REQUIREMENT OF MACHINERY

AND EQUIPMENT FOR FLEXIBLE

PAVEMENT CONSTRUCTION
BY R.K.Saxena, Former Superintending
Engineer (Mechanical), MORTH
 Category of Road Construction Equipments

 Crushing and Screening Plants

 Earth Work Equipments
 Wet Mix Equipments
 Compaction Equipments
 Bituminous Equipments
 Concrete Equipments
 Allied Equipments
 Classification of Equipments Required for Earth
Work, Sub-base and Base Course
 Earth Work Equipments  Compaction Equipments
- Dozer (Crawlor / Wheeled) - Self propelled single drum
vibratory roller
- Rotavator
- Pad foot roller
- Disc harrow - Vibratory tandem roller
- Cultivator - Static three wheel roller
- Motor grader / Grading - Double drum walk behind
attachment fitted on tractor roller
- Excavator (Tracked / - Single drum walk behind
Wheeled) roller
- Loader - Vibratory damper
- Backhoe loader - Plate compactor
- Rammer
 Wet Mix Preparation
- Wet mix plant
 Material Transportation Equipment
- Tipper
- Tractor towed trolley

 Material Laying Equipments

- Chip spreader attachment

- Mechanical Paver finisher
- Tractor towed mechanical broom

- Wet mix plant

 Track Dozer

 It is most versatile earth

moving machine
 It is known Bull dozer also

 It is mounted on a pair of crawler tracks, which

provides stability, better traction, higher grade-
ability and low ground pressure
 It can be used for various applications like dozing,
ripping, towing, pushing, tree felling
 The capacity of track dozer depends upon engine
hp, weight, blade capacity in m³ and length
 Its speed is quite low and movement on its power
for long distance is uneconomical, since track repair
is expensive
 Track dozer fitted with 125 hp engine, 12000 kg
weight, blade capacity 2.5 m³ is considered
reasonable for normal road work application
 Application
- For spreading the earth work
- For opening pilot roads on mountains and rocky
terrains
- To clear construction sites
- To maintain haul roads
- To clear land from the trees and stumps
- Backfilling trenches at construction sites by
dragging earth from one place to another
 Wheeled Dozer
 It is mounted on tractor
hence known as wheeled
tractor

 The big earth mover tyres make it to move faster

 Its capacity is specified in terms of engine hp,
weight and blade capacity in m³ and length
 Its ground pressure is high, hence cannot be used
on soft ground
 It cannot be used on slippery or snowy surface also
since it has lesser traction
 It is suitable for use in hilly terrain, where frequent
landslides occur; so that same can be shifted from
one place to another on its own power
 Difference Between Crawler and Wheeled Type
Dozer
Crawler Type Dozer Wheeled Type Dozer
 Its speed is slow up to 12  Its speed is more up to 50
kmph kmph
 More compact and powerful  Can handle only lighter
and can handle heavier jobs jobs
 It is costly  It is cheaper
 Its operation and  Its operation and
maintenance cost is high maintenance cost is less
 Crawler Type Dozer Wheeled Type Dozer

 Moves on rough road only  Moves on rough as well as

good roads

 Used for movement at short  Used for movement at

distance longer distance

 Requires skilled operators,  Requires less skilled

repair and maintenance staff operators, repair and
maintenance staff
 Crawler Type Dozer Wheeled Type Dozer
 Stick control provided for  Wheel steering control
steering control provided

Wheel Control

Stick
Control
 Motor Grader

 It is a six wheeled, self propelled

machine

 It is designed for levelling, grading, shaping and

finishing of earth work, berms, side slopes and ditch
making operations
 Its longer wheel base and heavy duty bigger tyre
size enables to travel over uneven ground and to
level it to an even grade
 It is also provided with scarified teeth to loosen the
earth before blade is used for grading
 Features of motor grader suitable for road project
- Engine HP 120
- Blade width 2500 mm
- All movements hydraulically controlled
- Tungsten carbide tipped cutting edges
- Turning radius 6500 mm
- Centre ground clearance 625 mm
- Wheel size 14.00 x 24
- Hydraulic brakes
- Programmable digital display system with LCD
screen
- Wider visibility
- Safety features
 Tracked Excavator
 It is more versatile, mounted on a
pair of crawler tracks

 It provides stability with better traction, higher

grade-ability and low ground pressure
 Its speed is quite low and movement on its power
for long distance is uneconomical, since track repair
or refurbishing is expensive and time consuming
 More suitable for application on uneven surface
 It is most suitable for fitment of rock breaking
attachment

 Capacity of track excavator

Weight Engine hp Bucket Remarks
capacity
8 tonne 76 hp 0.24 to 0.32 Suitable for
cum smaller works and
12 to 14 80 to 100 0.7 cum in hilly terrain
tonne hp
20 tonne 170 hp 0.8 to 1.2 cum Suitable for bigger
and above works
 Wheeled Excavator

 It is mounted on pneumatic
tyres and mobile
 Its running speed is up to 35

Kmph and can be moved from one site to another on

paved surface easily
 Its cost is less than tracked machine, due to its
lesser under carriage cost
 Wheels and brake system last longer and their
replacement is easy and repair cost less
 Wheeled excavators cannot drag as aggressively as
tracked excavator
 It can further improve productivity with the
assistance of certain attachments such as sloping
grade
 Wheeled Loader
 It is mounted on pneumatic tyres
 It is used for multiple application

like loading mix in to tippers, feeding the aggregate

in to bin feeder of wet mix plant and hot mix plant
 Its capacity depends on engine hp and bucket
capacity
 Loader with engine 76 hp and bucket 1 cum is
sufficient for highway works
 Backhoe Loader

 It comprises mainly of two

components

- Loader bucket and Backhoe bucket

 It is most popular equipment in road construction
 It has multiple application like excavation, rock
breaking, loading earth / aggregates in tippers,
feeding it in to bin of wet mix and hot mix plant
 Different capacities of Excavator cum loader are
available and selection can be done based on
requirement of bucket capacity, loading / digging
depth, soil conditions, project completion time,
economy and use in future projects
 These are available in 50, 76 and 92 hp
 Larger size front tyres give better resistance and
more traction during loading
 Rock breaker can be fitted on Backhoe loader 76 hp
 Four wheel drive backhoe loader preferred due to
- Higher traction on all four wheels giving mobility
even on slush and sand, enabling the machine to
overcome gradients easily
- Maximum speed enables quick and easy mobility
of machine from one site to another
- Heavy duty loader arm for better lifting capacity
 Rotavator
 Purpose
- It may be used for lime
stabilization purpose, therefore

pulverizing and mixing the soil with additives to the

specified degree, to full thickness of the layer being
processed

- Desired degree of mixing and uniformity of the

stabilized material can be achieved
 Disc Harrow
 Purpose
- Lime stabilization by

pulverizing and mixing the soil with additives

- Desired degree of mixing and uniformity of the

stabilized material can be achieved

 Features
- It can be fitted on all types of tractors with rear
hook or draw bar arrangement
- Its discs are in concave shape which enables their
- It is of two types
penetration in earth by combination of weight and
(i) Trailing type
(ii) Hydraulic mounted type
design
 Cultivator
 Purpose
- Used to mix the soil with
additives

 Features
- It can be fitted on all types of tractors

- Heavy duty spring loaded tines mounted on steel

frame provide excellent trash clearance with deeper
penetration
- It is fitted to the power take off shaft (PTO) of
tractor
- It can be fitted on tractor ranging 30 to 75 hp
- Width of rotavator is 1.0 to 2.4 metre and can be
selected based on the requirement
- Speed of rotor is 220 to 540 RPM
- It is regulated by means of skids
- Depth of tillage is up to 15 cm
- Constant tines vibration, shatter the sub soil which
- Normally 9 to 17 tines are provided as per
gets it mixed with additives
requirement
 Tractor fitted with Grading Attachment

