4/18/2018 Asphalt Plant - KCMAK

Asphalt Plant

Asphalt Plants Model / Type Capacity Location

Wibaw Asphalt Plant – (1) MOB200-Germany 120 T/H Amgara Area

Batching plant

Ammann Asphalt Plant – Uniglobe-AZ-29192

(2) Germany-Batching 240 T/H Amgara Area
plant

Component :

1. Cold Aggregate Storage

2. Drying Drum
3. Screening
4. Hot Storage
5. Automatic Control Room
6. Bag-Filter Unit

Hot Mix Asphalt Produced :

1. Conveyor belt system transporting mineral aggregate from cold teed bins to drying drum, where it is
preheated. The dryer is usually of the routable drum type filled with lifters to ensure good contact with the
burner combustion of gases.
2. The conveyor lift system transports the preheated coarse and fine aggregate together from the drying drum
to a vibrating screen, which separates the preheated aggregate into various fractions and deposits them into
hot bins.
3. Predetermined weights of aggregate discharges from the hot bins into a pug-mill (mixer).
4. A mineral filler system discharges specified weight into pug-mill.
5. Predetermined volume of bitumen is discharged into the pug-mill, the added bitumen is electrically heated
in storage bins before discharge into the pug-mill (mixer).

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6. The pug-mill (mixer) then wet mixes the preheated aggregate, mineral filler and bitumen together until a
uniform mixture is obtained and the resultant asphalt is then discharged into trucks and transported to the
road making site.

Asphalt Paving Crew :

1. Qualified asphalt paving crew led by a 35 years experienced supervisor.

2. Asphalt paving equipment list attached here with this methods.

Rate of Spread :

For a given width and thickness, the lineal meter long of the pavement per ton on paving mix can be
determined.

Source of Materials for Asphalt Mixtures :

1. Mineral aggregates gabbros stone that has been crushed and screened according to M.P.W road paving
specification that aggregate from Al-Slbookh Trading Co. stored in separate stockpiles at storage area in
the asphalt plant.
2. Asphalt cement (bitumen) 60/70 penetration grad from K.N.P.C – Kuwait.
3. Mineral filler consist of finely ground particles of limestone cement from National Industries Kuwait co.
4. Natural sand from Al-Bolshie Trading Co.
5. Prim coat (MC 70) from K.N.P.C — Kuwait.
6. Tack coat-Emulsified Asphalt slow setting cationic or anionic type of SS-1h or CSS-1h Grade from
Kuwait Asphalt Emulsion production Co.

QUALITY CONTROL PLAN

Stage I: Sampling and Testing Aggregates Stockpiles

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Aggregate submitted from the supplier should be tested as the following tests:

1. Sieve analysis of coarse and fine aggregate.

2. Unit weight of coarse aggregate.
3. Clay lumps and friable particle for coarse aggregate.
4. Sand equivalent for sand.
5. Specific gravity and absorption test for coarse and fine aggregate.

Stage II: Calibrating and Setting Feeders for Cold Bins

The cold aggregates feeder gates should be calibrated to prepare calibration chart for each cold bin
(11/2"@3/4"@3/8"@ Crushed Sand@ Natural Sand) using the same Aggregate in the asphalt mix design.

Stage III: Hot Bins Calibration

Hot bin calibration should be done for each type of asphalt according to the aggregate percent passing in
asphalt mix design which is approved from the M.P.W to determine specified weight scales to be taken from
each different fraction. Then standard aggregate weights are placed and attached to the asphalt aggregate scale
reading. Then a sample should be taken from each hot bin to determine the aggregate combination of mineral
aggregate, sand, filler and bitumen to compare with job mix specification.

Stage IV: Sampling @ Testing for Asphalt Mix Production

1. Checking on asphalt mix temperature during the production.

2. Checking the job mix composition by obtaining sampling asphalt mixture from storage tanks or truck
tanks during unloading asphalt mixes production to determine sieve analysis of aggregates and percentage
of bitumen in asphalt mixes using reflux extractor method.
3. Checking on Marshall Mix design for bulk density, stability and flow.
4. Sampling for checking specific gravity of compacted asphalt mix design. 

SPREADING HOT MIX ASPHALT :

1. After receiving asphalt mix in the site a routine task of our supervisor is to collect load tickets from truck
driver at the point of delivery in the site.
2. Asphalt mix temperature should be checked for every truckload before paving start.
3. When the paver is positioned on the road the screed should be lowered on the blocks having the thickness
control, screws on the screed are adjusted for the depth required. The paver should then begin spreading at
the proper depth of the material. As the paver spreads its first load of asphalt mix, the mat should
frequently be checked for thickness.
4. Compacting hot mix asphalt with rolling should start as soon as possible after the asphalt mix has been
spread by the paver to obtain the required density and well-kneaded surface using steel rollers with

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vibration for initial pass and then steel rollers without vibrating with pneumatic tired rollers together using
rollers which move at a slow but uniform speed equal to the drive roll or wheels nearest to the paver and
the speed must not exceed 3 mph for steel rollers and 5 mph for pneumatic tired rollers.
5. Rolling finishing is done solely for the improvement of the surface.

Sampling :

1. In addition to obtaining compacted samples for measurements for extraction and gradation tests, before it
has been compacted. These samples taken from behind the hopper of the paver, the sample is
representative to lot of measurements being tested.
2. The degree of compaction obtained by rolling is determined by density test and asphalt core cutting
machine used for taking samples provided from roadway.
3. These samples are transported to the asphalt plant laboratory to test it in accordance with the method of
the specific gravity of the compressed bitumen mixture AASHTO T 166

Daily Production Capacity and Asphalt Paving Crew Coverage Area :

Asphalt plants production capacity per day = 350 T/H * 8 (hours) = 2800 T/day

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