parts and their functions of Asphalt mixing plants and

paving equipments
1. asphalt batching plant 2. asphalt drum mixing plant 3. mobile
asphalt mixing plant 4. continuous asphalt mixing plan

1. ASPHALT BATCHING PLANTS

Batch plants obtain their name because during operation the asphalt mixture is produced in batches.
The size of batch varies according to the capacity of the plant pugmill (the mixing chamber where
aggregate and binder are blended together). A typical batch is approximately 6000 lb.
BATCH PLANT OPERATIONS AND COMPONENTS
At a batch plant, aggregates are blended, heated and dried, proportioned, and mixed with binder to
produce asphalt mixture. When recycled materials are used, they are proportioned and mixed with
the heated aggregates prior to mixing with the binder. A plant may be small or large, depending on
the type and quantity of asphalt mixture being produced, and also may be stationary or portable.
Certain basic operations are common to all batch plants:
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
the major components of a typical batch plant. Each component or group of related components is
discussed in detail in sections that follow; however, an overview of the processes required in plant
operations helps the Technician to understand the functions and relationships of the various plant
components. Cold (unheated) aggregates stored in the cold bins (1) are proportioned by cold-feed
gates (2) on to a belt conveyor or bucket elevator (3), which delivers the aggregates to the dryer (4),
the aggregate is dried and heated. Dust collectors (5) remove undesirable amounts of dust from the
dryer exhaust. Remaining exhaust gases are eliminated through the plant exhaust stack (6). The
dried and heated aggregates are delivered by hot elevator (7) to the screening unit (8), which
separates the material into different sized fractions and deposits the aggregates into separate hot
bins (9) for temporary storage. When needed, the heated aggregates are measured in controlled
amounts in to the weigh box (10). The aggregates are then dumped into the mixing chamber or
pugmill (11), along with the proper amount of mineral filler, if needed, from the mineral filler
storage (12). Heated binder from the hot binder storage tank (13) is pumped into the binder weigh
bucket (14) which weighs the binder prior to delivery into the mixing chamber or pugmill where the
binder is combined thoroughly with the aggregates. From the mixing chamber, the asphalt mixture
is deposited into a waiting truck or delivered by conveyor into a surge bin.

Figure 1-1. Major Batch Plant Components

2. ASPHALT DRUM MIXING PLANTS

Drum mixing is a relatively simple process of producing asphalt mixture. The mixing drum from
which this type of plant obtains the drum mixing name is very similar in appearance to a batch plant
dryer drum. The difference between drum mix plants (Figure 2.1) and batch plants is that in drum
mix plants the aggregate is not only dried and heated within the drum, but also mixed with the
binder. There are no gradation screens, hot bins, weigh hoppers, or pugmills in a drum mix plant.
Aggregate gradation is controlled at the cold feed.

Figure 2-1. Typical Drum Mix Plant

DRUM MIX PLANT COMPONENTS

The fundamental components of the drum mix plant (Figure 3-25) are:
1) Aggregate cold-feed bins 2) Conveyor and aggregate weighing system
4) Dust collection system

5) Hot mix conveyor 6) Mix surge bin

8) Binder storage tank

Referring to (Figure 2-2), the following is a brief, general description
of the sequence of processes involved in a typical drum mix plant
operation: controlled gradations of aggregates are deposited in the cold
feed bins (1) from which the aggregates are fed in exact proportions
onto a cold-feed conveyor (2). An automatic aggregate weighing
system (3) monitors the amount of aggregate flowing into the drum
mixer (4). The weighing system is interlocked with the controls on the
binder storage pump (5), which draws binder from a storage tank (6)
and introduces binder into the drum where binder and aggregate are
thoroughly blended by the rotating action of the drum. A dust
collection system (7) captures excess dust escaping from the drum.
From the drum, the asphalt mixture is transported by hot mix conveyor
(8) to a surge bin (9) from which the mixture is loaded into trucks and
hauled to the paving site. All plant operations are monitored and
controlled from instruments in the control van (10). The mixing
process is essentially similar in all drum mixing plants; however, there
are several plant designs available. These include the parallel-flow
drum, as shown in (Figure 2.2), the counter-flow drum, which has the
burner located near the outlet end of the drum, and the unitized
counter-flow drum, which has an outer mixing drum that surrounds the
dryer drum. The production of asphalt mixture meeting contract
Specifications is most easily done when the various parts and
functions of the plant are in balance; that is, when all parts are
properly coordinated to work together as a smooth working unit. Also
essential for consistent and high quality asphalt mixture is uniform
(uninterrupted) plant operation. Accurate proportioning of materials is
entirely dependent on the uniform flow of those materials. Plant stops
and starts adversely affect asphalt mixture quality.