 Purpose
- It is very useful and low cost
equipment to be used for
grading purpose in rural roads

 Function
- This attachment is fitted on tractor

- There are different types of grading attachments

based on the grading capacity and their width
 - It can be fitted on the tractor
having steering power
attachment

- Tractors with 55 hp and above are suitable for

fitment of this attachment
-The width of grader blade is between 2.1 to 2.8
metre
 Tractor fitted with Dozing and Grading Attachment
 Purpose
-To carry out dozing and grading
operation simultaneously

 Function
- Front dozing attachment is used to scatter bulk
material
- Grading attachment smoothens the surface, makes
it flat and provides slope as per requirement
- This attachment is fitted on four wheel drive tractor
of 75 hp capacity

- The front dozer blade can move in vertical direction

and centre blade in horizontal, vertical and
diagonally

- The circular drive provides the facility for

movement of centre blade at different angles

- The provision to offset the centre blade enables it

for side cutting of road
- Advantages of four wheel drive and bigger tyre size
(i) It has more traction effort
(ii) It has less slippage
(iii) Heavy duty front and rear axle makes it easily
workable in rough terrain
- It has got higher ground clearance
- It has wide range of speed which makes its running
economical
- It has proper load distribution
-The dozing and grading operations can be done
together, if required; since both have separate levers
for operation
 Dimensions of main components of tractor fitted
with dozing and grading attachment
- Over all length – 6800 mm
- Length of blade – 2130 mm
- Front dozer length – 1830 mm
- Camber cutting height – 600 mm
- Width of front dozer – 600 mm
- Height of blade from bottom – 480 mm
 Tractor Fitted with Attachments

 Front end Loader Attachment

 Dozing Attachment
 Loader and Backhoe Attachment
 Radial Attachment
 Dozing and Backhoe Attachment

 Grading Attachment
 Tractor Fitted With Dozing Attachment

 Purpose:

- Used for removal of thick

vegetation / roots/ trees
clearance/ earth work

 Features:
- Dozing attachment easily detachable
- It can be fitted on 60-70 hp tractor
- Lift height 775 to 900 mm
- Width of dozing attachment 2250 to 2400 mm
- Blade cutting capacity 120 mm
- Blade if damaged, can be replaced easily and
economically
- Dozing attachment fitted with single/ double
cylinder to control dozing
 Tractor Fitted With Front End Loader Attachment

 Purpose:
- Low cost equipment used to lift
and transport aggregate/ soil for
short distance

- Used for loading aggregates in to bins of Wet mix

plant/ hot mix plant
 Features:
- It can be fitted on tractor with minimum 55 hp
engine
- Bucket can be easily detached with out spanner
- It is provided with single lever joy stick
arrangement and bucket level indicator for easy
operation
- Normally bucket size is 0.6 cum
- Loading capacity 900 kg depending on model of
tractor
- Out put 48 cum per hour
- Operation cycle 40 seconds
 Use of Backhoe System
Backhoe
 It is used to excavate below the
Stick natural surface on which it rests

 It is used to excavate trenches, pits

Bucket for basements and also for grading
works, which requires precise control
works, which requires precise control of depths
of depths
 It can be efficiently used to dress or trim the
surface avoiding the use of manual effort for
dressing the excavated surface
 Tractor fitted with Loader and Backhoe Attachment

 Purpose:
- Used to carry out digging and
loading activities simultaneously

- It can be used for loading aggregate/ earth directly

in to tractor trailer/ tipper
 Features:
- It has two attachments (i) Backhoe (ii) Loader
- Back hoe attachment:
(i) It can be used for digging up to 3.5 metre with
bucket capacity 0.21 / 0.23 cum
(ii) Bucket can be used with maximum load up to 3.2
metre height
(iii) It can apply tear force 5700 Kg
(iv) The boom can rotate up to 180°
- Loader attachment
(i) Lifting height is 3.6 metre
(ii) Dumping height is 3 metre
(iii) Bucket capacity is 0.6 cum (900 kg)
 These attachments can be fitted on tractor 60 HP
and above
Tractor fitted with Dozing and Back Hoe Attachment

 Purpose:
- Used to carry out dozing,
digging and loading
activitiessimultaneously
activities simultaneously
 Features:
- Backhoe attachment can be used for digging up to
3.5 metre
- Attachment for digging above 3.5 metre can be
fitted on tractor above 60 hp
- Bucket capacity is 0.23 cum
- Can be used for loading material in tractor trailers/
tippers
- Length of dozer blade is 2400 mm
- Height of dozer blade is 900 mm
 Wet Mix Plant

 Purpose
- To prepare wet mix macadam base material, which
comprises of crushed, graded aggregate and granular
material premixed with water in desired proportion

 Features
- WMM plant 100 Tonne per hour capacity shall be
ideal in normal work, which depends on quantity of
wet mix available and completion time
 Essential Components:
- Minimum 4 bins with total capacity 30 cum
- AC/DC variable speed motor fitted under each bin
to control flow of material coming under each bin
- Slinger conveyor provided to carry material from
bins to pug mill
- Aggregate over size rejection vibrating screen
provided between gathering and slinger conveyor to
reject over size material
- Water tank minimum 10,000 litre, self priming
pump, control valve, spray bar with water flow
meter provided to add desired quantity of water in
pug mill
- Hydraulically operated gob hoper provided to
collect and release mix material instantaneously, to
avoid segregation
- Control panel is provided to control all activities of
plant
DG Set 82.5 kva is adequate for 100 TPH WMM
in sequential manner and their precise process
Plant
control i.e. operation of various drives, control the
proportion of different sizes of aggregates/material
 Following information is provided in control panel
(i) Aggregate weight in tonne / hr
(ii) Total cumulative weight of aggregate in tonne
during specified period
(iii) Water flow in litre per minute
(iv) Water flow in litre during specified period
 Tractor Towed Water Tanker

 Features:
- Capacity of water tanker is
approx. 5000 litre and towed with
45 hp tractor

- Sheet thickness – 4 mm
- Sturdy chassis 150x65 mm, Single axle of 75 mm
diameter fitted with two tyres size 900 x 16
- Normal length - 3050 mm, width - 1400 mm, height
-1170 mm and weight 1350 kg
- Fitted with sprinkler system for uniform water
spraying
 Tractor Towed Trolley
 Features:
- It is fitted with hydraulic tipping arrangement
Single Axle Load
Capacity : 8 to 10
Tonne
Double Axle Load
Capacity : 10 to 12
Tonne
- Size of trolley: (i) Length -3350, (ii) Width -1950, (iii)
Height - 600 mm, (iv) Floor thickness – 5 mm, (v) Side
wall thickness – 3 mm
 Tractor fitted with Air Compressor Unit

 Purpose:
- Demolition of structures,
cutting of hard rock and

cleaning of road surface before tack coating

- Compressor can be used for operation of jack

hammer, breaker and pneumatic tools
 Features:
- Compressor unit can be fitted on tractor 45 hp and
above
- It can be used for operation of one jack hammer
 Pad foot Roller

 It is known sheep foot roller also

 It offers a pin point pressure as in
a heard of sheep walking across
the field

 It has front drum with multiple pads, which has

vibrating arrangement and rear axle fitted with
pneumatic tyres
 It is used for compaction of earth work in
embankments,
As roller moves over the surface, feet penetrate
where compaction deep in to the
the soil to produce a kneading action and pressure to
With repeated passes of the roller, the penetration
layer
of feetofdecreases
earth is required
mix and compact the soil from bottom to top layer
 It gives best result in compaction, when the soil is
clay or predominantly cohesive and impervious
- It can compact soils having as much as 50%
cohesive content
 It can travel at a speed of 25 km per hour
 Its working speed is 11 km per hour
 The amplitude / frequency on front drum is
(i) High – 30 hz / 1.7 mm (ii) Low – 33 hz / 1.0 mm
 It may weigh up to 15 tonne or more even
 Self Propelled Single Drum Vibratory Roller
 Purpose
- It is used in embankment and
soil compaction work

