, mixing
If
until
it
material
placed
is
in
is
'0^^
is
two matenals
4.1.11
is
to
in
Pugmill
is
provided at the discharge end of the mixer to store

in
a hauling truck.
be processed
in
the plant, the reclaimed bitumen
a separate cold bin and transferred to the pug
mill
pavement
through a
added in desired proportion to the

has been superheated in dryer drum. The heat transfer and mixing of
done as they move through the pug mill.
Mineral
The mineral
tip
a continuous process. Therefore, a hopper of smaller
charging conveyor. The reclaimed material
aggregates that
discharged.
Paddle
can be delivered
reclaimed material
is
22 Sequence of Operations
capacity for temporary holding

the material
mix
Pugmil! gate closes to receive the next batch.

Fig.
In
is
4. The
The aggregates and
Paddle
arms
bitumen
disehargcd into pug

mill by a spray bar.
filler/dust control
is
system
cement are used for the purpose

and stored in a separate chamber to protect from dampness and to avoid its choking/
hardening from moistures. The system consists of (a) a screw feeder which carries filler
from filler tank 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
filler
such as rock
dust, hydrated lime or

it
24
IRC:90-2010
with a
vane feeder to meter the
of the
filler
bin,
fines into the plant.
is
is
rotor rotate
installed at the outlet
and transfer the
driven by air cylinder installed at lower part of the
opens/closes as per the requirement of filler
In
rotary valve
wherein rotary plates equipped within the
through the flapper gate, which
4.1.12
The
filler
rotor.
It
weigh hopper.
into
Control panel
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
work together through preset
cycling control
interlocking devices. Automatic dryer
control regulates the temperature of aggregates discharged from dryer automatically
within a preset range.

for
The control panel
for
batching console contains switches, circuits
automatic batching including preset controls for weigh batch, interlock controls,
tolerance controls and
The
limit
switches.
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
different electric
In
components. The function of complete plant including operation
motors
is
controlled from control panel.
addition to above, following controls of plant are exercised
displayed
in
Plant load (set as percent of plant capacity)
b)
Composition of
d)
and the information
control panel:
a)
c)
different materials:
1)
Plant load
2)
Moisture content
3)
Aggregates bins
4)
Bitumen
5)
Mineral
filler
Running weight of materials:

1)
Quantity of aggregates
2)
Quantity of bitumen
3)
Quantity of mineral
in
in
tonne per batch
kilogram per batch
filler in
kilogram per batch
Total quantity of materials flow during specific period

1)
of
Aggregates
in
tonne
25
IRC:90-2010
e)
4.1.13
It
2)
Bitumen
3)
Mineral
4)
Total production of
kilogram
in
filler in
kilogram
mix (1+2+3)
in
tonne
Temperature of
1)
Bitumen
2)
Aggregates
3)
Hot mix
Secondary pollution control device (bag house
filter)
consists of a large metal housing containing hundreds of inverted, tabular, synthetic,
heat resistant fabric

cleaner.
filters.
The housing
is
The
house
two chambers.
function of a bag
divided into
filter
(Fig. 23)
is like
vacuum
gas chamber
a)
Dirty
b)
Clean gas chamber.
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 out/sent back to mixing chamber for its reuse, if
desired. It is a highly efficient filter arrangement 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 higher efficiency.
Dust laden flue gas enters the
dirty
Reverse
air jets
Cleaned gas
Reverse
Outiet
air
cleaning
process
Dust
Frame
laden
tor
gas
support
bag
Inlet
Dust hopper
Valve
Fig.
23 Function of Bag House
26
Filter
IRC:90-2010
Hot mix surge
4.1.14
The
silo
hot mix received from hot mix plant can be loaded directly into tipper. Alternatively,
same can be transferred

loading
in
tippers.
is
It
into
surge
24) and stored temporarily
silo (Fig.
till
its
controlled
a cylindrical shell with dual chamber, duly insulated with thermo/
ceramic wool and can maintain hot mix temperature upto 3 hours approximately.
combination of hot
oil
and thermo/ceramic wool
circulation
is
capable
to maintain hot
mix temperature upto 16 hours approximately depending upon ambient temperature,
and
quantity of bituminous mix

silos are
normally available
may be connected
its
temperature, hot
oil
temperature and
to the holding bin of the silo, to monitor the
material being loaded
in
each
tipper,
which
is
amount
controlled/ indicated
Conveyor
flow.
A weighing
the range of 50 to 200 tonne capacity.
in
its
in
Surge
system
of hot mix
control panel.
Hot mix
plant
/<
Surge
silo
IK
Hot mix
receiver
Fig.
4.2
24 Transfer of Hot Mix
into
Surge
Silo
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:
The
a)
site
should be at appropriate distance to ensure proper laying
temperature.
The
b)
for
site
should have sufficient space for stocking the aggregates
minimum
equipments,
residential
shed
sheds
days
for
and
consumption,
their
repair,
other
storage
factors.
per hour capacity plant shall require

c)
Ground should be leveled and
soil
parking
of
Normally,
of
vehicles/
spares/fuel,
135/165
minimum 10,000 m^
staff
tonne
area.
should have good bearing capacity
to construct the foundation.

d)
Site should
be neat and clean
for free entry
'27
and
exit of tippers at plant site.
IRC:90-2010
The environmental
e)
effects that
should be considered
in
is
noise, vibration, dust, water pollution;
depth to prevent any harm to the residents or
farm location.
Proper water drainage should be provided
f)
for
smooth functioning
of
plant.
Advantages of Hot Mix Plant (Batch Type)
4.3
The
in
plant
is fitted
with secondary gradation control unit, thus the aggregates received
The aggregates and bitumen are measured in desired

per batch and mixed in pugmill. Thus, homogenous mix is received in desired
pugmill are well graded.
quantity
proportion.
Limitations of Hot Mix Plant (Batch Type)
4.4
a)
The
cost of the plant
The
c)
Smaller capacity plants, less than 90 tonne per hour are not available
plant
needs more space
Requirement of
Power
is
DG
to
commissioning has also
to
also limited. Thus,
it
is
remote area,
in
to
keep the environment
remote areas, besides minimum

to Electricity
pollution
fixed per
Board and cabling,
be borne by consumer. The working period of plant
is
The diesel generating set

economical and uninterrupted power supply to hot mix
a costly and time consuming
Normally 500 kVA diesel generating set
tonne per hour capacity
is
factor.
required for operation of 135/165
plant.
5
5.1
in
be paid on monthly basis
should be commissioned for

plants.
commissioning.
Set for Hot Mix Plant (Batch Type)
not frequently available
charges are also
kilowatt
for
the market, their operation being uneconomical and not feasible.
Hot mix plants are commissioned

free.
high.
b)
in
4.5
is
DRUM
MIX PLANT
Brief
The drum mix plant was adopted in India during late 1980's, for laying bituminous mix.
In drum mix plant, aggregates gradation is controlled at cold feed end and aggregates
heating, drying and bitumen mixing are done in same drum. It has been adopted
widely due to its a) Portability b) Higher efficiency c) Economy in basic cost d) Lower
fuel consumption e) Reduction in man power and maintenance cost f) Trouble free
28
IRC:90-2010
operation g) Ability to produce large quantity of mix at relatively low temperature and
h)
environmental
friendly.
The drum mix plant may be either Parallel flow type or Counter flow type. In Parallel
flow type drum mix plant, aggregates and hot gases flow in same direction inside the
same drum.
This
is
conventional type of plant and
is
used
in India.
Counter flow type drum mix plant, the aggregates and hot gases flow
direction within the same drum. These may be of two types:
In
1 )
2)
Drying and mixing of aggregates and bitumen takes place
opposite
same drum.
drum and aftenA/ards the dried

aggregates are transferred to another drum where mixing of aggregates
and bitumen takes place. This is known as dual drum plant also. A few
Drying of aggregates takes place
such type of plants are
Components
5.2
in
in
the major
In
addition to these,
it
operation
of Conventional
components
All
in
of
drum mix
in first
in India.
Drum Mix
Plant (Parallel Flow Type)
Flow Type) are shown in Fig. 25.

system. The hot mix surge silo and
plant (Parallel
includes mineral
filler
11
-Cold Bin Feeder (Minimum Bins-4 No.), 2-Aggregate Over size Rejection Screen, 3-Cold Feed Conveyor, 4-Automatic
Weighing System, 5-Dr\ er
cum Mixing Daim,
Primary^ Dust Collector), 9-Hot
Fig.
6-Exhaust Control System, 7-Bitumen Unit, 8-Pollution Control Device
Mix Conveyor, 10-Gob Hopper,! 1 -Control Cabm
25 Major Components of Drum Mix Plant
(Parallel
Flow Type)
secondary pollution control device are the optional components of the

details of the
Cold bin feeder
5.2.1
The
brief details
5.2.2
The
components are given below:
have already been furnished
in
Para 4.1.1.
Aggregates over size rejection screen
brief details
29
in
Para 4.1.1.
plant.
The
brief
IRC:90-2010
Cold feed conveyor
5.2.3
It
is
known as
slinger conveyor also.
The
brief details
in
Para 4.1.2.
Automatic weighing system
5.2.4
Load
provided at the center of slinger conveyor to measure the quantity of

material being fed in the drum.
cell is
5.2.5
It
is
and
Dryer cum mixing drum
a rotary shell
rollers. Its
a)
made
(Fig. 26)
of heat resistance steel 10 to 12
main function
mm thick,
supported on rings
is:
To remove moisture from aggregates by heating
it
at appropriate
temperature.
b)
.
To blend aggregates and bitumen in desired proportion

homogenous mix within 140C to 160C.
to achieve
Aggregate
Burner
Fig.
5.2.5.1
26 Components of Dryer cum Mixing Drum
Design aspects
a)
Dryer
1
cum
mixing drum
is
divided into two zones:
Combustion zone: The heating and drying of aggregates take place
in this
zone.
2) Mixing
place
b)
zone: The mixing of aggregates,
in this
The drum
is
filler
and bitumen takes
zone.
provided with replaceable different shapes of
flights,
which perform following functions:

1)
Kicker
flight
It
30
pushes the aggregates inside the drum
IRC:90-2010
2)
flight
It
eliminates showering of aggregates
directly into
3)
Notched
flight
It
allows the aggregates to
so
4)
Cup
flight
It
flame
that
all
forms a
veil of
does not reach

5)
Aggregates
rotation ring
It
collects the
fall
scattered,
heated uniformly.
particles are
aggregates so that flame
in
mixing zone.
aggregates received
combustion zone and moves
it
in
to mixing
zone.
-
6) J. flight
It
blends the aggregates
bitumen and
filler/fines.
Quantity and arrangement of flights depends on the output of the plant.

