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STUDY ON HOT MIX PLANT

BY
A.SURENDRA BABU
14341D2201
Department of Civil Engineering
G M R Institute of Technology
(An Autonomous Institute Affiliated to JNTU Kakinada, Kakinada, A.P)
(Accredited by NBA, NACC with A Grade & ISO 9001:2008 Certified
institution)
Approved by AICTE, New Delhi
GMR NAGAR, RAJAM-532127, A.P
March-2016

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CONTENTS
1. ABSTRACT
2. PROJECT FEATURES
3. INTRODUCTION
4. PROJECT DGPS MAP
5. JOB MIX DESIGN
6. COCLUSION

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ABSTRACT
The Government of India has launched major initiatives to upgrade and
strengthen

National Highways through various phases of National

Highways Development project (NHDP).

In this project a study on hot mix plant is been explained here with the
field experience at the project site for the road construction, widening,
rehabilitation and reconstruction of the NH-565
Hot mix plant working, operation and production of the Dense Bitumen
Macadam(DBM) and Bitumen Concrete(BC)

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PROJECT FEATURES

The project stretch is one of the newly assigned national highway number NH
565 from NAKREKAL in Telangana to ERPEDU in Andhra Pradesh.

This project is an important connectivity between NH-65 and NH-71

Rehabilitation and Up gradation of Nakrekal to Nagarjuna sagar section of NH565 from Km. 1+000 to Km. 86+057 in the state of Telangana to two lane with
paved shoulders under NHDP-IV through Engineering Procurement &
Construction (EPC) Basis Contract

This project connects Nakrekal, Pangal, Nalgonda, Haliya and Nagarjuna sagar
covering a distance of 85.057 kms originates from Nakrekal and terminates at
Nagarjuna sagar.

The project is to be executed by contractor GVR Infra PROJECTS ltd. as EPC

(ENGINEERING-PROCUREMENT-CONSTRUCTION) project

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INTRODUCTION
Rapid industrialization has created a demand for improved road
surfaces. For the production of high quality hot asphaltic mixtures
conforming to the desired specifications, suitable mixing plants are
required and the formulation of a standard specification for mixing
plants has become necessary.
The main purpose of this project is to know about the hot mix plant
working and production of the Dense Bitumen Macadam (DBM) and
Bitumen Concrete(BC)
The major part of the road construction contains the bitumen which acts
as a surface coarse or protection coarse from the road users and
environmental effects

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DGPS MAP

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Hot Mix Plant At the Project Site

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MATERIALS SOURCE
AGGREGATES: The aggregates are extracted from the locally
available mines at the nalgonda using the mobile and fixed
crushers. The aggregates are crushed to required shapes
based upon the requirement of the plant
BITUMEN: It is imported from Chennai IOCL company of
bitumen VG30 through tankers

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MACHINERIES
Crushers: mobile & fixed crushers
Hawlers: For transporting the DBM & BC from
plant to on site of 30 tones capacity
JCB: For filling the aggregates & filler material in
cold bins of the hot mix plant

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HOT MIX PLANT

An asphalt mixture plant is an assembly of mechanical and
electronic equipment where aggregates, recycled materials or
other additives are blended, heated, dried and mixed with binder
to produce asphalt mixture meeting specified requirements.
Types Of Hot Mix Plant

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1. BATCH MIX PLANT

2. DRUM MIX PLANT

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BATCH PLANT OPERATIONS

The operations include:

1) Aggregate storage and cold feeding
2) Aggregate drying and heating
3) Screening and storage of hot aggregates
4) Storage and heating of binder
5) Measuring and mixing of binder and aggregate and recycled materials
(when used)
6) Loading of finished asphalt mixture

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Major Batch Plant Components

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BATCH PLANT OPERATION

The cold bins are filled with the materials of different aggregate
sizes and the filler dust
These aggregates in the cold bins are transported by the
excavator which is situated at the bottom of the hopper to dryer

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AGGREGATE DRYING & HEATING

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From the cold bins, aggregates are delivered to the dryer. The dryer
removes moisture from the aggregates and raises the aggregate
temperature to the desired level

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SCREENING OF HOT AGGREGATE

After the aggregates have been heated and dried, the aggregate is
carried by a hot elevator (an enclosed bucket conveyor) to the
gradation unit
In the gradation unit, the hot aggregate passes over a series of
screens that separate the aggregate into various-sized fractions
and deposit those fractions in "hot" bins

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Cross-section View Showing Details of

Flow Material Through Screens and Bins

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From the weigh hopper, the aggregates are deposited into the
plant pug mill(mixing chamber) to be blended

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INTRODUCING THE BINDER

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PUGMILL MIXING OPERATIONS

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TEMPERATURES
The temperatures at which the aggregates are dried in a typical
dryer is 160C 170C
The temperatures of the Bitumen is to be maintained is 150C 160C
The mixing temperatures for the Bitumen and aggregates in the
pugmill is to be maintained is 140C 150C
The laying temperatures of Dense Bitumen Macadam
(DBM)and Bituminous Concrete(BC) should be 120C

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CONTROL STATION

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CONTROLS AT THE CONTROL ROOM

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JOB MIX DESIGN FOR DBM

AGG MIX
PROPORTION

1000
KG

1200
KG

1400
KG

1600 KG 1800 KG

2000 KG

36 mm 23.97 % 239.675 287.610 355.545 383.480

431.415

479.350

22 mm 18.22 % 182.153 218.584 255.014 291.445

327.875

364.306

10 mm 19.17 % 191.740 230.088 268.436 306.784

345.132

383.480

4 mm

621.238

690.264

34.51 % 345.132 414.158 483.185 552.211

Bitum 4.13 %
en %

41.300

49.560

57.820

66.080

74.340

82.600

TOTAL 100

1000

1200

1400

1600

1800

2000

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JOB MIX DESIGN FOR BC

AGG MIX
PROPORTION

1000
KG

1200
KG

1400
KG

1600
KG

1800
KG

2000
KG

28 mm

17.37 % 173.700 208.440 243.180 277.920 312.660 347.400

16 mm

42.46 % 424.600 509.520 594.440 679.360 764.280 849.200

10 mm

21.23 % 212.300 254.760 297.220 339.680 382.140 424.600

4 mm

15.44 % 154.400 185.280 216.160 247.040 277.920 308.800

Bitume
n%

3.5 %

35.0

42.0

49.0

56.0

63.0

70.0

TOTAL

100

1000

1200

1400

1600

1800

2000

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MOVEMENT OF THE TRUCKS

The movement of the truck traffic should be free and accessible
for filling the DBM and BC
There should be no collisions between one truck to another
truck
The path of trucks should come around the plant i.e. circular
motion to come for filling
After filling the material into the truck it should be taken to the
weigh bridge and weigh slip is generated to the truck

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CONCLUSION
The WBM and the BC are produced upon the prescribed or

required job mix design

These are free and more productionable for major projects
These are freely operatable
These are more economical for completing the projects in time
The main disadvantage is these are not operated during the heavy

rain because the mixing temperatures will be reduced or changed

Every night of the working day the maintenance work has to be

done

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