- It is know as soil compactor also

 Features
- It has got one steel drum in front and two
pneumatic tyres
- The steel drum vibrates during vibration mode
- The frequency of vibration is in the range 25 to 50
hertz
- The amplitude is in the range 0.8 to 2.0 mm
- The shape of pad foot in pneumatic tyres provides
lesser contact area, thus more static linear load
resulting better compaction
- Higher amplitude also provides better compaction
on earth and embankment
 Frequencies and Amplitudes for Different
Application
S.No Application Frequency Amplitude
(In Hertz) (In mm)
(i) Embankment of sub- 25-30 1.5-2.0
grade soils
(ii) Granular, stabilized 25-50 0.8-2.0
base and sub base
 Vibratory Tandem Roller

 It consists of two rolls, which get

vibration through hydraulic motion

 It is in the range 80 to 100 and 60 to 80 kN weight

 It is used for compaction on stabilized sub-base,
base and bituminous work
 The combination of static pressure and dynamic
force in vibratory roller effects better compaction
 Vibratory tandem roller of similar weight as of
static weight roller gives better compaction
 Its frequency is in the range 33 to 50 hertz and
amplitude 0.3 to 0.8 mm

Static linear load = Static weight of roller N/mm

Rolling width
 It can be used for compaction of loose layer
thickness up to 400 mm and compacted layer
thickness 200 mm
 Static Three Wheel Roller

 Purpose
- It is a conventional roller being
used for compaction since decays
 Features
- Static linear load is the deciding factor in
compaction

- Its static weight is 80 to 100 kN

- Rolling width is 1810 mm, front roll width 950 mm,

 rear roll width 535 mm with over lap of rolls 100
- Minimum static linear load on front and rear roll
mm
- Speed of Roller is in the range 1.5 to 9.0 km/hr
wheels
- Speed isof 28 kg/cm
Roller and 48 based
is selected kg/cmon the type and
(considering rollerbeing
depth of material weight 8 kN)
compacted
 It is used for ordinary rolling work, where deep
compaction is not required
 Static weight of roller may be increased from 80 kN
to 100 kN by filling water or sand ballast in hollow
cylinder
 Process Involved and Equipments Required in
Bituminous Work (BM, SDBC, PC)

 Preparation of Hot Mix

- Drum Mix Plant / Hot Mix Plant (Batch Type)
 Transportation of Hot Mix
- Tipper
 Tack coating
- Bitumen Pressure Distributor
 Spreading and Laying of Hot Mix
- Mechanical Paver finisher / Hydrostatic Paver
finisher
 Compaction of Bituminous Mix
- Tandem Vibratory Roller / Three Wheeled Static
Roller/ Pneumatic Tyre Roller
ESSENTIAL FEATURES OF HOT MIX
PLANTS
 Hot Mix Plant
 Purpose
- It is used to produce hot mix meeting to
specifications for laying on bituminous road
 History
- Initially inducted in 1910
- In 1930, the hot mix plants were developed to
prepare hot mix in
(i) Continuous type plant
(ii) Batch type plant
- Inducted in India through import in 1962 with
10/15 and 15/20 TPH capacity
- Developed in India in 1975
- These plants were continuous type and batch type
and 20/30 TPH capacity
- The improvement in technology resulted to import
Drum Mix Plant 60/90 TPH capacity in 1988
- Presently Batch Type Plant 135/165 TPH and Drum
Mix Plant 60/90, 40/60 TPH are normally used
 Capacity of Hot Mix Plant
 Capacity of hot mix plant is specified in two terms
- Out put of plant at 6 % moisture content
- Out put of plant at 2 % moisture content
Therefore, Hot Mix Plant 40/60 TPH capacity will
give production @ 40 TPH at 6% moisture content
and 60 TPH at 2% moisture content
- The production drops with increase in moisture
content
 Drum Mix Plant
 Basic features
- Aggregate gradation is controlled at cold feed end
- Aggregate heating, drying, bitumen mixing done in
same rotary drum
 Advantages
- Conventional plant components eliminated
(i) Gradation screen
(ii) Hot bins
(iii) Weigh hoppers
(iv) Pug mill
- Portability i.e. Easy to transport
- Higher efficiency
- Economy in terms to
(i) Basic cost
(ii) Fuel consumption
(iii) Man power
(iv) Maintenance cost
- Trouble free operation
- To achieve more quantity of mix meeting to
specification at relatively low temperature
- It is Environmental friendly
 Classification of Drum Mix Plant

 It is classified based on type of flow of aggregates

and hot gases inside the drum
 Parallel flow type
- Aggregate and hot gases flow in same direction
- Heating and mixing takes place in same drum
 Counter flow type
- Aggregate and hot gases flow in opposite direction
- Heating and mixing takes place in same drum
 Rap Aggregate Flow
Exhaust

Bitumen
Line
Hot mix discharge
Hot Mix Discharge

Drum Mix Plant (Parallel Flow Type)

 RAP Exhaust
Aggregate

Air
Burner

Bitumen
Air
Hot Mix
Discharge
Drum Mix Plant (Counter Flow Type)
 Drum Mix Plant ( Parallel Flow Type)
1 3 4 9 10
6 11
2
5 8
7

Essential Components
1 - Cold feed bins - minimum 4 no
2 - Aggregate over size rejection screed
3 - Cold feed conveyor
4 - Automatic weighing system
5 - Dryer cum mixing drum
6 - Exhaust control system
7 - Bitumen unit
8 - Primary dust collector
9 - Hot mix conveyor
10 - Gob hopper
11 - Control cabin
Optional
1.  Hot mix surge silo
2.  Pollution control device
 Cold Aggregate Feeder System
 Minimum requirement of bins - 4no
 Bin walls should have steep slope of 60-70° to
ensure smooth flow of aggregate

 It should have easily adjustable bin gates for

smooth flow of aggregates as per requirement

 Capacity of all four bins should be to run the plant

for minimum 30 minutes

 Width of bin to be more than loader bucket width

 Vibrator to be fitted in bin containing fines for their
smooth flow

 Vibrator is fitted in 1st bin of cold bin feeder system

 Belt conveyors are provided below each bin,

driven by synchronized variable speed motors

Vibrator

Manually operated bin gate

 Aggregate flow is initially controlled through gate
opening adjustment

 The aggregate / bitumen proportion is controlled

through variable speed motor

 Aggregate is weighed before drying i.e. necessary

correction is required to delete moisture content
from aggregates while adding bitumen

 Mineral filler ( Hydrated lime / Cement)

- It is added pneumatically in mixing zone
 Dryer Cum Mixer Drum

 It comprises of Rotary shell made of steel 10 to 12

mm thick, supported with two rings and four rollers
 Function:
- To remove moisture from aggregate
- To heat aggregate uniformly

- To blend aggregate and bitumen and achieve

homogenous mix within 140 - 175° C
 Function Of Dryer Cum Mixing Drum

Moisture removal Heating Coating

 Flight Arrangement in Dryer cum Mixing Drum

 It plays an important role in drying the aggregate

and preparation of mix
- It is provided with replaceable folded steel plates
(flights of different shapes and sizes) which performs
following functions
(i) Pushes material inside the drum
(ii) Eliminates showering of material directly in to
flame
(iii) Provides dense veil of material across width of
drum
(iv) Scatters material such that it gets heated
uniformly
(v) Blending of heated aggregate, fines, filler and
bitumen done uniformly
 Dryer cum mixing drum is divided in two zones
(i) Radiation / combustion zone
(ii) Conduction / mixing zone
 Aggregate retention ring
Kicker
Notched flights
flights
Sweep J flights Aggregate
Cup
discharge W flights inlet
flights