c)
Rate of drying the aggregates depend upon the moisture content present
in
The dwell time in dryer cum mixing drum, can control the drying of
aggregates and achieve homogenous mix. It depends on following factors:
it.
d)
drum should be
the range of 4 to
1)
Length
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 cm/metre.
to
diameter
ratio of
in
6.
Burner
1)
The
fuel
furnace
used
oil.
in
the burner
Preheater
is
in
drum mix
plant
is
essential for use of furnace
light diesel oil/

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

45
to
shorter,
more intense and
50 percent through forced draft
50-55% through induced

Fig,
27 Burner used
in
Dryer
31
cum
Mixing
Drum
highly radiatory.
IRC:90-2010
4)
should have auto flame failure detection system to avoid coating

of aggregates with fuel. Photocell is used for detection of flame.
5)
It
6)
There should be no
It
should have auto ignition system to avoid explosion.
down
7)
e)
is in
shut
position.
for
line
Liquid bitumen
is
not sprayed into drum.
such pressure, from where
f)
when burner
Excess air, approximately 25 percent should be supplied

complete combustion of fuel.
Bitumen
1 )
dribbling from nozzle tip
it
It
is
pumped
discharges by gravity
same may
to a point with
into
drum.
2)
should be close to
gas stream.
3)
should be more inside the drum but within mixing zone due to
longer dwell time for better mixing.
It
flights
so that
not be picked up with
It
Bitumen fines receiver
The dust received from dust
collector or
filler
received from mineral
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.
filler
Fig.
5.2,6
28 Bitumen Fines Receiver
Exhaust control system
main function is to induce

remove evaporated moisture
Its
a)
Exhaust
fan:
in
It
cum
drum
complete combustion, to
aggregates and products of combustion. It consists of:
air in
is
dryer
mixing
for
and adequate capacity. In case it

the steam shall not be pulled out of drum
of centrifugal type
is not of adequate capacity,

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 40/60 tonne per hour and 25 horse power with
60/90 tonne per hour capacity plant to achieve optimum efficiency.
32
IRC:90-2010
Exhaust damper it is provided at burner end to control automatic

based upon vacuum pressure measured inside the dryer.
b)
5.2.7
Bitumen
The bitumen
a)
unit
mainly consists
unit
draft,
of:
Bitumen tank
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 40/60 and 60/90 tonne per hour capacity plants
It
is
insulated, of
respectively.
It
consists of a tank
fitted
with burner
in
flue tube.
The
fuel
burner is light diesel oil/furnace oil. Dialindicator 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.
used
b)
in
Bitumen pump
pump
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
It
is
a positive displacement
driven by variable
C)
are
strictly
Hot
oil
It
followed to maintain the quality of mix.
System
consists of hot
^
oil
tank, hot
oil
'
-r-^-..
pump and bitumen
line jacketing.
used to maintain uniform temperature of bitumen and avoids

in bitumen line. The system may be used either as duct heating or
its
It
is
clogging
indirect
heating as described here:

1)
Direct heating:
An
"
insulated tank approximately
25
litre
capacity containing hot
oil
with
independent burner in flue tube is mounted on the chasis of bitumen

and fuel from existing bitumen heating system are used for
heating hot oil. Hot oil in the range of 1 50C-1 80C is circulated through
bitumen pump and bitumen line jacketing with an independent pump.
tank. Air
2)
Indirect heating:
Hot oil tank is installed at the top of bitumen tank, from where hot
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.
oil
33
IRC:90-2010
5.2.8
The
brief details
5.2.9
The
Primary pollution control device (dust collection system)

in
Para 4.1.4.
Hot mix conveyor
hot mix prepared
in
dryer
cum
mixing drum
is
taken to gob hopper through hot
mix/load out conveyor.

5.2.10
Gob hopper
Gob hopper
collects the hot mix material
and transfers
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
The
it
to tipper
Control cabin
brief details
have been furnished
in
Para 4.1.12.
no system to measure the temperature 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 12C less than the exhaust gas temperature.
In
drum mix
5.2.12
The
is
filler
have been furnished
in
Para 4.1.11.
in
Para 4.1.14.
silo
have been furnished
Secondary pollution control device
of two types, a)
Control are given

a)
system
Hot mix surge
brief details
5.2.14
It
Mineral
brief details
5.2.13
The
plant, there is
in
Wet scrubber b) Bag house
filter.
Hot Mix Plant Emission and
their
Annex-C.
Wet scrubber type
unit
"
.
and dust particles are trapped by

water shower/forced water spray, thus separating them from gas stream. It can
In this
type of
unit,
gases pass through the
34
inlet
IRC:90-2010
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
be removed frequently preferably within 2 to 3 days

These are of two types, the details of which are given below:
particles settled should
better efficiency.
Open spray tower
1).
for
its
type (Fig. 29)
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.
The
dirty
Clean
out
air
let
Water
inlet
i|
Dirty gases inlet
Drain for slurry
Fig.
Pollution Control
venturi scrubber type, dust laden
Device
'
Venturi type (Fig. 30)
2)
In
29 Open Spray Tower Type
gases are made
pass through a venturi section

high pressure. The flue gases
to
which is constantly wetted through stream of water at

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.
Dirty gases inlet
Jj
ff^T-J
Clean
out
air
let
Water
nozzles
.Separator
Discnarge for
slurry
Fig.
The
5.3
30 Venturi Type Roliution Control Device
efficiency of venturi type
wet scrubber
Advantages of Hot Mix

a)
The cost
cf the plant
Plarft
is
is
higher than open sptaylower type.
(Drum-Mix Type)
less.
35
IRC:90-2010
The
b)
plant
needs
less
space
for
commissioning and
its
transportation
different capacities ranging
from 40/60 to
also easy.
is
c)
The plants are available

400 tonne per hour.
d)
The operation and maintenance
in
cost of plant
is
less,
as compared to
other types of plants.
Limitations of Hot Mix Plant (Drum-Mix Type)
5.4
a)
The
b)
The
does not have second gradation control unit

material could be used to achieve desired mix quality.
plant
i.e.
only graded
does not have any system to measure aggregates

temperature. Aggregates temperature is assessed by deducting 12C
from exhaust gas temperature.
plant
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
Normally,
drum mix
in
India
and
is fitted
total
with electric motors for operation of different units.
and 60/90 tonne per hour capacity are being used

power for different units is approximately 1 05 and 1 30
plants of 40/60
requirement of
horse power respectively, the details of which are given below:
a)
Horse power required
Details of unit
SI.No.
Auxiliary conveyors (4nos.)
b)
Gathering conveyor
c)
Vibratory screen for oversize
60/90 tp.h
8.00
5.00
3.00
40/60 tp.h
5.00
5.00
20.00
8.00
5.00
3.00
rejection
d)
Slinqer conveyor
e)
Dryer cum
Exhauster
Dust collector conveyor screw
Load out conveyor
Hydraulic power pack
Asphalt pump
Air compressor for mineral filler
Burner air blower
Burner fuel pump
Hot oil circulation pump
others
f)
9)
h)
i)
i)
k)
1)
m)
n)
0)
mixing drum
25.00
25.00
1.50
1.50
7.50
5.00
5.00
5.00
15.00
15.00
2.00
1.00
7.00
130.00
Total
36
20.00
5.00
5.00
10.00
10.00
1.00
1.00
5.50
105.00
IRC:90-2010
All
the motors are not
in
operation at
kVA and 110 kVA are adequate
to run
The generating
load continuously.
full
set 82.5
40/60 and 60/90 tonne per hour capacity drum
mix plant respectively.

5.6
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
In
utilized
more
a)
effectively in following
The
manner:
inner shell of the dryer
drum de-moisturises and heats the
aggregates upto required temperature and discharges

b)
The outer
shell (annular portion) fitted with
it
arms and
virgin
to outer shell.
tips is utilized
aggregates with reclaimed bituminous

pavement, filler material and liquid bitumen. It works as pugmill and
produces homogenous mix with use of reclaimed bituminous pavement
to
mix the hot and dried
virgin
upto 50 percent.
5.6.1
Sequence
a)
for preparation of hot
mix
The aggregates in desired

to dryer drum (counter flow
flap
arrangement
proportion are fed from cold bin feeder
and shaken well with a vibratory

dryer drum, which loosens the dust
type)
at the entry of
particles sticking to the aggregates.

b)
The dryer chamber
consists of three sections
of flights for efficient drying of aggregates
The arrangement
Combustion
Fig. 31
Arrangement of
is
is
Showering
Different
Types
37
with different types
effective heat utilization.
shown in the (Fig.

also shown below:
of flights
different types of flights
and
fitted
31).
The
function of
-
Conditioning
of Flights
in
Double Barrel Plant
lRC.90-2010
These
as the
the lumps
UP tn
eoH to
o break up
are used
or sticky materials
Conditioning flights:
aggregates enter the '^'y^^^^^!!^^!!^^
cONOmONiNG
Fig
FUGHTS
32 Conditioning
Fliglits
^ ^^^^
Showering.ghts.T^^^^^^^
2)
lift
and
the aggregates
ensurethe|r_^___^
^
make sure
Showering fiighb
that the moteriai
through the hot
Fia
gas stêom-
33 Showering
thP combustion zone
Comb.on zone
Fig.
Flights
P;^^Su^sJ
34 Combustion
38
Flights
and prevent
iRC:90-2010
The drum
rotates
incited pos,.on.
in
^^J^J^^^,,
g
and oth
3, per job
biturTînouspavernent
^^^^^^
reclaimed
'^''^'"^
in
formula present
,^'"7^3^^
mtea at the out^
Pddles/arms
the
^^^^^^^
aqainst gravity by
d'ryer
slow -^^t^"^'
drum. Due to
^f,Xre the same is
pushed
r.ix
^
to the
time for P-P^^V-^'^^^^S chamber). It also utilizes the

gets sufficient
of m,
the uppe end
^^^^ consumption,
outlet (towards
final
dryer chamber,
radiant heat of
section, the hot
which
^^.^^ ^^^^
pavement
-"P^^'^^^^^J^'l^^fSd bituminous
-th
chamber
.^^^ ^.e, (dose to the outlet o
of \he dryer
"^'^'"S
externally fed to
pavement absorbs the
(RBP) being
,n this
Sed
aggregates).
The
'-^"'l^.^'^^^'Zes
aggregates a^;
^ me
heat from virgin
present on re la
bitumen
'p^sent in it. Old
aggregates thi y
the virgin
melts and coats
.
mixing temperature.
S^l^^î^;;;^^^^^
d)
bituminous pavement
^^^^^^^^^^
the
which coats both
additives
N^'^î^^^P^^rof Sen. The fines/
bitumen film
into thick
Virgin and old
embedded
-f-^t.rSgetJ
The
liquid
bitumen
is
a^r s^^^^^^^^
are added at
\w nu
and mixing continues
components
1)
moisture conten
of doub/e barre,
drum m/xp^nf
(minimum bins-4nos.)
cold bin feeder
39
IRC:90-2010
2)
Cold feed conveyor
3)
Double
4)
RBP
5)
Primary dust collector
6)
Bitumen
7)
Drag conveyor
8)
Gob hopper
9)
Control cabin
barrel
feeder
10) Mineral
"
filler
unit
Secondary
11)
drum
system
(Bag house
filter
system)
12) Hot mix surge/storage silo