3) Drum mixer

7) Control van

3. Mobile asphalt mixing plant Type MBA

Mobile Asphalt Plant is principally used by in construction of roads on small or medium scale. This
plant is basically designed for effortless assembling and disassembling for convenient moving from
one place to another very often. Engineered to give trouble free performance with enhanced fuel
efficiency, the plant is suitable for mixing stone dust, sand and more with correct temperature
requirement.
Mobile Asphalt Mixing Plant

ZAP-M Mobile Asphalt mixing plant features

1.Modular design, convenient and fast to move and install.
2.Screening, hot storage, weighting are on one folding frame, can realize main tower one truck to
trail.
3.Few transport vehicle, installation foundation need no special handle.
4.Compact design, cover very small area.
5.Accurate screening, weighting, batch mix can guarantee high quality.
6.International classic quality control system, has long distance fault detect and maintain function.
7.Each integration trailer is designed with "distributed" power distribution cabinet; all the
connecting cables are connected before delivery, more convenient and safe.

ZAP-M mobile asphalt mixing plant structures

Mixing Tower
1.Main building of mobile asphalt plant
can be hauled overall without disassembly. Easy for transitions.
2.High efficiency with special 4- layer and 7-section design features energy-saving and small noise.
3.Large volume hot aggregate storage bin equipped with high and low material level meter and realtime monitoring material level.
4.Aggregate feeding and weighing hopper are equipped with efficient dust cover preventing dust
spillover
5."Distributed" power distribution cabinet(wiring of all motors and electrical component on the
tower are connected to a power distribution box on the main tower, equipment removing relocation,

without dismantling the parts connection, achieve rapid relocation transitions. Installation again,
just use quick line to contact "distributed" power distribution cabinet with total control room)
6.Twin-shaft asphalt mixer owns high mixing efficiency and low consumption, no mixing blind
angle. High wear-resisting scale board, blade and mixing arm greatly reduce replacement of
wearing parts and lower the cost.
7.High strength double bridge bearing suspension, greatly assure the through capacity of various
kinds of road surface. 8 tires provide powerful support and ground friction.
8.Through a lifting installation, the main building of ZAP-M series asphalt mixing station has
become the main building of classic batch asphalt mixing station. Its use, operation and
maintenance are the same with classic batch asphalt mixing station.

Aggregate drying and hoist

1.Drying drum, hot aggregate elevator, burner etc. are integrated into a trailer frame, achieve rapid
movement, installation.
2.Only contact hot aggregate elevator with vibrating screen on the main building during
installation. To achieve convenient installation at the same time, the connectors are designed into
quick connection.
3.Hot aggregate hoist of ZAP-M mobile
asphalt mixing plant designed with hinged
connection to the trailer frame, which could
automatically find the installation location
during hoisting.
Hot aggregate elevator of this series asphalt
mixing plant are designed with highperformance noise-free non-return device,
prevent hopper reversal (boot for the first
time should pay special attention).
Mobile cold aggregate storage and transportation system
1.Belt feeder adopts frequency control, automatic control speed according to the output and ratio.
2.The complete set of cold aggregate hopper is equipped with high strength lifting leg and support
base. Fast installation, move.
3.Each hopper is equipped with anti oversize aggregate screen, prevent oversize stone jamming
resistance, damaging conveyor belt.
4.Discharging port of each hopper is equipped with no material alarm device, real-time monitoring
material flow supply of aggregate hopper
5.Sand bin is equipped with a broken vibration motor

Mobile dust collector

1.Primary dust collector, secondary dust collector, induced draft
fan system are integrated into a mobile trailer frame, installation
and commissioning are finished in the factory.
2.Adopt pulse bag house dust collector(characteristics of
detailed content, please refer to the introduction of dust
collector)
3.Super convenient move, installation. Without special
installation foundation, greatly save installation time and cost.
Powder system
The powder system of our ZAP-M asphalt mixing plant mainly
have the following features:
1.The powder silo is equipped with dust filter device (silo top
dust filter).
2.Butterfly valve is assembled to the exit of screw conveyor
which can control the conveying volume.
3.Powder storage bin adopts air blow to prevent blocking.

4.Continuous Asphalt Mixing Plant

In continuous plants there is no interruption in the production cycle as the rhythm of production is
not broken into batches. The mixing of the material takes place inside the dryer drum which is
elongated,

as

it

dries

and

mixes

the

material

at

the

same

time.

Since there are no mixing tower or elevators, the system is therefore considerably simplified, with a
consequent

reduction

in

the

cost

of

maintenance.

The absence of the screen however makes it necessary to have precise controls at the beginning of
the production cycle, before the aggregates are fed into the dryer and before they are consequently
discharged from the dryer as asphalt.
in continuous plants the length of the mixing action must necessarily stay constant.
Continuous Plants where low operational costs and continual production are essential, of course
if you have constant quality in the aggregates..

Continuous asphalt mixing plant

is the new developed product on the basic of intensive studying the international advanced
technology.
Our ZAP-C series continuous asphalt mixing plant is mainly composed of cold supply system,
dryer drum, burning system, dust collection system, finished products storage bin, bitumen tank,
mineral adding system and control system.