Fines Mixing zone Burner

Combustion zone
pipe
Bitumen pipe

Internal Section of Dryer Cum Mixing Drum

 Radiation / Combustion Zone:
- Kicker flights: These are fitted at the inlet gate
which pushes the aggregate quickly inside the drum
- W flights :These are known as energy saving flights.
These eliminate showering of aggregate directly
into flame
- Notched flights: These allow aggregate to fall
scattered, such that all particles are heated
uniformly
- Cup flights: These form a veil of aggregate so that
flame does not reach in mixing zone
 Aggregate Rotation Ring:
- It collects aggregate received in combustion zone
and moves it to mixing zone
 Conduction / Mixing Zone:
- J flights: These mix aggregate, bitumen, fines and
filler
 Quantity and arrangement of flights
- It depends on the out put of plant
 Hot Mix Plant with
low production rate,
maintains the veil
dense with uniformity

W Flights – Energy Saving

Flights
 Details of Burners Used in Drum Mix Plant
 Fuel
- The fuel used is light diesel oil / furnace oil

- Thirteen (13) kg air (approx) is required per litre of

fuel for complete combustion with no excess air.
This is known stoichiometric condition

 Principle of combustion in burner

- Air is forced through a constricted area to a point

where it meets the fuel
 Burner Used in Hot Mix Plant on Forced and Induced Draft Principle

 Burner used in drum mix plant is made specifically

for heating and drying aggregate
 Combination of forced and induced draft principle
is used in burners fitted on these plants
- 55% air by exhaust fan and 45% by air blower is
inducted through induced and forced draft
 45-50% Exhaust fan
Forced air
Excess air

Blower

Products of Steam
combustion
50-55% Induced air

Burner fitted in Drum Mix Plant based on Forced

And Induced Draft Principle
--
- 25% excess air supplied for complete combustion
within fraction of a second
 Function of Exhaust Fan in Drum Mix Plant

 It pulls out steam formed due to evaporation of

moisture in aggregate, excess air and products of
combustion to control the production of plant

45-50% Exhaust fan

Forced air Excess air

Blower

Products of Steam
combustion
50-55% Induced air
 Essential Features of Dryer cum Mixing Drum
(i) Speed of drum Approximately 10 to 12 RPM
(ii) Slop of drum Not exceeding 9 cm per metre
(iii) Length to Between 4 to 6
diameter ratio
(iv) Dwell time 2 to 3 minutes depending upon
(time taken by slope, length of drum, flight
material to pass arrangement, rotational speed
through drum and quantity of material flow
 Essential Features of Drum Mix Plant
 Burner should have auto ignition system

 Burner should have auto flame failure detection

system
- Photo cell is used for this purpose

- There should be no dribbling from nozzle tip when

burner is shut down
 Rate of drying should be uniform, to achieve
similar mix temperature
 Frequent start and stop of plant results
fluctuations in aggregate temperature and be
avoided
 Exhaust fan of adequate capacity to be provided in
exhaust control system to control fuel consumption
 In mixing zone, bitumen line should be as close as
possible to flights, so that bitumen is not picked up
in gas stream
 Bitumen line should be more in side drum to
increase dwell time for mixing and minimise dust
carry out to achieve better mix quality
- It should be three times the dryer drum diameter
from burner point
 In case of segregation due to coating of aggregate,
bitumen line be placed as much inside the drum as
possible
 Adjustment of Bitumen Line

Bitumen
line

 Liquid bitumen is not sprayed in to drum

 Liquid bitumen is pumped to a point, from where it
discharges in to drum by gravity
 Bitumen Fines Receiver

 Fines received
from dust collector
is inducted in dryer
drum in desired
proportion through
bitumen and fines Design of Bitumen Fines Receiver
receiver
 Primary Dust Collector
 It is initial pollution control device
 It works on centrifugal separation principle
- Cyclonic separator consists of large diameter
cylindrical shell having conical base
- Dust laiden gas after reaching at bottom spirals up
and sucked out (due to vacuum created by exhaust
fan) through a coaxial cylinder fitted at top
- Large size dust particles thrown out due to spinning
motion of gas
- These particles slide down and collected in a
hopper at bottom, which are sent to mixing zone; if
required
 Multiple unit of cones with longer length of
cyclones are preferred due to their higher efficiency
 The valuable fines lost in dryer exhaust may be
compensated with mineral filler at later stage
 Gas Out Let Through Exhaust

Gas In let
From Dryer
Exhaust

Fines

Screw System Collected

for retention Fines
of Fines
Cyclone Dust Collector
Secondary Dust Control System
Air
discharge

Water
flow
Air

Slurry
discharge

Open Spray Tower Type

 Secondary Dust Control System
(Ventury Scrubber Type)
Dirty
Air In Clean Air
let Out let

Water
Nozzles

Slurry
Discharge
 Control Panel
 It is the heart of plant to control all its activities
 It comprises of
- Start/stop button of motors. Start button will
energize contactor and motor
- Stop button or overloading of motor will drop
contactor and motor will stop
 Details of motors for various operations
- Bin vibrator
- Gathering conveyor
- Slinger conveyor
- Vibrating screen (Over size rejection screen)
- Fuel oil pump
- Drum drive
- Load out conveyor
- Hydraulic system for operation of gob hopper
- Screw conveyor
- Exhauster
- Hot oil system
- Bitumen pump
- Bitumen burner
- Screw conveyor
- Compressor unit
- Water pump motors for secondary pollution control

unit
 Systems Provided In Control Panel Of Drum Mix
Plant
1. Percentage of different materials
(i) Plant load 0-100% setting of plant capacity
(ii) Moisture 0-10% setting for moisture
content content
(iii) Aggregate 0-50% setting for feeder 1 to 4
bins
(iv) Bitumen 0-6% setting for bitumen
content
(v) Mineral filler 0-6% setting for mineral filler
2. Running weight of materials

(i) Running rate of aggregate in tonne/hour

(through load cell)
(ii) Discharge of bitumen pump in kg/minute
(iii) Discharge of mineral filler pump in kg/minute
3. Total Flow of materials during specific period
(i) Aggregate in tonne
(ii) Bitumen in kg
(iii) Mineral flow in kg
4. Total production in tonne
4. Temperature
(i) Bitumen tank
(ii) Mix material
(iii) Exhaust gases
 Capacity of Electric Motors Required in Different
Units of Drum Mix Plant
S. Details of unit Horse power of
No electric motors
60/90 TPH 40/60 TPH

(i) Auxiliary conveyors (4no) 8.00 8.00

(ii) Gathering conveyor (1no) 5.00 5.00
(iii) Vibratory screed (1no) 3.00 3.00
(iv) Slinger conveyor (1no) 5.00 5.00
(v) Thermo drum main drive (1no) 25.00 20.00
(vi) Exhauster (1no) 25.00 20.00
(vii) Dust collector’s discharge screw 1.50 1.50
(1no)
(viii) Load out conveyor (1no) 7.50 5.00
(ix) Hydraulic power pack (1no) 5.00 5.00
(x) Bitumen pump (1no) 5.00 5.00
(xi) Twin lobe air compressor (1no) 15.00 10.00
(xii) Mineral filler discharge screw 1.00 1.00
(1no)
(xiii) Burner air blower (1 no) 15.00 10.00
(xiv) Burner fuel pump (1no) 2.00 1.00
(xv) Fuel transfer pump (1no) 1.00 1.00
(xvi) Hot oil circulation pump (1 no) 1.00 1.00
(xvii) Others 5.00 5.00
Total 130.00 107.00
Recommended Temperature of Bitumen, Aggregate
and Mix

Bitumen Bitumen Aggregate Mix

grade temperature temperature temperature
65 150 - 165° C 150 - 170° C 165° C
Maximum
90 140 - 160° C 140 - 165° C 155° C
Maximum
 Requirement of DG Set for Drum Mix Plant