5.6.2.1
The
brief details
5.6.2.2
It
is
Cold bin feeder
in
Para 4.1.1.
Cold feed conveyor
known as
slinger
conveyor
also.
The
brief details
Para 4.1 .2
5.6.2.3
have already been fumished
in
Double barrel drum
double barrel drum consists of tvô 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.
Loader
Primary dust
collector unit
RBP bin
Conveyor
-t
n
K.
Double
Fig.
.
K
barrel drum
.
36 Process Flow Diagram
for
40
s^^^î^
screen "
Exhaust to
atmosphere
Feeder
Cold aggregate
^'"^
IRC:90-2010
The dryer drum

dryer
chamber
with low noise
is fitted
and high efficiency burner
at
one end. The
with flights of three different configurations to ensure proper
is fitted
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
annular portion of the dryer drum

hot virgin aggregates
is fitted
with externally
bitumen and other additives
chamber
out of the dryer
for
to the mixing
chamber. The
with mixing paddles/blades for churning the
added reclaimed bituminous pavement,
homogenous mixing as per job mix
formula.
liquid
The
hot
mix inside the mixing chamber are pushed against gravity by the mixing blades and
finally
come
5.6.2.4
out of the mixing
RBPfeeder
chamber as
final
product.
"
^
.
'
pavement
to double barrel drum. The reclaimed bituminous pavementfeeding arrangement
may comprise of an impact crusher and close loop screening arrangement
It
consists of bin and conveyor, which feeds the reclaimed bituminous
as optional to ensure proper down sizing of milled reclaimed bituminous
pavement.
5.6.2.5
The
The
have been given
Bitumen
unit
in
Para 4.1.4.
unit
mainly consists of bitumen tank, bitumen heating system, bitumen
and delivery
liquid
Primary pollution control device (dust collection system)
brief details
5.6.3
pipe.
Bitumen pump
fitted
with variable
bitumen as per job mix formula through hot
speed motor
oil
is
used
pump
to feed the
jacketed bitumen pipe
line.
In
addition to this, other controls like tachometer, flow meter etc. are provided to ensure
correct feeding of bitumen

5.6.4
The
5.6.5
The
mixing chamber.
Drag conveyor
hot mix prepared
to the
in
is
discharged from mixing chamber through drag
surge bin or hot mix storage
silo.
Gob hopper
brief details
41
in
Para 5.2.10.
slot
conveyor
IRC:90-2010
Control cabin
5.6.6
The
entire operation of plant being run
centralized control room.
y'^
i.r^, ,,.;}..''>
The
on automatic
mode
controlled from a
is
brief details
Para
in
4.1.12.
5.6.7
The
brief details
5.6.8
The
Mineral
filler
system
'
have been furnished
in
Para 4.1.11.
Secondary pollution control device (bag house
brief details
have been furnished
filter
system)
'
Paras 4.1 Jl 3 and 5.2.14.
in
have been furnished in Para
5.6.9
Hot mix surge
5.7
Advantages of Hot Mix Plant (Double Barrel Drum-Mix type)
silo: Tfie brief details
4.1.14.
Double barrel drum mix plant has got following advantages over other type of
a)
The
size of similar capacity of double barrel
the hot mix plant (batch type) and
its
drum mix
transportation
plant
is
plants:
less than
also easy and
is
economical.
b)
The plant being of counter flow type and having

chamber optimizes energy utilization.
c)
The
d)
Infrared sensors fitted at mixing
fuel
consumption
for heating the
aggregates
is
chamber sense and
insulated mixing
on lower
side.
control the desired
hot mix temperature and ensure even production.

e)
The mixing takes place in pugmill, thus more homogenous mix evenly coated
with uniform bitumen film thickness
f)
The use
negligible oxidation
to
produce consistently high quality of hot
Limitation of Hot Mix Plant (Double Barrel

of double barrel
a)
is
achieved.
Higher percentage of reclaimed bituminous pavement upto 50 percent,
can be used
5.8
and
drum mix
Second gradation
grading
is
piix.
Drum-Mjx type)
plant has following limitations:
control unit
is
not provided
in
the plant, thus accurate
not assured.
b)
Only graded materia!
c)
The
cost of double barrel
mix
plant.
is
to
be used.
drum mix
42
plant
is
high
in
the category of drum
1RC:90-2010
OPERATION OF HOT MIX PLANTS
Principles for Operation
6.1
The
following principles govern the operation of
The operation should be
a)
'
c)
carefully planned,
The operation should be
b)
supporting
staff,
hot mix plant:
so that the
final
product
is
of a high quality.
modern
are
run by a competent manager,
all fully
conversant with the
plant,
its
who
with his
operation and
maintenance.
The aim should be
continuity
operation, avoid break-down and
in
intermittent working.
d)
6.2
The adequate stock
must be ensured.
of ingredients
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
and mix material should be taken
of aggregates, bitumen
and
at regular intervals of time

b)
The stock
c)
The operation
piles of
tested.
aggregates should be checked
of cold feeders (setting of cold feeders) should
checked twice daily and more frequently,

and got calibrated, if required.
.
d)
The operation
e)
The
of the dryer should
if
variation
appears
in
be
the mix
be checked
regularly.
hot screens, hot bins and dust collector should be checked daily
for uninterrupted flow of

f)
regularly.
aggregates.
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
h)
drum mix plant and double barrel drum mix plant, the bitumen pump
should be checked for its accuracy and got calibrated, if required.
i)
of mixer unit should
be checked
regularly.
In
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
laid
and
pertaining to quantity of aggregates, bitumen,
their temperature,
be maintained.
43
mix being
!RC:90-2010
Precautions During Operation of Plant
6.3
The
following precautions should be observed during various
performance and optimum
of the plant to achieve better
sequence
of operations
utilization:
6.3.1
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
to allow
fully,
even flow through the feed gate
in
a particular set position.
The approximate tonnage per hour for gate openings

form of calibration chart
c)
for
Arching of fine aggregates
provided
is
in
the
each gate.
is
prevented by placing a vibrator
the bin
in
containing fines.
d)
Moisture on fine aggregates should be avoided, so that clogging

not take place.
e)
To avoid any damage
between gate and

1.5 times the
may be
belt,
conveyor
belt,
by getting the aggregates stuck
feed size of aggregates.
required, grizzly
If
kept over the bins to prevent large pieces of stone coming
may
in
clog the gate.
After completing the
work
for day, bins
should be
material especially during rainy season.

belts
the discharge gate openings of bins be kept
maximum
the bins, which

f)
of
may
and drives while
starting four bin
It
will
left
with
ensure less
minimum
strain
on
feeder next day and their longer
life.
g)
The
material build up should b
checked periodically
from turning and remove the same.

6.3.2
to prevent rollers
Cold ag^gregate 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
c)
Ensure aggregates are not accumulated
d)
In
case of
rains during previous night,
cold elevator
is
removed.
to give long
life.
in pit.
ensure the water logging
in pit
of
IRC:90-2010
e)
Don't start the feeder,
until
the dryer burner has
been
incited.
Dryer unit
a)
Before starting the dryer, ensure the feed box bottom door
is
opened,
dust removed and cleaned.

b)
Before starting the plant, the nozzle and burner should be cleaned with
kerosene
c)
oil.
Don't allow the aggregates to flow through the dryer drum,

vertical hot elevator
d)
bucket
is
when
the
not working.
Before starting the dryer drum, the aggregates should not be inside
since a very high torque
is
required to start the dryer
drum
filled
it;
with
aggregates.
e)
If
furnace
down
its
oil
is
used
in
the burner,
passing
viscosity, before
it
it
should be pre-heated to bring
through burner. The furnace
oil
to
be preheated between 100C-110C.
new installation, ensure that combustion chamber of dryer
f)
Before starting a
drum and bitumen
boiler are completely dry. Refractory lining of combustion
chamber should be
dried with low
g)
Don't permit open
fire
h)
Always stand and hold torch
in
i)
around
wood
fuel
oil
fire
and not by
oil firing.
tanks.
prevent getting burnt
at desired length, to
case burner puffs back.
While
lighting burner,
never allow excessive fuel to be sprayed
into
combustion chamber of drum.

j)
more than five

the dryer drum, as the dryer drum
Don't keep the burner lighted for a long time preferably
minutes, without aggregates inside
may
bulge. Operate the burner on low flame,
when
it
is
not loaded
fully.
k)
I)
Shape
is
Maximum
swirl will
long cigar
shaped flame.
If
regulated by
means
produce a short wide flame and minimum
swirl
pump delivery is irregular or negligible, prime the pump and see

pump does not suck air through joints on suction side.
Observe the exhaust smoke during operation.
means incomplete combustion