Continuous asphalt mixing plant components performance:

Dryer drum system
1. Four-wheel friction drive, with smooth transmission, low noise and long service life.
2. The drive reducer adopts hard tooth surface reductor, with large load capacity and impact
resistance.
3. The specially designed "butterfly" elastic connection plate will be more uniformly forced after
the drum heated expansion. It completely solved the elastic plate heat cracking problem.
4. The roller and roller carrier shaft using high quality alloy steel forging with long service life.
5. The external drum using high quality thermal insulation material plus stainless steel mask
packaging, with favorable heat preservation performance and neat and beautiful appearance.
6. The drum body using heat boiler plate.
7. The internal blade also uses boiler plate and connects with bolt, with long service life and fast
and convenient replacement.
8. The dry drum heat the aggregate to a certain temperature through counter flow heating(the
control system would adjust the flame of burner automatically), as the drum moved, aggregate in
the drum were repeatedly elevate and fall down by the plate, formed aggregate curtain which
enhanced heat exchange effect.

Powder system 1.The powder silo is equipped with dust filter device(silo
top dust filter).
2.The powder silo is equipped with high and low indicator.
3.The screw conveyor adopts the design of varying-pitch an ti-block.
4.High-reliability weighing sensors.
5.Weighing screw conveyor adopts frequency converting control.

Finished product silo

1. The bottom of material scrape device is entirely is
heated by hot oil, in case of temperature loss when the
finished asphalt is conveyed.
2. The scrape plates are made of high-chromium wearable
materials and the liners are thickened to prolong the
service life to produce 100000T finished asphalt.
3. The chain specially used for the material scrape device
is efficient and wearable.
4. The finished asphalt storage bin is equipped with
weighing device so that the user can know the asphalt
volume precisely at any time.
Belt weigher
1. Choose the preset formula through the IPC, start the system after confirm the formula. The
feeding system will automatically control each batching machine according to the settled formula.
2. Semi-automatic/manual type.
3. Manually set the recipe on the controller ratio, manually start the controller, BW500 Totalized
control inverter and weigh feeder feeding.
4. Scale aircraft structure is simple.
5. Scale aircraft have modular features and high commonality.
6. Scale weighing with high precision.
7. Scale shelves have no fulcrum, no moving parts, there was no such fulcrum wear.
8. Easy maintenance.

Whole Continuous asphalt mixing plant features:

1.Ultra low power consumption, large production capacity, fuel consumption is lower under the
condition of same capacity.
2.Equipment consistent is simple and with reliability, low failure rate, easy to move and maintain,
low equipment investment.
3.Has strong and simple RAP expend ability.
4.Need no installation foundation(only need simple smooth and harden).
5.Kinds of each material successive, can guarantee the continuous of mixing time and space, form
flow line production.
6.The application of latest international weighting technology, can guarantee the precision of each
material, has a revolutionary innovation compared with

Asphalt Paving Equipment

Sweepers / brooms for removing dust
from surface to be paved

Asphalt distributor truck for

applying prime, tack or seal coats

Pavers for hot mix asphalt placement

DISTRIBUTORS
A distributor is used to apply liquid asphalt material such as prime and tack coats to surfaces to be
paved. The distributor consists of an insulated tank mounted on a truck or trailer. A power-driven
pump forces the asphalt through a system of spray bars and nozzles onto the construction surface. A
burner, usually oil-fired with flues within the tank, is used to heat the asphalt to the proper
application temperature. The major units for a typical distributor are indicated in below Figure.
The distributor is required to:
1) Maintain the liquid asphalt at a
uniform temperature
2) Apply material at a uniform rate
3) Apply material at variable widths
The distributor is required to be
equipped with:
1) A tachometer (Bitumeter) to
measure the speed during
applications
2) Pressure gauges
3) Accurate volume measuring
gauges or a calibrated tank
4) A thermometer for measuring
temperatures

5) A power unit for the pump

6) Full circulating spray bars to prevent material cooling in the spray bars. The spray bars are
required to be adjustable both laterally and vertically.

Asphalt Pavers
Hopper
Function: Receive Hot
Mix Asphalt (HMA) from
hauling trucks
Operational
Consideration:
Intermediate stops waiting
for truck loads negatively
impacts the smoothness of
the mat surface, as such ;
Integral or attachable
Windrow Pickup
Elevators are available for continuous hopper loading operations, for a given paving stretch
Material Transfer Devices are also available to receive multiple truckloads of HMA, remix and
deliver to the hopper.

Conveyor Auger
Conveyor: Move the mix
through a
tunnel under the
engine to the auger at the rear
end

Auger: The auger receives

HMA from
out
evenly over the
width to
be

Screed
Function: Control the HMA width and depth
Provides Initial mat finishing and compaction

the conveyor
paved

and

spreads

it