Total Power Requirement 130 HP 107 HP

for all Units or 97.5 KW or 79.8 KW
Normal power requirement 130X0.8= 107X0.8=
for operation of plant units 104 HP 85.6HP
@ 80% of total power or 78 KW or 63.8 KW
requirement
Assuming 90% efficiency of 115 HP or 95HP or
generating set, total power 85.8 KW 70.8KW
capacity
i.e. Minimum capacity of 100 KVA 82.5KVA
DG Set required
 Use of Waste Plastic in Bituminous Wearing Course

 Provision for use of waste plastic exists in Rural

Road Specification Clause 512

 It can be used in bituminous wearing course (25

mm SDBC, MSS and 20 mm PC)

 Waste plastic should conform to the size passing

through 2.36 mm sieve and retained on 600 micron
sieve
 The quantity of waste plastic shall be 6 to 8 % of
weight of bitumen
 The requisite quantity of waste plastic is injected
with a pipe under compressed air in to drum mix
plant

 The pipe shall be at 2/3 rd length of drum, which

shall
The waste plastic initially coats the heated
be at start of mixing zone
aggregate
 In next stage, Waste plastic coated aggregate is
mixed with hot bitumen for 15 seconds
 The temperature of binder shall conform to
temperature of grade of binder and type of mix
 The mix can be transported by tipper for laying
 The temperature of mix at the time of laying shall
be 110 to 120°C
 Discrepancies Observed in Drum Mix Plant
 Plants are not of repute make
 Width of bin is less than loader’s bucket width

 Vibrator not fitted in cold bin feeder containing

fines

 Load cell is not fitted on slinger conveyor

 Proper screen is not fitted in oversize vibratory

rejection unit
 Inclination of dryer drum is more
 R.P.M of Dryer cum mixing drum is on higher side
 Belt scraper not functioning properly
 Hot oil system not in operation
 Capacity of exhaust motor is less
 Control panel functions not calibrated regularly
 Increase in moisture content will result
- Higher fuel consumption
14
Moisture
12
content
(%) 10

Fuel 8
In litre/ 6
tonne
4
2
0
1 2 3 4 5 6 7 8
Effect of moisture content on fuel consumption
 Increase in moisture content will result
- Drop in production of plant
Production of plant 100

50
in tonne / hour

1 2 3 4 5 6 7 8

Moisture content (%)

Moisture content (%)

Production of plant in tonne / hour

 Effect of altitude on production rate
- Higher altitude results -
(i) Reduction in oxygen -
(ii) Increase in fuel density -
(iii) Ultimately reduction in plant out put
- Out put of plant is derated @ 3.5% (approximately)
every 300 meter rise in elevation above sea level
 Effect of Altitude on Production Rate of
Hot Mix Plant
3500
Altitude(In metre)

3000
2500
2000
1500
1000
500
0
1 2 3 4 5 6
Production rate 90 83.7 77.4 71.1 64.8 58.5
Altitude 0 600 1200 1800 2400 3000

Production rate (tonne / hour)

Production rate
Altitude
 Other parameters
- Calorific value of fuel
- Combustion efficiency due to flame impingement
and burner maintenance
- Presence of fines in aggregate
- Ambient temperature
- Design of drum mix plant which includes
arrangement of flight
- Preventive maintenance of plant
 Space Requirement for Drum Mix Plant

 The area required for installation of drum mix plant

is 35 metre x 35 metre which includes 2 days
aggregate storage also
Hot Mix Plant (Batch Type)
 Major Components of Hot Mix Plant (Batch Type)
1. Cold feed bins 8. Screening unit
2. Cold feed conveyor 9. Hot bins
3. Cold elevator 10. Weighing system
(Load cell)
4. Dryer drum 11. Mixing unit (Pug mill)
5. Dust collector 12. Mineral filler storage

6. Exhaust Stack 13. Bitumen storage tank

7. Hot elevator 14. Bitumen weigh bucket
 Different Operations Involved In Hot Mix Plant
(Batch Type)
 Aggregate storage and cold feeding
 Aggregate drying and heating
 Screening and storage of hot aggregates
 Storage and heating of bitumen
 Measuring and mixing of bitumen and aggregate in
desired proportion
 Loading of finished hot mix in tipper
 Hot Mix Plant (Batch Type) Fitted With
Rotary Motion

Screening drum

Hot bins
Burner
Cold bins
Slinger
conveyor
Pug mill
Hot mix discharge
 Features of Rotary Motion

 Drying and screening takes place in same drum

 Heating and drying takes place following counter
flow process
 Four sections of screens with screw flight plates on
outer surface sieve the aggregates
 Different sizes of aggregates are collected in hot
bins
Rotary Motion In Hot Mix Plant (Batch Type)

Screens

Different
Burner Compartments
 Hot Mix Plant (Batch Type) Fitted With
Reciprocating Motion

Vibrating
Hot elevator screen

Hot bins
Dryer drum
Cold bins Pug mill

s
Hot mix
Burner discharge
Reciprocating Motion of Vibrating Screen in Hot Mix
Plant (Batch Type)
 Hot aggregates Hot aggregate received from
hot elevator Over size
received from hot
rejection
elevator pass over a
series of vibrating
screens of different sizes

 The screens separate the aggregates based on their

specific sizes and deposits them in to hot bins
 Vibratory System of Screen

Over size
Vibrating
rejection Chute
screen
for 30 mm
and above

13 to 30 mm 0 to 2.5 mm
2.5 to 5mm
5 to 13 mm
 Hot Screens

 Function
- To separate aggregates in to specific sizes
 Scalping screen provided at top
- It rejects and carries off over size aggregate
-The intermediate size screens decrease in size from
top to bottom
- Last screen is for sorting fines
 Induction of finer aggregates in to a bin intended to
contain next larger size is called carry over
- Carry over normally fluctuates in bin no 2, which
affects job mix formula
- To prevent excessive carry over, screens must be
checked daily for cleanliness
 Screens must be clean, robust and maintain
balance with the capacity of dryer drum and pug mill
 Separation of Aggregates Through Screens

• Over size • Chu

30 mm te
Screens rejection

• 13 • 2.5 to • 0 to
to 5 2.5
• 5 to 13
30 mm
mm
 Different sizes of screens are one over the other in
sequential manner
 Hot Bins
 These are used to store heated and
screened aggregates of different sizes

temporarily
 Each bin has individual compartment / divided by
partitions - 4 in no
 Each bin to be of sufficient capacity to hold
aggregate and avoid their intermingling, while plant
is in operation at full capacity
 Capacity of all hot bins to be of about 10 batches
production
Each bin be equipped with an over flow pipe to
prevent
Over filling of bins will result heavy carry over of
excess amount of aggregates to operated
flow to
aggregates
Each bin compartment is pneumatically
and chances of damage to screens
other binsstage discharge gates control by computer
with two
 Hot Bin Leveling Indicator

 It detects aggregates quantity

stored in hot bins and indicates
the level when it falls below
certain limit

 Indicators may be operated electronically or

pneumatically
 Aggregates inside bin puts pressure on walls of bin
- Incase aggregate drops to predetermined level, it is
displayed through indicating lamps/ warning sign
provided in control panel and feeding of aggregates
restarts
 Bin Sampling Device

 It is used to take sample of hot

aggregates from bins
 It diverts flow of aggregates
from hot bins in to sample Sample of Hot
Aggregates Being
containers Received From Bin
 Fine particles fall on one side and coarse particles
on other side
This device assists to calibrate grading of aggregates
 Aggregate Temperature Measurement Device

 Thermocouple is used to measure aggregate

temperature and provided in hot bin containing fines
(1st bin)
 Weigh Box
 Measured quantity of aggregate is with drawn
from hot bins and accumulated in weigh hopper
 Sequence of aggregate collection is designed such
that fine aggregate is at the top of weigh hopper
-- It avoids their leakage from Bottom
 Aggregates collected in weigh hopper are
transferred in to pug mill for blending with bitumen
 Proportioning of Aggregates in Hot Mix Plant
(Batch Type)
1. 2.