In
of air swirling action.
fuel
the
m)
of the flame
case of white smoke,
it
of fuel
If
is
found black,
and feeding of excess
shows the presence
Necessary action may be taken accordingly.
45
it
of moisture
it
fuel.
in fuel.
IRC:90-2010
Ensure no holes are formed
n)
in
excess dusty conditions
at site.
The
dryer
the cyclone
unit,
which
may add
drum should be uniform. It should

be over loaded by passing more quantity of aggregates from four
o)
flow of material
feeder to dryer drum.
in
to
not
bin
should be checked by measuring hot aggregates
It
temperature, to be maintained at about 180C and moisture content

not to
exceed 0.5 percent.
The heat
P)
loss of aggregates from dryer to mixer
to laying site
should be checked at regular intervals of time.
At the end of day, put
q)
and hot mix from mixer
the dryer
off
drum burner by stopping
fuel oil
supply and then the motor.
Burner
6.3.4
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
Before starting the plant, the material at the foot of elevator should be
a)
removed through
flap door.
Don't allow the aggregates to flow from dryer drum,
b)
bucket elevator
is
weekly
to
is
provided with liners and to be checked
determine the extent of wear.
Hot aggregates from dryer drum should be delivered
d)
only
vertical
not working.
Hot elevator discharge chute
c)
when
when
to vertical elevator
the motor of elevator picks up the speed and runs at rated
revolutions per minute.
Care should be taken
e)
to
see that buckets receive the material
directly
with out digging.
6.3.6
Gradation unit
6.3.6.1
Screening
The screen must be
a)
-
b)
unit:
and arranged
in
of
adequate area, having correct size of openings
sequence.
The screen must be
set at proper slope for
46
smooth flow
of aggregates.
IRC:90-2010
c)
The screen should
The clogging
not have holes.
of screen
will
not
allow the aggregates to pass through. Therefore, the screens must be
inspected and cleaned frequently.
Weighing hopper:
6.3.6.2
always stored
a)
Ensure that
b)
The automatic
leveling control device to maintain
aggregates
any
sufficient material
in
predetermined
is
bin stops the plant,
four hopper bins.
in all
minimum
aggregate
if
drops to
level
should be checked periodically.
level;
level of
It
may
also be
The
cold feed
aggregates should be taken from each hot bin
at regular
ensured that over flow from any
bin should not occur.
should be controlled accordingly.

c)
The sample
intervals to
d)
:
6.3.6.3
...
of
check
for
proper grade.
The proper gate openings should be ensured, since the output and
proportioning of aggregates depends upon the same.
Proportioning the aggregates:

a)
Ensure that aggregate feeder gates are set as per

provided on each gate.
b)
Gradation tests
may be carried out on each sample,
calibration chart
collected at regular
intervals.
c)
Check up the scales
d)
The aggregates should be discharged from hot bins

starting with coarse and progressing down to the
for
zero error at no load every day.

into
weigh hoppers,
finest, in
the batch
plant.
e)
The aggregates,
correctly
6.3.7
filler
and bitumen weighing scales should be calibrated
and checked
periodically preferably
once
in
two weeks.
IVIixerunit
a)
The
pugmill does the job of proper mixing,
found clearly above the mix. An under
paddles to work properly.
above the paddles and

b)
is
In
an over
not
The mixing should be done

uniform mix.
If
fully
in
the mixing time
to heat
and
air.
will
the tips of paddle arms are

pugmill
filled
filled
does not allow the
pugmill, the material floats
mixed.
shortest possible time, to produce
is
too short, the particles would
not have a uniform coating of bitumen.
bitumen coating
if
If
the time
is
too long, the
harden because of long exposure of bitumen
An average time
47
for dry
mixing
could be about
1RC;90-2010
15 seconds followed by 30 to 45 seconds of mixing, after bitumen
is
c)
added.
Over size aggregates entering the mixer, tend the mixer arms to bend.
The clearance between the paddle tips and inside lining of mixer box
should not be more than 2 cm.
d)
Check aggregates hopper gates and bitumen feed valve
to
see that
they close tightly and no leakage takes place into mixer after the feed
is
e)
f)
stopped.
Ensure sequence offeeding the
material. Therefore, coarse aggregates
first,
followed with smaller sizes progressively
See
that the paddies
and
tips
in
order of size.
are set to ensure proper mixing action.
g)
See that the lining and tips are not worn. The tips have a tendency
wear faster in macadam work compared to seal coat.
h)
Check
distribution of
covering
i)
all
bitumen uniformly over entire width of mixer
parts.
Check the temperature

tippers.
to
of mix frequently, as
soon as
it
is
dumped
into
Ensure that the temperatures of aggregates and bitumen are
within the specified range.

j)
6.3.8
Check the mix temperature
Bitumen
a)
unit
Ensure before
the bitumen tank,
filling
a small amount of water
times
b)
Fill
frequently for laying and rolling.
its
will
its
does not contain water. Even
cause hot bitumen
normal volume, resulting
up the bitumen tank to
it
in its
to
over flow.
80 percent capacity
only, since the
volume
The over
flow of
ensure
safety,
of bitumen increases while raising the temperature.
bitumen can be
c)
The
fire
boiler should
reduce the
bitumen
strain
line.
The
foam up several
hazardous.
be located nearest
to the plant to
on the bitumen pump and prevent the clogging of

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
under the
firing
flue
towards the hottest firing end. Cold bitumen

then drain down the inclination towards the
inclination
tubes
will
end and can be drained without choking.
48
IRC:90-2010
d)
The top
lids
be kept closed, since the water,

good and clean bitumen. Clean the external
of the bitumen tank should
dust are the deterrents to
sides of barrels, before charging to prevent foreign matter going into
The dust and
the boiler.
tubes, which results
in
poor heat transfer,
and cracks are produced

fire
e)
down around
fine particles settle
tubes
local heating of flue
welding resulting
in
the flue
leakage, which can be
in
hazardous.
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
In
for lighting the burner.
It
is
always safe to
start the
blower
first
before
turning on the fuel.

f)
Bitumen must be maintained
may cause
g)
cracking and
Whenever there
it
may be
a change
is
at specified
temperature. Overheating
difficult to
pump.
type of bitumen to be used, the bitumen
in
tank should be drained and cleaned thoroughly with solvent before

further use.
h)
Certain solvents
diesel
like
to
oil
be used
for cleaning are highly
inflammable and must be thoroughly drained before bitumen

circulated.
i)
If
the traces of such solvents reach the mixer and

fire
Bitumen tank burner may be
when
inside the tank

j)
is
Circulate the hot
out,
the level of bitumen
about fifteen minutes to melt the bitumen sticking
for
bitumen
While inducting hot
oil
line.
into
a cold
line,
open the valve very
slowly, to
allow piping and jackets heat up gradually. Rapid induction of hot

into cold lines will result in
the connecting points

I)
The
hot
falls,
m)
6.3.8.1
oil
level
check
for
uneven expansion of
should be checked regularly
any leakage
in
pump
a)
a rotary gear type of pump
is
on the
kettle side
oil
and may damage
in line.
Bitumen
b)
lines
hot
oil
in
the hot
oil
tank.
in
If
the level
or jacketed bitumen pipe lines.
Ensure that the dust does not enter the meter relay box and
It
ir
higher than the heating tubes.
oil
to the walls of the

k)
cannot be ruled
contact with the heated aggregates, risk of

lighted, only
come
is
dial
head.
which while working, suction develops
and pressure on the delivery side of the pump.
The gear pump should be thoroughly drained at the end of each

operating period. The failure to clean the pump results in solidifying the
49
IRC:90-2010
and may break the gear teeth or
bitumen around the
rotor
when
applied.
rotor
the power
is
is
The
by heating the pump, which
c)
Never run the pump
d)
When
"Weeping" becomes apparent
persist,
It
is
it
means
of relieving the clogged
troublesome.
dry state.
in
the gland nuts carefully, one
e)
only
flat at
at the
bottom
a time.
If
pump
made
a practice to disengage the
operation. Otherwise,
if
the plant
is
gland, tighten
"Weeping"
soon becomes a leak and gland packing
should be
driving shaft,
is
pump
to
allowed to
is
be replaced.
drive at the
end of
started next day, before the bitumen
pump
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
is
sufficiently
heated
for circulation, the
drive,
if still
the V-belt drive gradually. Slipping of the belt over the

pulley indicates that the rotors are clogged
them. Never apply the drive quickly, as
pump
In
it
pump
driving
and need heating to relieve

may cause damage to the
rotors or shaft.
case chain drive
that the
being used, engage the clutch slowly and ensure
is
pump gears
are not clogged, which
is
indicated by excessive
slipping of the clutch.

f)
If
pump
the rate of flow of
slipping of clutch. In
case
falls
is
it
may be
pump rotors
during operation, the cause
not so,
it
would mean that
have worn out and need renewal.

g)
It
has been
practically
found
in
the
field that
clogged bitumen
relieved by heating the case, either by using a blow
soaked waste. These methods destroy the

should not be used.
the
h)
i)
oil
Boiling water
may
to relieve the
clogged
pump
is
pump or igniting
pump gland and
also be poured continuously over the
pump
housing
rotor.
When a new pump or pump with new rotor is fitted, the pump at times
the bitumen. To overcome this, uncouple the pipe from
may fail to
lift
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.
delivery side
j)
Bitumen
to
before the
be used
pump
is
in
the mix should be heated to ensure
started.
The bitumen must be allowed
50
its fluidity,
to circulate
IRC:90-2010
for atleast fifteen
minutes before the mixing commences, so as
keep the meter, spray bar warm and also

throughout the
circuit.
test
cock
to
relieve the solidified deposits
return line, close to the kettle
in
is
provided to ensure that bitumen has completely circulated.
ESSENTIAL ACTIVITIES WHILE STARTING, OPERATING

AND SHUTTING DOWN PLANTS
Check
7.1
The
List Before Starting the Plant
following items covered
in
ticked before starting the plant.

list
the check
list
should be verified by the operator and
The date and time should be mentioned
in
the check
and kept as record:

a)
Have you
b)
Have you topped up

oil
and
carried out daily

all oil
maintenance schedule as per
instructions.
tanks and gear boxes with proper grade of
fuels.
c)
Have you checked
the
d)
Have you checked
the tension of "V" belts,
e)
Have you checked
all
f)
Have you checked
all
oil
level in the air
cleaner and topped

flat
belts
it
up.
and chains.
grease points.
guards and covers
fitted in
the plant complying
the safety norms.

g)
Have you heated
the bitumen pipe line through hot
system
oil
for
uninterrupted supply of bitumen.

h)
Have you cleared
the accumulated stones before starting Ihe bucket
elevator.
Have you checked the conveyor
belts for
j)
Have you checked the conveyor
rollers for free turning.
k)
I)
Have you checked

chamber of dryer.
The
too
in
is
no water
not sprayed into the combustion
in
the bitumen tank before pouring
for Starting
and Shutting Down the Plant
and shutting down the plant should be done
smooth running. The sequence

a)
is
fuel
the tank.
Sequence of Operation
starting
much
Have you checked there

the bitumen
7.2
any damage or wear.
i)
for starting various
Exhaust fan
51
in
chronological order for
components
of plant
is
its
as under:
IRC:90-2010
b)
Dust cleaning system
c)
Filler
d)
Vibrating screen
e)
Hot elevator
f)
Dryer
g)
Inclined belt
h)
Collecting belt
i)
feeding system
j)
Burner
k)
Mixing unit
1)
Cold bin feeder
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:
During shutting
The
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
i)
Exhaust fan
following points should also
filler
system
be considered, while
starting
and 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
52
IRC:90-2010
Now
cuts off the fuel supply.
shut
off
the dryer motor.
When
the
final
batch has been mixed and discharged, both ends of paddle shafts
should be cleaned with
diesel
light
speed
or high
oil
diesel to ensure
that they are free to rotate at the time of starting the plant next day.
c)
The
plant should not be stopped,
plant
d)
may be stopped
Now, put
off
the bitumen
if
in
case the material
dryer, elevator, screens. Dins,
The
is in transit.
mixer are empty.
the bitumen tank burner by stopping the fuel supply. Stop
pump and
reverse
wheel or reversing the motor
its
drive immediately, either by
rotation.
Move
hand
the lever on pressure
regulator (metering system only) to draining position. Fix the discharge

of weigh/ spray
system hopper
in
open
pdSition.
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
may be
left
fitted in
open over
the delivery line just after the pump, which
night to prevent the clogging of the
pump.
cleaning solvents are used, these should be thoroughly drained
If
off,
before re-circulating the bitumen.

