track b asphalt plant operations: material storage, handling, & … · 2020-03-05 · asphalt...
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1 © Copyright 2012 Daniel J Edelman Inc. Intelligent Engagement
Track B – Asphalt Plant Operations:
Material Storage, Handling,
& Delivery
2020 MAPA Spring Training – Black to Basics
Holiday Inn Executive Center – Columbia, MO
February 27-28, 2020
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• Separated
stockpiles
• Good drainage
• Minimize
segregation
Aggregate Storage
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Stockpile Moisture
• Water retention is maximized with well graded fine aggregate with high - #200 content (i.e., screenings)
• Screenings will typically hold more moisture than manufactured sand
• RAP and RAS stockpiles are also very prone to holding moisture
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Stockpile Moisture
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Stockpile Moisture
• Avoid contamination by removing material
from just above grade
• Reduce possibility of segregation by
rotating up and through material
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• Dividers on Aggregate Cold Feed Bins
• Material bins should not be heaped above
divider walls
Aggregate Delivery
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• Aggregate Cold Feed System
– Provides uniform flow of aggregates to dryer
– Flow rate controlled by:
• Gate opening
• Belt speed
– Consistent feed rate
Aggregate Delivery
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• Aggregate Cold Feed System
– Scalping Screen rejects oversize
– Weigh Bridge monitors flow rate
• Must be maintained
• Properly calibrated
• Wind Guards installed
Aggregate Delivery
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RAP Delivery
• Special Requirements and
Designs:
– More horsepower (larger
output required)
– Special designs to promote
flow of material
– RAP more prone to bridging
– “Lump breaker” often found
at discharge
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Asphalt Cement Storage
• Tanks can be horizontal
or vertical
• Tanks typically have hot
oil heating coils
– Some are heated
electrically or with a
burner
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Asphalt Cement Temperatures
• Critical to proper coating of the aggregate
• Critical for proper placement and
compaction
• Critical for a quality paving product
• Control AC temps through tolerances on
mixing temperatures
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Asphalt Cement Temperatures
• Manufacturer recommends it
• Protects asphalt from over-cooking
–Blue Smoke
– Loss of light ends
• Having a minimum temperature helps
with compaction on the road
–Ensures that the mixture will stay in a
condition favorable to achieve
compaction
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Asphalt Cement Storage
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Asphalt Cement Distribution
• Asphalt binder flow is controlled by the
plant automation
• Automation adjusts asphalt binder flow at
the asphalt pumping/metering unit
• Thermocouples used to measure
temperature of binder at meter should be
calibrated to make sure proper binder
temperature is being taken
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Asphalt Cement Distribution
• Verify proper specific gravity or AC
weight/gallon is entered in meter
• Air leaks in binder lines can cause meters
measuring gallons to count air as asphalt
–Extracted binder content will be low
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Asphalt Mixture Storage
• Many configurations:
• Portable
• Stationary
• Single Silo
• Multiple Silo
• Over Truck Scale
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Asphalt Mixture Storage
• With silos we are mostly
concerned about:
• Segregation
• Temperature Loss
• Oxidation
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Asphalt Mixture Storage
• When using a silo, the
contractor shall deliver
material that is:
– within the tolerance
ranges as set forth on
the Job Mix Formula
– without segregation
– without balling or
hardening
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Asphalt Mixture Storage
• Segregation is a much
higher risk in silos that
do not use a “Batcher”
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Asphalt Mixture Storage
• Batchers drop a large
mass of material at one
time to reduce
segregation
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Asphalt Mixture Storage
• To reduce the opportunity
for segregation:
–Feed all batchers in
center
–Feed split-feed type
batcher in-line with
splitter
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Asphalt Mixture Storage
• Insulation and hot oil
heat helps reduce the
effects of heat loss to
the atmosphere.
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Asphalt Mixture Storage
• Heat can escape out
the batcher and draws
in cool air to oxidize the
mix
• Insulated batchers and
heated silo gates
reduce this effect
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Asphalt Mixture Storage
• Seals on the bin top and
silo gate area lengthen
storage times by
reducing the “Chimney
Effect.” Air is trapped in
an insulated and sealed
environment.
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Asphalt Mixture Loadout
• Truck Driver
Communication
– Truck routing
– Release agents
– Silo identification
– Loadout procedure
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• Truck Loading– Use multiple drops
– Loading sequence:• front
• back
• middle
– Always transfer HMA in “bulk”• do not allow mix to dribble
from silo1
Asphalt Mixture Loadout
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• Truck Loading– Use multiple drops
– Loading sequence:• front
• back
• middle
– Always transfer HMA in “bulk”• do not allow mix to dribble
from silo1
Asphalt Mixture Loadout
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• Truck Loading– Use multiple drops
– Loading sequence:• front
• back
• middle
– Always transfer HMA in “bulk”• do not allow mix to dribble
from silo21 3
Asphalt Mixture Loadout
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Haul Trucks
• Insulated and tarped
– Especially for thin overlays
– Front and both sides of
bed
• Clean, smooth bed
– Approved release agent
–No diesel!
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Haul Trucks/Material Transfer
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Mix Delivery
• Correct Number of Trucks for Uninterrupted
Delivery to Paving Site
• Truck Driver’s Training
- Constant Delivery
- Getting In and Out of the Paver
- Expeditious Cycling of Trucks
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MTV remixer blends
segregated mixture
from truck and
delivers it to the
paver
Use of Material Transfer Vehicles
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• Material Transfer Vehicle
– Can help both mixture and temperature segregation
– Keeps paver moving
– However, it does add another LARGE piece of equipment to
the paving train
• Too big for some projects
• Vertical clearance issues
• Underground utilities
• Bridge weight limits
Mix Delivery
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Summary
• Aggregate stockpile management and
control is the first step at the production
facility towards quality mixtures
• Cold Feed system must be properly
maintained and calibrated in order to
achieve the JMF target
• Asphalt Cement storage and distribution is
also vital to ensuring quality mixtures and
long-life pavement performance
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Summary
• Proper silo storage practices are important
for maintaining the integrity of the plant
produced mixture
• Even something as fundamental as loadout
can have a significant impact on the quality
of the final mat texture
• Truck Driver training is vital to the success of
the final pavement’s performance