Aggregate poured from Aggregate drops to a preset

discharge gate of aggregate weight of scale reading, the
bin in to weigh box discharge gate is closed.

3. 4.

Scale reading reaches a

The discharge gate of next preset weight, the
aggregate bin is opened discharge gate is closed
 This process continues to weigh different sizes of
aggregates and mineral filler in hot mix plant
(batch type)
5. These steps are repeated for remaining aggregate
sizes and mineral filler also
 Preparation of Hot Mix in Hot Mix Plant (Batch Type)

1. 2.

Gates of weigh box opened and Bitumen is discharged in pug

aggregate falls in pug mill mill through spray bar

4.
3.

Pug mill gates opened and

Aggregate and bitumen mixed finished mix discharged
 5.

Pug mill gates close to receive

next batch

Process for bitumen spray, preparation of mix and its

discharge in hot mix plant(batch type)
 Mixing Unit (Pug Mill)

 It is the chamber in which aggregate and bitumen

are mixed thoroughly to achieve homogenous mix
 Paddle tips, arms are made of wear resistant high
nickel hardened cast alloy steel for longer life and
low maintenance cost
 It has hot oil jacketing system to avoid mix
temperature drop
 Paddles must be selected such that there are no
dead areas in pug mill
 Dead area is a place where material can
accumulate out of reach of paddles and cannot be
mixed thoroughly

- If material level is too high, top

most material tends to float and
does not mix thoroughly
- If material is too less in pug mill,
it results raking of tip paddles with
out mixing material

- The clearance between

paddle tip and liner should Live
Zone
be less than half the
maximum aggregate size

- For maximum mixing efficiency, paddle tips should

be barely visible at surface of material during mixing
 Bag House Filter

 It consists of heat Clean

resistant fabric filters Air
Outlet
Dirty Air
 It can separate up to Inlet
one micro size particle
with 99% efficiency
Dust Collection Hopper

 It is normally used with batch type plant

 Surge Silo
 It is cylindrical shell with Hot Mix Plant
Conveyor
insulated chamber to
maintain temperature of
Surge
hot mix temperature up Silo
to 3 hours (approx)
Hot Mix
Receiver

 Ceramic wool and hot oil circulation can maintain

temperature up to 16 hours (approx)
 These are available in the range 50 to 200 ton
capacity
 It is used to store hot mix temporarily received
from hot mix plant
 Weighing system may be connected to holding bin
of silo to measure the quantity of hot mix being
loaded in each tipper
 Comparison Between Drum Mix Plant and Hot Mix Plant
(Batch Type)
S.No Operation and Drum Mix Plant Hot Mix Plant
Other (Batch type)
Parameters
(i) Aggregate At cold feed (a) At cold feed end
gradation end (b)Through
control gradation screed,
hot bins and weigh
hopper
(ii) Aggregate In rotary drum In rotary drum shell
heating, drying shell
(iii) Bitumen In rotary drum In pug mill
mixing shell
(iv) Flow of hot mix Through gob Directly from pug
hopper mill
(v) Flow of Parallel flow (in Counter flow
aggregate and conventional
exhaust gases plant)
(vi) Aggregate Does not exist. Exists
temperature Aggregate
measuring temperature
device assessed 10-
12°C less than
exhaust gas
temperature
(vii) Portability Transportation and Being
erection is easy voluminous
transportation
and erection is
time consuming
and needs crane
(viii) Efficiency (a)Higher thermal --
efficiency
(b) Higher production --
(ix) Basic cost Low Approx. 4 times
higher than
drum mix for
similar capacity
(x) Man power Less More
(xi) Maintenance Less Higher
/operational
cost
(xii) Operation Trouble free May result frequent
break down, if not
maintained properly
(xiii) Quality of mix - Comparatively better
(xiv) Environmental Friendly Not so friendly
effect
(xv) Suitability For all capacity For higher
production
(xvi) Production Less Comparatively more
cost
 Bitumen Pressure Distributor

 Purpose:
- It is used to spray thin, uniform and accurately
measured quantity of binder under pressure

- The rate of spray of binder should be kept uniform

by driving the pressure distributor at constant speed

- It is used for tack coating purpose

- Binder may be bitumen or bitumen emulsion

 Types of Bitumen Pressure Distributor:
- These are of two types
(i) Self Propelled Type
(ii) Tractor Towed Type
 Self Propelled Bitumen Pressure Distributor

 It consists of truck chassis of

adequate capacity suitable
for mounting bitumen tank
with all accessories

 The bitumen tank 5000 to 6000 litre capacity may

be used in highway works and 3000 to 4000 litre
capacity in rural road
Tractor Towed Bitumen Pressure Distributor

- Bitumen tank may be 1500 to

2000 litre capacity

- All accessories with bitumen

tank are mounted on chassis
and towed with tractor
 Bitumen Sprayer

 Purpose:
- To spray bitumen uniformly for tack
coat purpose, application in pot
hole/ patch repair and other small
bituminous works

 Features:
- It can be towed with tractor or road roller

- It is provided with accurate spray control system

 Paver Finisher

 Inducted at the beginning of 1930

 Inducted in India
- During 1962 through import
- Indigenously developed in 1975
- Hydrostatic Paver finisher with electronic sensor
control device developed in 1988
- Hydrostatic Paver finisher developed with provision
of laying two layers (BM and SDBC) simultaneously
in 2010
 Purpose of Paver finisher
 Used for laying
- Aggregate layer in base/sub base
- Bituminous layer
 To achieve good surface evenness and correct
grade as per road design specification for safe and
comfortable ride
 Specified transverse slope for water run off from
normal reach and on elevated curves
 To lay even layer thickness with homogenous mix
 Uniform degree of compaction by using tampers
and vibratory agitator
 Uniform bearing capacity over entire surface
 Even surface achieved by Paver finisher prevents
unfavorable impact loads created by surface
irregularities
 Classification of Paver finisher

It depends upon
 Type of Paver finisher
 Traction effort being applied
 Capacity of Paver finisher
 Mobility of Paver finisher
 Type of Paver finisher
 Mechanical Paver finisher
- Controls the screed level
manually which once set
gives the output as per
desired profile

- Screed remains fixed and minor adjustment done

by operator as and when needed
 Hydrostatic Paver Finisher with Electronic sensing
control device
- It receives information from sensors fitted on
Paver finisher and determines grade / slope
correction
- The corrected signals are sent to hydraulically
operated tow arms, which adjusts the screed
accordingly
- Screed adjustment done hydraulically
 Type of Traction Effort

 General
- Paver should be capable to apply sufficient traction
force to pushup a loaded dumper of 20/25 tonne
capacity at 10% gradient

 Classification
- Crawler mounted/ Tracked Paver finisher
- Wheeled Paver finisher
 Crawler mounted / Tracked Paver finisher

1 2

Smooth material flow through

1- Hopper, 2- Conveyors, 3- Auger, 4- Screed
 Driven by crawler tracks which have large contact
area of tracks and provides good traction effort
 Used for laying width up to 13 metre
 Suitable to work on soft or loose sub base, difficult
under foot conditions and steep gradient
 No slippage on tack coat
 Higher initial cost
 Transportation possible by trailer only, which is
little costly
 Wheeled Paver finisher

 It can have single/double

bogie axle wheels in front
and single/double drive
axles in rear

 Bogie wheels are made of steel with molded

rubber
 Driven wheels are pneumatic tires of adequate
capacity with good traction effort
 Single drive axle are suitable up to 5 metre and
double drive axle up to 8.5 metre
 Can travel more easily and at higher speed i.e.
making its use more convenient
 Time saving in movement from one lane to another
and end to end
 Used primarily on hard surfaces and narrow paving

width
 Initial cost is less
 Less traction in two wheel drive can result slippage
on tack coat
 Wear and tear of tires is on higher side
 Capacity of Paver finisher
It depends upon
 Paving width