e)
The
f)
Defects,
fuel
tank should be
if
any or unusual sound should be reported
engineer and got

g)
filled.
Check and
to the
concerned
rectified.
rectify
any leakage, especially
in
bitumen and hot
in
the chain,
oil
system.
h)
Check
i)
Inspect the blower of exhaust fan for balancing and play of bearings,
all
bolts, nuts for tightness
j)
Weld the cracks
k)
Clean the
belt/
I)
in
the sheets,
if
and tension
found.
dust/aggregates collected underneath the
plant, specially
chain conveyors and lubricate
Keep
all
points.
the motors and exhaust pipes covered to avoid rain or
dew
entering inside.
7.3
if
the plant
Upkeep of the Plant During

is left in
open
for
more than
especially on mobile plants

a)
Isolate
the
and
in
six
Idling
weeks, certain precautions should be observed,
extreme climatic conditions, which are as under:
mains supply
unaijthorized starting.
53
to
electrically
driven
plant
to
prevent
IRC:90-2010
b)
Cover the exposed
c)
Wrap
and
V-belts including pulleys with a strong, self-adhesive paper
all
lubricate
Grease
d)
starter panels.
all
exposed chain
drives,
adjusting screws, dryer swiveling support rollers, motor slide
adjusting screws, jacks to prevent rusting.
rail
e)
Protect the dryer burner nozzle.
f)
Remove
the pneumatic tyred wheels of a mobile plant and keep
hubs
safely. Protect the

roller
shutters are
them
of axles also.
fitted
on the mixer housing, lower and lock them up.
g)
If
h)
Close the windows of the control cabin and keep the doors locked.
i)
Cover the top
j)
Cover the
k)
If
I)
The
the door
plant
of the exhaust fan to prevent ingress of water.
inlet of
the burner air blower.
is fitted in
may be
the dryer feed end box, pin
painted,
if
it
in
the closed position.
required to prevent corrosion.
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 schedules
and given
'site
for
in their
maintenance
of hot mix plants are prescribed
maintenance manuals. Sometimes the working conditions
need frequent checking of specific items due
are added
forms
in
daily,
by the manufacturers
to their
premature
the maintenance schedules as per requirement.
failure.
These items
The maintenance schedule
weekly, fortnightly, monthly, quarterly, half yearly should be got printed, the
items checked as per format, signed by the maintenance staff and kept
history sheet of plant should also
plant to
of particular
in
records.
The
be maintained properly and transferred along with the
assess the requirement of
critical
components
at particular spell of time.
It
may
be ensured during maintenance that recommended type and grade of oil, lubricants are
used
at
in
the plant.
Annexure-G.
The Do's and Don'ts
A brief of normal
maintenance schedule
8.1
Maintenance Schedule
8.1.1
Daily maintenance schedule

a)
Lubricate
all
maintenance of hot mix plant are mentioned
for
parts as given
in
54
is
given below:
daily lubrication chart.
IRC: 90-20 10
b)
Check the gear box
when
plant,
the
oil
oil will
level atleast
one hour
down and
settle
after the shut
down
of
indicate the correct level.
If
necessary top them up.

c)
Top up
d)
Tighten
arms,
e)
The
all
drip feed lubricators.

bolts after completing day's operation, especially mixer
all
tips, liners,
elevator buckets, dryer
lifters, roller
paths
etc.
following points should also be attended to during operation of the
plant:
Bitumen cocks are operated
i)
These should be
material.
for production of
every batch of mix
lubricated at an interval of every two
hours. Other cocks need lubncation daily.

ii)
Check the bearings and ensure
iii)
Turn on
iv)
Turn the key on the
all
Open
does not
occur.
chain drive drip feed lubricators.

in
filter,
periodically during the day, to

v)
that over heating
the burner fuel supply pipe line
remove water and sediments.
the tap of moisture separators of air receiver twice daily.
-J
vi)
Check the gland
vii)
Be
viii)
Tighten the bucket bolts on hot elevator.
ix)
Recheck the angle
of dryer
if
"Weeping"
is
evident.
to loose bolts.
drum under frame
to
ensure that no
sinkage has occurred.
Weekly Maintenance Schedule
1)
pump. Tighten
undue noises, which may be due
alert for
local
of bitumen
(Fifty to sixty hours):
does not happen momentarily.
takes place slowly due
In
hot mix plants the trouble
to
slackness of belts/chains, loose bearings and other factors. The plant has open
gearing,
to
its
open chain
drives/flat belt/ V-belt drives, anti-friction metallic
low revolutions drive.
once a
The grease used
when absorbs the

week and new grease
material,
it
a)
Lubricate
b)
Clean the
c)
If
filters
soak
It
all
applied.
components as
fitted
lightly in
gear lubrication becomes a grinding
dust and fine sand. These should be cleaned at least
filters
are
for
bearings due
instructed
in
weekly
on suction side of the burner
fuel
lubrication chart.
and bitumen pump.
on the blower, remove the element, wash
fresh
oil
and
refit.
55
it
in
paraffin,
2010
d)
Check
V-beits
all
and chain drives and do necessary adjustments
accordingly.
e)
Inspect feeder and conveyor belts for
Check the
are
g)
scrapers on feed unit and
belt
good condition and
in
tear and broken
fasteners.
f)
wear and
Check the conveyor
effective.
belts;
gob hopper. Ensure they
in
necessary, replace them.
If
case of holes or
in
repair
cuts,
them
immediately by lacing or vulcanizing.

h)
Clean the cyclone of dust
i)
Periodic inspection of flue tube
collection.
essential to prevent a
is
fire
accident
resulting out of punctured tube.
Monthly Maintenance Schedule (Two hundred

a)
Clean the burner nozzles as per
b)
Check
all
and replace,
c)
if
Two hundred
fifty
hours):
instructions.
and cables
electrical wiring
to
for loss of insulation or corrosion
required.
Check the screen
cloth,
meshes and
screen
repair/
replace,
if
required.
d)
e)
Check the elevator

Check the
pins, links
and replace,
load cell and replace,
if
if
worn
required.
Quarterly Maintenance Schedule (Eight hundred to

a)
Drain the
oil
of
gear boxes, flush them and
recommended gear
b)
out.
One thousand
refill
to correct level with
oil.
Inspect the dryer chain ring for worn out or broken pins.
affected
segments
of the ring/pins
c)
Check the
d)
Inspect the liner plates
oil
discharge
level in
chute
hours):
and
dryer feed
interior
the
and replace them.
exhaust fan bearings and top up,

in
Remove
of
ring,
if
required.
discharge chute, elevator
paddle
mixer
and
replace,
if
required.
e)
Check the burner combustion chamber

clean
f)
Clean
g)
Do
it
and
repair,
if
refractory for carbonization,
required.
electric contact
and relays
the calibration of load
cell
56
in
control panel.
and weigh bucket.
IRC:90-2010
'
Maintenance of
4)
a)
Isolate the
b)
Cover
all
Electric motors:
mains supply
to
prevent unauthorized starting.
the exposed motor starter panels and controls, with tarpaulin
or plastic sheet to prevent their
Always place the proper size
c)
damage
during rains.
of fuse, while replacing
it.
Never put a
substitute of different size.

d)
Do
e)
Keep the motors and contacts always
earthing of entire electric supply line properly.

clean, by blowing
away
the
dust.
Test check no-volt coils and over load protection devices for their proper
f)
function.
g)
All
the wiring should be placed under insulated cabling and properly
covered trench.
Requirement of Tools and Plant for Maintenance
8.2
The
it
is
and
hot mix plants are located

essential to
allied
in
remote area, where repair
have a small workshop
equipments
for their
plants should be available
in
for the repair
upkeep and
facilities
and maintenance of hot mix plant
effective utilization.
the workshop at
are not available,
The
following tools and
site.
a)
Diesel welding set
b)
Small electrical tools for
c)
Pillar drill
d)
Gas welding
e)
Chain pulley block (three tonne capacity).
f)
Hydraulic jack of adequate capacity for erection of plant.
g)
25
mm
length.
h)
One
machine 25
drilling,
mm
grinding etc.
capacity.
set.
Manila rope length 50 m, 100
mm
Wire rope clamps. Packing timber
set of
hand
tools
wire rope about 70
like
such as spanner, screw
in
railway sleepers.
drivers,
hammers, chain
spanners, screw spanner, chain and pipe wrench.