 Paving thickness
 Type of material to be paved
 Out put (lay down rate in tonne per hour)
 Prime mover out put
 Paving speed

 Travel speed
 Paving Width of Paver Finisher

 Fixed screed width

- Used on Mechanical Paver finisher
- Screed width is 2.50 meter with mechanical
extension up to 4.00 metre

 Hydraulically
Extendable
Telescopic Screed
- It has telescopic extensions operated hydraulically
- Its basic width is 2.5 to 3.0 metre extendable up to
6.0 metre
- In some Pavers extension possible up to 10 metre
 Hydrostatic Paver Finisher for paving width beyond
10 metre
- Mechanical screed comprising mechanical
extension pieces, tampers, vibrator, heating system
etc. provided up to 13 metre width
 Paving Thickness and Type of Material to be Paved

 Paving Thickness
- Mechanical Paver Finisher -10 to 200 mm
- Hydrostatic Paver Finisher -10 to 350 mm
 Type of Material to be Paved
- Aggregate mixes such as aggregate for B.U.S.G,
Wet mix macadam, Dry lean concrete

- Bituminous mixes such as BM, DBM, BC, SDBC

 Out Put of Paver finisher

 It is measured in tonne per hour which depends

upon
- Width being paved
- Thickness being paved
- Paver speed
 Range of out put
- Mechanical Paver finisher up to 100 TPH
- Hydrostatic Paver finisher up to 700 TPH
 Paving and Travel Speed of Paver finisher
 It should match with feeding of material in hopper and its
laying on surface
 Mechanical Paver finisher
- Paving speed : 1.25 to 25 metre per minute
- Travel speed : 0 to 16 Km per hour
 Hydro static Paver finisher fitted with sensor
- Paving speed : 0 to 40 metre per minute
- Travel speed : 0 to 7.5 Km per hour
 Tracked Paver finisher
- Paving speed : 0 to 16 metre per minute
- Travel speed : 0 to 3.6 Km per hour
 Mobility of Paver finisher

 It depends on the frequency of its use and

distance
to which Paver is to be shifted from one site to
another
 Wheeled Paver is preferred, if frequent shifting is
involved
 Components of Paver finisher
 It consists mainly of two units
- Tractor Unit

- Screed Unit
Hydraulic tow arm cylinder
Tractor Unit
Raw mat Tow point
material Mat thickness
adjustment

Wheel
Paved mat material Screed
base
 Components of Paver finisher

 Tractor Unit  Screed Unit

- Motive power through - Screed plate
crawler or pneumatic tyre - Tamping unit
- Pushing roller - Tow arm assembly
- Receiving hopper - Mat thickness
- Feeding conveyor adjustment mechanism
- Distributing auger
- Crown control
- Transmission
- Screed heater
 Different Components of Tractor Unit
Pushing
 Pushing Rollers Receiving Pushing
Roller
Hopper Roller
- These are two cylindrical steel
rollers at front end of main
frame, with adjustable height
and oscillation arrangement
Auger Conveyor
-Properly spaced to contact rear
wheels of tipper, while material
is fed from tipper to hopper
 Hopper
- It should be of adequate capacity and abrasion
resistant steel plate
- Larger size of hopper assists
(i) To increase cooling time of mix
(ii) To continue work while interchanging tipper
 Feeding Conveyor
- It consists of two bar (slat) type conveyors with
variable hydrostatic drive arrangement to operate
them individually
- It moves material from hopper to spreading augers
- Its speed and size, governs the capacity of paver;
which is termed as lay down rate in tonne per hour
- Mix flow is controlled by flow gates
- Even flow of material to screed be maintained
- Conveyors speed to be adjusted by material limit
switches

 Required head of material to be maintained

constantly to avoid surging of screed
 Auger System

- Consists of two spreading

augers with independent drive
which distributes material
evenly
- Augers are operated hydraulically

- Augers can be raised or lowered to suit varying

layer thickness

- Capacity of auger depends upon its diameter, pitch

of flights, revolutions per minute
 Ultrasonic Sensor

 It is an optional item
 It is a sensor which does
not come in contact with
mix materials being laid

 It is provided at auger ends (out board position) of

screed
 Its purpose is to allow smooth and desired quantity
of material flow to screed in best possible manner
 Control the quantity of mix material flow
- It can be controlled by adjusting revolutions of
- It can be operated conveniently by turning a
auger automatically
governor
For larger production, sensors may be provided in
placed on out side of sensor
receiving hopper and feeding conveyor system also,
to control augers for better control of material flow
 Screed Unit – Its components and function

 Its purpose is to lay and finish the mat surface to

desired profile, grade and slope
Components of Screed Unit :
 Screed
- It is attached to Paver by two arms at tow points
on each side
- It is floating, self leveling type
- It strikes off the material before further compaction
 Hydraulic Tow
Cylinder Arm
Screed
Tow
Point

Wheeled Paver
- The forward movement of Paver tows the screed
unit and paving material flows under screed. It
causes screed to float on mat or material, thus
establishing mat thickness
- Screed is completely free to float up or down

- It follows its own angle of attack depending on

combination of forces acting upon screed

Screed’s Manual Adjustment

Angle Of Attack

Function of Screed
 If head of material is too If head of material is too low,
high, screed is forced screed is forced downwards
upwards
Ideal Condition
during Paving

If 2/3rd auger screw is covered with material, total forces

acting on screed are in equilibrium and it maintains desired
level
Head of Material Affecting Height of Screed
 Vibration System of Screed Plate
 It is operated hydraulically with low amplitude and
high frequency ranging 0- 3700 vibration per minute
to screed plate
 The tamper edge marks on pre-compacted mat are
smoothened by vibration of screed plate
 It gives further smooth finish to the mat
 Frequency depends on mat thickness, density,
working speed and material specification
 1

2
1- Tamper, 2- Vibrating screed
Screed equipped with Tamping And Vibrating mechanism
 Tamping Unit
 It consists of tamping bar with chamfered edges
and provided along length of screed
 The tamping bar moves up and down vertically
with
(i) Amplitude varying 3 to 5 mm
(ii) Frequency 0-2000 strokes/minute
- It is operated hydraulically
- The tamping bar provides initial compaction to the
material, which facilitates the movement of screed
 Tow arm assembly

- The signal received from control panel energizes

the hydraulic pump which lifts/lowers the tow arm
assembly, ultimately raising/ lowering the screed
 Screed and Tamping Heating System

 It is essential to preheat the screed plate and

tamper to desired temperature before paving the
hot mix

 It prevents the bitumen picking up or sticking to

screed plate or tamper bar

 Heating may be done in three ways

- *Diesel / Oil fired burners
- *Gas burner
*It needs 15 minutes time for heating
- Electrical heaters (It needs extra generator and 45
minutes for heating)
 Recommended Temperature of Mix, Laying and
Compaction

Grade of Mix *Laying *Rolling

Bitumen Temperature Temperature Temperature
65 Maximum Minimum Minimum
165° C 125° C 90° C
90 Maximum Minimum Minimum
155° C 115° C 80° C

*Laying and Rolling should not be carried out, when the

temperature drops to minimum level
 Screed Plate Adjustment in Positive Crown Position

Screed Plate Adjustment in Super Elevation Crown Position

 Essential Parameters To Control Mat Quality

 Adequate head of
material covering almost
2/3rd auger shaft should
Ideal condition of Auger Screw

be available to keep the forces in equilibrium

 Continuous Operation of Paver
- Paver should be allowed to work continuously
uninterrupted
- In case it is not possible to maintain constant speed
of Paver, the interruption to be minimised and
change in paving speed carried out gradually, to
achieve smoother mat finish
- Paver should not be allowed to await the tippers
for unloading the material in to hopper
- Paver speed should match the rate of material
supply in to hopper to allow its continuous operation
and eliminate its starting and stopping
- During restart of Paver, the material force against
screed increases, causing the screed to rise. It takes
approximately 3 to 4 tow arm length to destabilize
it at previous planned angle with resultant bump.
Thus, restart of Paver to be avoided