1)
Grease guns,
j)
General items of store

belt, jitter,
oil
cans, trays.
like bolts, nuts,
washers, pins, fasteners, fan
cotton waste and other fast moving items.
57
IRC;90-2010
Requirement of Spare Parts and Lubricants
8.3
for Repair
and Maintenance
adequate inventory of fast moving spare parts and recommended

lubricants should be available for repair and maintenance of hot mix plant. The
manufacturer's recommendations for fast moving spare parts may 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
10 percent cost of plant is adequate. The bulk purchase of spare
of spare parts
parts and lubricants should not be carried out, which involves space, blockage of
investment, chances of pilferage and fire hazard. In case the procureme.nt 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
It
!S
essential that
into consideration.
SAFETYASPECTS AT HOT MIX PLANT
The
safety of equipments, operating and maintenance staff should be the prime criteria
at hot
mix plant
zone.
In this
9.1
SITE
site. Efforts
should be
made
to
make
the plant site as accident free
connection, following precautions should be
strictly
followed:
Worksite
a)
Create awareness regarding safety
b)
There should be no
c)
Provide proper training to
d)
Always employ a
e)
Every worker should be medically
f)
Provide
g)
Keep
h)
i)
j)
first-aid
slip-shot
skilled
among
and short
staff
on
cuts.
safety.
and trained worker

fit
for the job assigned.
equipments
in
operational condition.
Ensure that workers wear helmets, safety

other items as necessary.
tools
for the job.
boxes with adequate supplies.
fire fighting
Use proper
staff.
and
belts,
goggles, gloves and
tackles.
Ensure proper and clean platform/pathways
for the
work men
to
pass
through.
k)
Provide adequate illumination.
I)
Provide guards and railings wherever necessary.
m)
Blow
n)
There should be an emergency switch located

plant,
siren before start of plant every time.
which
will
stop
all
plant operations
58
"I
in
at a short distance
from the
the event of an emergency.
IRC:90-2010
0)
p)
A First Aid Box
should always be available,
Smoking should be
in
the control room,
prohibited near binder or fuel storage tanks.
Plant and Equipment

a)
Keep the equipment
b)
Never operate unsafe equipment.
c)
Be
d)
Look around before
e)
Never leave the equipment unattended with
f)
Keep operator's
g)
Operate the equipment only from operator's seat/platform.
h)
Never carry out

is
familiar with
all
in
good running
controls,
condition.
gauges, instruments.
and equipment.
starting the plant
platform clean and free from
servicing, adjustment
and
engine running.
its
oil
and grease.
repairs,
when
the equipment
running.
1)
Never permit unauthorized persons
to
j)
The operator must have maximum
unrestricted view of the operating
handle the equipment.
area.
k)
Avoid loose connections
I)
Ensure that engine is switched
system.
in electrical
off and
immobilized against unauthorized
use.
m)
Don't leave the control,
n)
Be
careful
in
when
the equipment
removing the radiator cap,
is
working.
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
r)
Keep away from
s)
Be
t)
Inspect
u)
Shut down procedure:
away from
plant.
hot bitumen.
careful while attending to lighted burner.
cables of plant periodically.
all
1)
Put
2)
Shut
all
the controls
off
in
neutral.
the engine after allowing
it
to idle
and gradually cooled
down.
v)
No open
fire
should be allowed around bitumen or fuel storage tanks.
59
IRC:90-2010
Loading and Tansportation of Plant and Equipment
9.3
a)
Load and unload the plant and equipment on the leveled ground.
b)
Use the
indicated
lifting
points, while
lifting
the plant and equipment
with a crane.
c)
Ensure correct loading and unloading procedure
for different type of
equipments.
d)
Use ramp
e)
Block transport vehicle, so that
f)
Tie
of
adequate strength.
it
cannot move.
and block the equipment securely
for transport.
Maintenance of Plant and Equipment
9.4
a)
Avoid
b)
Carry out repair and servicing
fire
hazards. Close fuel shut
off valve.
in
accordance with manufacturers'
recommendations.
c)
Before working on hydraulic system,

is
d)
make
sure that hydraulic pressure
released.
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.
Wear gloves,
f)
while handling bitumen, parts of sharp edges and during
welding.
MAJOR FACTORS AFFECTING THE PERFORMANCE
10
OF HOT MIX PLANT

The performance
of hot mix plant
depends on
its
design criteha, operational
efficiency,
maintenance and availability^ of allied machines. The following are the major factors
which affect the performance of drum mix plant:
10.1
Presence of Moisture Content
The presence
of moisture content
in
in
Aggregates
aggregates plays a
vital
role in preparation,
production of hot mix and fuel consumption of hot mix plant.

If
moisture content
of flights
in
is
a uniform
very high say 8-10 percent, the aggregates shall not

veil,
fall
out
thus there shall not be uniform and adequate heating of
60
IRC:90-2010
aggregates. Thus, the increase
increase
The
10.2
in fuel
consumption
indicative relation
in
moisture content results
in
in
drop of production and
also.
between moisture content and output
Dust Content
With increase
in
is
given
in
Annex-D.
Mix
dust content
mix, output falls
in
because there
is
more surface area
be coated by bitumen which requires greater mixing time. The indicative

between dust content and output is given in Annex-D.
to
10.3
relation
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
The output
Drum
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 60C. The drum shell should be insulated with glass wool or
aluminium painted to avoid heat losses.
of plant
11
11.1
SUGGESTIONS
Following suggestions are
free operation, efficient running
and
made
for selection of hot
mix
plant,
.its
trouble
to achieve qualitative mix:
make and proven
a)
The
b)
The capacity
of plant should
space
commissioning, quantum of work and time period for
its
Guidelines, instructions, maintenance schedules prescribed
in
hot mix plant should be of reputed
for
its
be selected based on
design.
availability of
completion.
c)
The
manufacturers' manual should be

d)
strictly
followed.
History sheets/log 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
e)
in
stock.
Fast moving spare parts should be kept

idling of
the plant.
61
in
stpre at plant site to avoid
IRC:90-2010
f)
Pyrometers/thermocouples are very sensitive instruments. These

should be shielded from the heat of dryer drum, vibrations of the plant
and got calibrated

g)
The
frequently; atleast
vibrating screen cover should
once during the
be opened
vy/orking period.
regularly,
checked
for
sieves wear and tensioning conditions and adjusted accordingly.

h)
Control panel of hot mix plant should be got calibrated regularly to
ensure accuracy of hot mix and output of

i)
j)
k)
down
In
case
in
operational manual should be followed.
of break
plant.
of plant, instructions given for trouble shooting
Genuine spares to be procured from plant manufacturer,

down and keep their interchangeability.
Skilled operators, technicians duly trained
to avoid break
by plant manufacturer or
otherwise, should be deployed for smooth operation
maintenance of
plant.
I)
Control Panel should have provision to store real time process data for
reference and review.
m)
High speed drives should be properly guarded, electrical wiring should
have proper
insulation
safety codes should be
and should be properly earthed and

fully
complied
in
all
relevant
design, erection and operation
of the hot mix plant.
given at Annex-A.
11.2
Information to be furnished by the purchaser
11.3
Information to be supplied by the manufacturer to the purchaser
is
is
given at
Annex-B.
11.4
The Parameters
11.5
The Sample
Plant
is
The Sample
Annex-H.
11.7.
mentioned
11 .8
Hot Mix Plant are given at Annex-E.
Calculation to ascertain the rate of
usage charges
of Hot Mix
given at Annex-F.
11 .6
at
for the selection of
Calculation forthe output analysis of Hot Mix Plant
Annex-I.
Some
mentioned
Calculation to work out requirement of Hot Mix Plant
The Sample
at
is
inputs regading calibration of Hot Mix Plants are given at
62
Annex-J.
is
IRC:90-2010
ANNEX-A
(Clause 11.2)
INFORMATION TO BE FURNISHED BY THE PURCHASER WHILE MAKING AN

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

1)
2)
Site Conditions:
a)
Space
b)
Altitude
c)
Temperature and climate
d)
Any
above mean sea
level
other special conditions under which hot mix plant
Type of Hot Mix
is
to
be used
Plant:
Drum mix coater/Drum mix
with
mixer with centre
RBP/Hot mix
drum mix
3)
available for commissioning the plant.
inlet for
embedded
burner/Plain
drum mixer/Drum
plant (Batch type)/Double barrel
plant
Type of flow:
Counter flow/Parallel flow
4)
Methodology adopted
for preparation of hot mix:
Continuous type/Batch type

5)
Mobility of Hot Mix Plant:

Stationary type/Mobile type
6)
Essential and optional units of Hot Mix Plant:
The components shown below may be selected based on the type

requirement of
plant.
a)
Cold bin feeder (Minimum- 4 No.)
b)
Aggregates over size
c)
Cold elevator/cold feed conveyor
rejection screen
63
of
IRC:90-2010
d)
Aytomatic weighing system
e)
Dryer drum
k)
Dryer
g)
h)
Hot elevator
i)
Screening
j)
Hot bins
k)
Weigh box
I)
Bitumen
m)
Mixing unit (Pugmill)
n)
Mineral
o)
Control panel
p)
Secondary
cum
filter in
mixing drum
unit
unit
filler/
dust collection system
component as Bag house

as wet scrubber type in drum mix
pollution control device (Essential
batch type plant and optional
plant)
q)
Hot mix surge
silo
(Optional component)
64
IRC:90-2010
ANNEX-B
,.
(Clause 11.3)
INFORMATION TO BE SUPPLIED BY THE MANUFACTURER

TO THE PURCHASER
The manufacturer should
ANNEX-A.
In
purchaser to
furnish the information to the purchaser as
shown
in
be supplied to the
get him acquainted with the product and assist him in selection of
addition to that, following information should also
plant.
1)
Model and type of Hot mix plant offered
2)
Brief description of the plant along with
3)
Specific features of the plant,
4)
Type ahd No.
5)
Capacity of electric motors
6)
Capacity of
7)
Overall dimensions and weight of different units of the plant for transportation
of flights
DG
in
if
its
units
and
their capacity
any
Dryer/Dryer
fitted
cum
mixing drum
with different units of plant
set required for operation of plant
purpose
8)
After sales-service, nearest to the commissioning site
9)
Supply of spare parts catalogue, operation and maintenance manual

assured
moving components assured
10)
List of fast
11)
Details of similar
12)
Provision of training
model
of plants supplied
facilities
65
so
far,
year wise
IRC:90-2010
ANNEX-C
(Clause 4.1.4 & 5.2.14)
TYPICAL HOT MIX PLANT EMISSIONS AND THEIR CONTROL
The
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
pollution
guiding factor.
Emission Factors for Particulate Matter
(PM^^),
CO, No^ SO2 and VOCs

,
Emission Factor (kg/tonne)*
Process
Batch mix asphalt plants
CO
NO
SO,
VOCs
0.17
0.013
0.0025
0.0072
0.035
0.084
0.12
0.02
0.028
0.015
0.0017
0.022
0.0018
0.038
0.028
0.03
:-
Natural gas-fired dryer

Oil-fired
dryer
Drum asphalt
plants"
:-
Natural gas-fired dryer

Oil-fired
dryer
Batch Mix Asphalt Plants
Drum Mix Asphalt
Plants'^
Process
PM10
(Kg/tonne)
PM10
(Kg/tonne)
Natural gas-fired dryer:

Uncontrolled
Fabric
filter
2.2
2.2
0.0098
0.0041
2.2
2.2
0.03
0.015
Oil-fired dryer:
Uncontrolled
Fabric
filter
Source:
USEPA document AP-42
tonne of asphalt produced, includes
(1995),^ Factor units are

botti parallel
66
kg of PM^^ emitted per
and counter flow asphalt plants.
IRC:90-2010
Typical Hot Mix Asphalt Plant Emission Control Technologies
Emission
Control Technique
Pollutant
Typical Efficiency (%)
Source
50-75
\J\J
1
PMô
Miiltinip
rurlnnpQ
Spftlinn
rharnhpr
<J
< 50
Ranhf)ii<5P
QQ _ qq 7
Vpntiiri "^rriihhpr
qn - qq s
Process
Drvpr anfi rnmhii<?tinn
nrnrp*;*; mndifiratifin*;
86
VOCs
1
50
imp;tnnp
SO,
....
Low
80
sulfur fuel
60-99
Paving maintenance
Wetting
Fugitive dust
&
70-80
crusting agents
Crushed reclaimed Asphalt Pavement Material
Adapted from
Gunke., Kathryn. O'C. 1992.
Buonicore, Anthony
J.,
and Wayner
Manual. Van Nostrand Reinhold,
New
T.
Hot-Mix Asphalt Mixing
Davis, Editors.
York, NY,
67
70
USA.
Air Pollution
Facilities.
Engineering
IRC:90-2010
ANNEX-D
(Clause 10.1, 10.2, 10.3)
TYPICAL CHARTS OF HOT MIX PLANT OUTPUT VS

DIFFERENT PARAMETERS
DEPENDENCY OF OUTPUT WITH SALIENT PARAMETERS

Moisture-vs-Output
120.00%
"Parallel-flow"
3?
"Counter-flow"
100.00%
20.00%
a
3
0.00%
'V-
'b-
<o^
iH-
ô\o
oV>
^"A^
^Q^^
\-
<b-
o\o
o\o
^<i^^
<i^^
<b-
o\o
o\o
o\o
(fi^
C?>^
kHz
Moisture (%)
Moisture
in
Output (TPH)
aggregates (%)
2.00%
100.00%
100.00%
3.00%
85.76%
86.67%
4.00%
71.53%
73.33%
5.00%
60.68%
62.33%
6.00%
51.86%
54.00%
7.00%
46.44%
47.67%
8.00%
41.69%
43.00%
40%
100
9.00%
37.63%
38.33%
50%
94
10.00%
33.90%
35.00%
60%
88
11.00%
30.85%
32.33%
12.00%
28.14%
29.67%
70%
82
Dust
Output
content
68
"
IRC:90-2010
Output v/s Dust Content
100
S4
82
If
50
Output
in
Mix
B Output %
40
'
Dust content
M
Dust Content
EFFECT OF ALTITUDE ON PRODUCTION OF MIX

5
Effect of altitude
on the production of mix
in
a Hot Mix Plant on a 7' diameter drum with
300 F (148.9C) mix, 310 F (154.44C) stack temperature and 5 percent moisture
removed.
Factor
Production Rate
TPH
0
1.00
267
500
0.98
262
>
LU
1.000
0.96
257
SEA
1,500
0.94
252
>VE
2,000
0.92
247
<
2,500
0.91
243
EET
3,000
0.89
238
z.
4.000
0.86
230
UDE
5,000
0.83
222
ITIT
6,000
0.80
214
7,000
0.77
205
8,000
0.74
197
9.000
0.71
191
10,000
0.69
184
_l
LU
_l
CO
Ll_
<;
69
IRC:90-2010
ANNEX-E
(Clause 11.6)
CHECKLIST FOR SELECTION OF HOT MIX PLANT

SELECTION PARAMETERS FOR HOT MIX PLANT
Selection item
1)
2)
Capacity
Type
Options available
Selection Criteria
3TPH-650TPH
i)
Volume
ii)
Completion time
iii)
Availability of site
iv)
Quantity required to b produced per day
i)
Purchase cost
ii)
Maintenance cost
iii)
Position of availability
iv)
Gradation
v)
UseofRBP
vi)
Emission norms
vii)
Noise
a)
Batch type/Continuous
type
b)
"
of
Static/Portable/Mobile
restriction
viii)
Vahation of Mixes
i)
Size of the Plant
ii)
Volume
and
"
after sales service
C;
of mix to be
uonvenuonai layouu
uj
r didlicl rlUW/L'Uuf llcJl
a)
Plain tank/Specialized
oiie area avaiiauie
ii)
Ease of erection
I)
rUiuildbc OUol vib-d-Vlb iUcI odViily
ii)
iii)
UseofRBP
i)
Requirement of using
Multicyclone/Bag
House
Filter
straight run or modified
and
after sales service
Ease
of maintenance
ii)
Locai
fire
i)
Need
to
ii)
Local emission control norms
/Wet Scrubber
after sales service
i)
Heater
4) Pollution Control
and
bitumen
ii)
Direct Heating/Hot Oil
requiremeni
\)
tank for modified bitumen
b)
locai
Cost of erection vis-a-vis transportation
Flow/Double Barrel
Bitumen Tanl<
meet
produced and the period
iii)
Tower type layout
System
area
'
inereoT lo
3)
work
70
safety/emission control norms
use recuperated fines
IRC:90-2010
(Clause 11,7)
SAMPLE PROCEDURE FOR CALCULATION OF RATE OF USAGE

CHARGES OF HOT MIX PLANT
'
Assumptions
'
"
'^'^
'''''v^:--^-^.^'''^-?
a)
Salvage value = 15 percent of the cost of equipment
b)
Storage charges =
percent of
total
investment to be depreciated, spread
over the economic

c)
at site
life
..
Repair and maintenance charges per hour including replacement of

tyres ~ 150 percent of total investment to be depreciated spread over the
economic
d)
life
Over head charges
@ 5 percent of the sum of wages per hour + Servicing
charges (Manpower and material cost)

1.
For Equipments Used Departmentally
1.1
Ownership charges
A)
work (This includes A/T
Total investment at site of
cost, sales tax,
excise/custom and other duties, transport expenses consisting of

freight
by ocean or
insurance, loading/ unloading charges,
rail,
= Rs.
erection and commissioning on receipt)
@ 15 percent of
B)
Deduct salvage value
C)
Total investment to
D)
Economic
E)
Depreciation per hour
life
of
total
in
(say)
investment = 0.15X
= 0.85X
be depreciated
machine
hours
hours
= Rs. 0.85 XA'

per hour
F)
Storage charges per hour

the
economic
Total
1.2
(1
percent of "C" spread over = 0.01 x Rs.0.85
life)
X/Y
= (E) +
ownership charges
(F)
Operation charges
G)
Repair and maintenance charges per hour (including maintenance and
replacement of tyres)
life
= 1.5x(C)/(D)
is
150 percent of "0" spread over the economic

II
71
IRC:90-2010
Overhead charges
1.3
5 percent of ownership and operation charges
0.05x
Rs
Operation charges per hour
Rs.
Overhead charges per hour
Rs.
Ownership charges per hour
>
.
(l+ll)
III
Running charges
1.4
Operating staff/labour wages
Designation
i)
Operator
ii)
Helper
iii)
Cleaner
iv)
Misc.
Total
No.
Unit
wage per month
Wages
per month
.:
Expenses
wages
required for Operating staff and labour per
Sum
month =
of
wages per
month
H)
Total
wages
required for Operating staff and labour per hour = Total
wages
required for Operating staff and labour per month/Hours per month
I)
Servicing charges
Servicing charges includes
Designation
i)
Mechanic
ii)
Cleaner
Total
wages
Total
wages
No.
Unit
cost
wage per month
Wages
per month
required for servicing staff per month = Rs.

required for servicing staff per hour = Total
servicing staff per

J)
man power
wages
required for
month/Hours per month
Servicing charges (Material cost)
Fuel/!ubricant
i)
Fuel
ii)
Lubricants
Rate per
litre
Consumption
per month
72
(!n litre/kg)
Expenditure
per month
IRC:90-2010
iii)
Grease
iv)
Hydraulic
v)
Gear
vi)
Cotton waste
vii)
Furnace
"
/
oil
oil
oil (In
case of hot mix
Total expenditure per
Total servicing
plant)
month = Rs
charges (material cost) = Total expenditure per month/Total hours
per month
K)
Cost of lubricating
L)
Total running
oil,
fuel
consumed per hour
charges per hour = H+l+J+K
Over head charges
@ 5 percent of
total
IV
= 0.05x(L)
Hire charges = l+ll+lll+IV+V

2.
For Equipments Given to Contractor and Outside Agencies
When
the equipments are issued to contractors,
10 percent of the average investment per year
and insurance charges
interest
will
be calculated as under and
added.
M)
100
1500
on 5 years
100
Rs.
Interest
and insurance charges per hour
Therefore the
total
charges
in
that
case would be as
Ownership charges (E+F+M)
follows:
Operational charges
II
Running charges
IV
l+ll+IV+V
Overhead charges
charges per hour
Hence
hire
@ 5 percent of total
(l+ll+IV)
charges per hour
73
>
IRC:90-2010
ANNEX-G
(Clause 8)
DO'S AND DON'TS FOR MAINTENANCE OF HOT MIX PLANTS

Do's:
^.
Maintain proper gap between Skirt rubber and Auxiliary belt
Ensure
Gate opening of
Greasing of bearing and
Rubber guard should be
Slinger belt should be center run and greasing of bearing
belt center run position
..r-.-.
...
bins should be as per requirement
all
oil
checking
gear boxes
in all
,;.
'
properly and greasing of bearing.
fitted
and
checking
oil
in
gear
box.
Load
cell
frame should be free during operation and locked when plant
is
not
working
Check the
Proper setting of thrust wheel of drum
Greasing of
Ensure the trunion wheel adjustments.
Tighten the nuts and adjustments bolts.
Ensure proper adjustments/tighten of drum drive gear Motor chain.
Ensure proper
Pre-heat the
Start burner with zero
Before starting burner, clean both the ignition electrode
Observe the smoke
level in
oil
all
all
gear boxes.
bearings.
"
>
"
'
'
^-^
;
'
lubrication of
Drum
drum
'
'
''y/.,''\./:v--\\:'^/''\''\-'
'
;
drive chain.
before feeding of aggregates
damper
position
of burner during operation to
ensure that the burner operates
properly.
..
Ensure leakage free operation of pump and solenoid and pressure
Ensure photocell working
for
auto
mode
of burner
exhauster with close position of exhauster
Start the
Belt tightening of
Watch out
Monitor the differential pressure during operation.
Monitor the
for
exhauster
'
belt.
any black smoke
smoke temperature
at
chimney
outlet
while running.
74
relief
valve
IRC:90-2010
Ensure continuous operating
Grease the
Check
Clean the
Check the Compressor pressure
Ensure clean
Carry out maintenance at regular intervals
Water earth
Follow safety rules.
Maintain Generator, monitor Voltage and Frequency
Keep the
Keep panel power
Keep
Remove
Check the
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

beyond the 120
Check alignment/tighten
Close the main valve
of the
cascading
ring.
vibrating screen daily before the start
up of the plant
'
the cylinders before start up of the plant
ail
air filter
and
oil fiter daily.
air inlet to
the
air
daily
'
i^^^^^'
--^
compressor.
^.
-
^
^
all
'^^^'^'^^^^^
pits regularly
control
-^^
room clean and remove

off
all
.-.^....y::-
unwanted materials
while carrying out any welding work
in
the plant
panels under shelter, water should not enter the panels.

all
material from the plant before shut
calibration at regular intervals. Also
it
down
is
bitumen temperature reaches
after the
at regular intervals
at the fuel tank before servicing fuel pipeline;
place suitable container or vat under pipe joint before loosening
Disconnect the load
work
is
...
.
carried out
cell,
in
inverters
and other
electrical
it.
when
the welding
the plant.
Stop the operation of the plant when you see the

thunder and also shut off the electrical lightning.
Adjust
Do
all
devices
prepare and
the vibrator weights to the
lighting
same phase and
the checking of the Level of the Hot
oil in
hot
oil
the
near by or hear clap of
same mass.
tank
Don'ts:
Do
not operate Bin Vibrator
Do
not allow the level of bitumen
Don't close bin gate
Don't operate Vibrating Screen
when
when
Plant
bin
in
is
empty
the Bitumen tank to
is in
operation:
in idle
mode.
75
fall
below safety
level
^
IRC:90-2010
Drum
Don't feed the higher size of Aggregates
Don't stop the
Don't disturb the burner working pressure during operation
Do
not operate the Burner without operating exhauster
Do
not
Do
not operate Exhauster with Full
Don't touch the hot
Do
not operate the plant without proper knowledge. This could be dangerous.
Do
not start
fully
drum
till
it
in
reaches the ambient temperature.

'
and Drum
open the Damper gate while running.
pipe line by hand directly
oil
Drum motor
drum before power
is
open Exhaust Damper
directly
switched
on load
try to
remove load or give momentum
to
ON
Do
Never use wires instead
Do
not
Do
not run the plant at
Do
not run without proper earthing
Do
not run the panel without proper supply
Do
not touch the panel without wearing shoes
Do not close the breaker on

damage your eyes
Do
not try to carry out the maintenance with
Do
not bypass safety of any equipment with
Do
not use under size cables or motors .This can result
Never touch the metal parts of terminal with your finger
Do
not start or stop the bigger motor frequently on load
not
of fuse links.
Spare fuse
provided
links are
in
the panel
power the panel without proper earthing
smoke
in
more than
power condition
load without cover or arc chutes ;the flash
the vicinity of the
tank and fuel pipe
rated capacity
HMP
line
and
ON
power ON
power
fire
in
hazards.
certainly not within 5
<:v'-..
76
may
..
meters of
fuel
IRC:90-2010
ANNEX-H
(Clause 11.6)
SAMPLE CALCULATION FOR OUTPUT ANALYSIS

OF A HOT MIX PLANT
Time period
by 60-90
SI.
1)
No.
for
completion of
TPH Drum Mix
Type
75
of
Km
Pavement
mm BM
Quantum
work involved
2 lane (7.00 m)
in
cum
to
NH Road
in
mx1x1000
Tonnes/Km.
= 525x2.2
=11 55 Tonnes
cum
7 mxO.025
tonnes of aggregates
Quantity of aggregate
assuming density 2.2
7 mxO.075
25mmSDBC
Total
of
in
= 175
3)
Bituminous Pavement Construction
Plant
= 525
2)
(2 lane)
mxIxlOOO
=175x2.2
= 385 Tonnes
cum
be prepared
Hot Mix Plant: 1155+385 = 1540
in
Tonnes
4)
Average output
5)
Assume
6)
Total
7)
Time required
of Plant
60-90
TPH
Plant working hours per day
Tonnage produced
1540
for
in
a day
Plant
Say) 75
- 7.5 Hrs
TPH
;^
75x7.5 = 562.5 Tonnes
producing 1540 tonnes aggregates.
2.73 days
(Say) 3 days
562.5
77
IRC:90-2010
ANNEX-I
-
(Clause 11.7)
SAMPLE CALCULATION TO WORK OUT REQUIREMENT

OF HOT MIX PLANT
Assumption
Km of 2 lane
SDBC in a year.
200
i)
road (7.00
m width) to
be strengthened with 50
/
Quantity of aggregates for 50
mm BM
for
200
Km
= 7
mm BM and 25 mm
x 0.050
m x 200 x
1000
= 70,000 cum.
Assume
density of aggregates
Quantity of
11)
BM
2.2
70,000 x 2.2 = 1,54,000 Tonnes.
mm SDBC
Quantity of aggregates for 25
for
200 Km. = 7
m x 0.025 x 200 x
000
= 35,000 cum.
Assume
density of aggregate
Quantity of
iii)
SDBC
2.2
= 35,000 X 2.2 = 77,000 Tonnes
aggregate
Total quantity of
to
be prepared
in
Hot Mix Plant
1,54,000 + 77,000
= 2,31,000 Tonnes
iv)
Suppose the work

output = 75
v)
will
be executed with 60-90
TPH Drum
TPH
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
Mix Plant, Average
2,31,000
'
75 x 1500
1.71
=2
Plants
in
a year
IRC:90-2010
ANNEX-J
(Clause 11.8)
CALIBRATION OF HOT MIX PLANTS

Calibration
is
the process of adjusting the settings for
measurement is made or a process

an expected result. Because of random and
time a
is
known
levels of accuracy. Every
performed, there
is
an actual
result
and
variability with a definite pattern, the actual
from the expected result. Calibration is done to either identify/

the non-random variability or account for it in such a way that the difference
result usually differs

rectify
between the actual and expected
results
is
negligible.
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
is
Calibration, for
example, of a load
a drum mix plant
cell in
is
undertaken
for three to
four control settings covering the production range anticipated for the material.
Calibration of the
The
load
cell in
Load
Cell
Drum Mix
Bitumen. The calibration
Plant
is
is initially
used
done
measure the flow rate of aggregates and the

the static mode and then in dynamic mode.
to
in
a)
The default settings (factory settings)
b)
Thereafterthestaticcalibrationoftheloadcell(beneaththeslingerconveyor)
be checked.
If there is any change, there is a
requirement to calibrate. The speed
of the slinger conveyor is checked which is LN/60 where L is the length
of the slinger conveyor and N is the RPM.
of the load cells are to
needs to be done with the help of a standard weight .Therefore theoretical

value of the TPH is equal to Weight (Kg) x Speed of the slinger conveyor
(m/sec)x (3600/1000) TPH
c)
The
plant
is
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.
allowed to run for a fixed time duration and the output
The weight of the material is calculated after

loaded truck. The actual TPH is calculated from the weight
trolley/truck.
is
collected on the
calculating the weight of the
of the material output from a
given feeder, time of output and percentage of this aggregate (from the job Mix formula).
79
IRC:90-2010
This process
followed for at least three control settings.
is
(Actual TPH/Theoretical
TPH)
is
The Load
cell
constant
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
three observations.
speed
In
of the
pump
the actual weight
If
is
is
repeated
for at least
less than the theoretical weight then the
is
increased.
the case of Batch Mix Plant the load
Bitumen. The details have to
and
be followed as per the manufacturer's recommendations
cell is
calibrated for Aggregates,
Filler,
Manuals.
For the sake of
aggregates
An example
chart
1)
is
to
illustration.
be used
in
Manufacturers prepare a calibration chart for each of the
the hot mix.
of determining the control settings for
each cold feed using the
as follows:
Mix Design Criteria
Coarse Aggregate
20 percent (Cold Feed #1)
Intermediate Coarse Aggregate
Fine Aggregate
Filler
Binder Content
5.0 percent
Flow Rate Per Cold Feed
TB
Required Flow Rate per Bin
Plant's Mix Production
Rate
Percent of Aggregates
in
P
(t/h)
(t/h)
Mix (as decimal)
80
calibration
IRC:90-2010
P = Percent by Weight
of Total Mix (as decimal)
Plant Production of 350
t/h
Q(Cold Feed #1) = 350\
.95 X .20 = 66.5 t/h
(Cold Feed #2) - 350 X .95 X .40 = 133
(Cold Feed #3) = 350 X .95 X .30 = 99.8
t/h
(Cold Feed #4) = 350 X .95 X .10 = 33.2
t/h
The
3)
t/h
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
= 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.
X
c
Percent Max.
81
RPM
(The
Official
amendments
published by the IRC

shall
in its
document would be
periodical, 'Indian
be considered as
code/guidelines/manual,
to this
etc.
effective
and as
Highways' which
part of the
from the date specified therein)

Irc Gov in 090 2010

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JRC:90-2010

HOT MIX PLANT

Digitized by the Internet Arciiive

Price Rs. 300/-

(Packing & postage charges extra)

Part of this Publication shall be reproduced,

any form or by any means without the

permission of the Indian Roads Congress)

Printed at Aravali Printers

Capacity of Hot Mix Plant

Hot mix plant (continuous type)

Hot mix plant (batch type)

Direction of Flow of Aggregates

and Hot Gases

Counter flow type dryer-mixer

Parallel flow type

Mobility of Hot Mix Plant

Type Hot Mix Plant

Salient Features of Batch

of Hot Mix Plant (Batch Type)

Cold bin feeder

Cold elevator or cold feed conveyor

Primary pollution control device

Mixing unit (pugmill)

Hot mix surge

pollution control device (bag

Selection of Site for Hot Mix Plant (Batch Type)

Hot Mix Plants (Batch Type)

Limitations of Hot Mix Plants (Batch Type)

Hot Mix Plant (Batch Type)

Plant (Parallel Flow Type)

Cold bin feeder

Aggregates over size

Cold feed conveyor

Automatic weighing system

Exhaust control system

Primary pollution control device (dust

Hot mix conveyor

Hot mix surge

pollution control device

Limitations of Hot Mix Plant (Drum-Mix Type)

Double Barrel Drum Mix Plant

of Hot Mix Plant

for preparation of hot

double barrel drum mix plant

pollution control device (bag

Hot Mix Plant (Double Barrel Drum-Mix Type)

Limitations of Hot Mix Plant (Double Barrel

Operation of Hot Mix Plants

Principles for Operation

Precaution During Operation of Plant

Cold aggregate feeder

Cold aggregate bucket elevator

Essential Activities while Starting, Operating and

Hot mix surge

before Starting the Plant

and Shutting Down the Plant

of the Plant During Idling

Maintenance and Upkeep of Hot Mix Plant

Spare Parts and Lubricants

Plant and Equipment

Loading and Transportation of Plant and Equipment

Maintenance of Plant and Equipment