 Appropriate tire or track pressure to be

maintained on Paver finisher

- Tire condition and air pressure to be checked

periodically
- Tire pressure to remain same on both sides of Paver
- Low tire pressure will result uneven mat surface
- There should be no built up of material on tires/
track, which spoils the surface
 Exchange of tipper
- Exchange of tipper to be carried out as smoothly as
possible to avoid disturbing the smooth,
uninterrupted, forward motion of Paver with
following precautions
- Mix delivery tipper should stop close to Paver
- Paver should pick up the tipper for shifting of mix
during running
- Never allow tipper to bump the Paver
- Tipper driver should apply light pressure on brakes
which is sufficient to maintain contact with Paver
- Avoid to pull the tipper away till complete material
is dumped in to hopper
- Bunching of tippers should not occur at Paver site
 Direction of travel

Adjustable
Flow Gate

Tipper being Push Conveyor Helical Vibration

pushed forward Roller Assembly Screw of of Screed
by Paver Auger

Mix Being Unloaded From Tipper to Paver For Laying

- All tippers to follow the shortest, most practical
and similar route from Plant to Paver site

- Ensure, all tippers arrive in same sequence in which

they were loaded at plant site and unload them in
hopper accordingly

 Mechanical condition

- Maintain Paver in sound mechanical condition

following manufacturer guidelines
- Set tow points corresponding to mat thickness
- Adjust screed to desired crown profile
- Adjust height of auger suitably
 Mix design
- Maximum aggregate size, proportion of aggregate,
fines and bitumen to be selected carefully
- Mix temperature should be uniform while dumping

it from tipper to hopper of Paver

 Automatic Leveling Control System
 It is the main system, which controls the mat
thickness during operation of Paver
 It may be either sonic sensor or string line
 It comprises of following components
- Control box –2 no (Left side -1 no, Right side – 1 no)
- Elevation control sensor – 2no
(Left side -1 no, Right side – 1 no)
- Slope sensor – 1no. (Fitted in center)
 Junction Junction box
Control box Slope Control box
box left right side
left side sensor right side
side
Elevation
Elevation control
control sensor
sensor left right side
side

Different components of automatic leveling control system

Function of Automatic Control System in Hydrostatic
Paver Finisher
 Elevation Control Sensor
- It measures screed height and sends information to
control box
 Slope Sensor
- It measures screed slope and sends information to
control box
 Control Box
- The signals received from Elevation control sensor
and Slope sensor are sent to hydraulic valves.
- The hydraulic valves operate tow point cylinders
and adjust screed height and screed slope
 Junction Box
- All signals in correspondance between Elevation
Control Sensors, Slope Sensor and Control Box pass
through Junction Box
Function Of Automatic Leveling System In Hydrostatic Sensor
Paver Finisher
Control Box-2no. Evaluates and sends corrected signals to Hydraulic
valves through Junction Box

Elevation Control Junction Box-2no. All Slope Sensor-1no.

Sensors -2no. signals from Elevation Measures screed
Measures screed / Slope sensor to slope and sends
height and sends Control Box and information to
information to control Control Box to control box
box through Junction Hydraulic valves pass through Junction
Box through Junction Box box

 Tow point cylinders – 2 nos. adjusts screed height and screed slope

 Screed – 1 no. Height and slope adjusted as per above information

 Pneumatic Tyre Roller
 It consists of Pneumatic tyre

- It has two tandem axles

with 3 to 4 tyres in front and
4 to 5 tyres in rear

 The weight per wheel load is the deciding factor for

compaction

- The machine with lesser wheel load has lesser

compaction performance specifically in depth
 The compaction effect is determined by two
parameters
(i) Wheel load
(ii) Ground contact pressure of tire, which is
correlated to tire inflation pressure
- Number of wheels affect the wheel load directly
 Pneumatic tyre ensures more even load
distribution on road surface and leads to equal and
uniform compaction
 -Tyres are designed such that
they over lap 30 to 50 mm
(approx.) at normal pressure

- Overlap between pressure contact area is more

important for uniform compaction effect on
bituminous layer.
Wheel Load = Total weight of PTR + Ballast*

Number of tyres
*Scrap iron bars or sand is used as ballast
 Pneumatic tire rollers normally 7 to 9 wheels with
maximum wheel load of 3000 Kg per wheel is
sufficient for compaction
 Role of Tyres
- Tyre geometry plays an important role on
compaction characteristics
- Tyres must be inflated to nearly equal pressures
with variation up to 5 psi, to keep uniform pressure
during rolling
 Bitumen Pickup
- In initial rolling, pneumatic tyre picks up bitumen.
Diesel may be applied while tyres are warming up
Alternately
- Roller may be run on a surface which has already
been compacted by steel wheel rollers and still hot
- Once temperature difference between bituminous
mat and tyre is less than 20°C, bitumen will
not stick to tire
 Forces exerted by pneumatic roller during
compaction are shown below

Pressure contact area overlaps.

Apart from individual pressure
bulbs, the interaction of pressure
bulbs give greater depth effect Kneading Effect
 Compaction of Bituminous Layer

 Rolling on bituminous layer to be carried out in

three consecutive phases
- Initial / Break down Rolling
- Intermediate Rolling
- Finish Rolling
 Initial / Break down Rolling
- Roller should be close to Paver finisher, so that mix
can be compacted at highest temperature
- Static roller / Tandem vibratory roller should follow
the Paver in sequential manner

Direction of travel

Tandem Vibratory Roller Following Paver During Break

Down Rolling
 Direction of Travel

Static Roller Following Paver During Break Down Rolling

 First pass of roller on freshly placed mat is most

important and critical phase of rolling

- Drive rolls put more force, therefore, same should

face the paver finisher for better compaction
- In static roller, rear rolls are drive rolls, thus rear
rolls should face the paver finisher
- In initial rolling, air voids are removed, mix
particles
brought closer which helps in retaining heat
 Two passes of breakdown rolling are usually
sufficient for compaction
 If mix is too hot, it will cling to steel drum of roller.
In such case roller to be back off, wait few minutes
till mat is cool
 Mat too hot

Mat to compact at highest

possible temperature

Mat too cold

Effect of Temperature on Compaction of Mat

 Maximum temperature for break down rolling can

be established by trial and error method. Any how it
is normally 160°c

 Roller used may be 8/10 ton static roller or tandem

vibratory roller 6/8 ton in static mode
 Intermediate Rolling
- It should follow break down rolling and as close as

possible to roller being used in break down rolling

- It should continue till desired mat density has been
achieved
- Roller used may be 8/10 ton static roller or 6/8 ton
tandem vibratory roller in vibration mode or
Pneumatic tire roller with minimum 5.6 kg/sq cm
 Finishing Rolling
- Density should have been achieved prior to start of
finishing rolling operation
- It is done solely for improvement of surface finish,
therefore, for removal of roller marks or other
blemishes left during rolling

- The mix should be warm (approx 80°c) for removal

of roll/tire marks
- Roller used should be 6/8 ton tandem vibratory
roller in static mode
 Essential Tips For Use of Vibratory Road Roller On
Bituminous Work

 The highest compaction energy produced by

vibratory tandem roller should be in following
sequence

(i) First pass to be carried in low compaction energy

i.e. with low amplitude or in static mode

- It allows the machine to roll without damaging the

material sticking to the roller
(ii) Next passes to be done in high amplitude,
suitable for compaction of bituminous mix

- Do compaction until roller shows the tendency to

jump or bounce

(iii) Following passes to be carried out with low

amplitude

(iv) Final pass to be done in static mode

- During initial high energy setting, compaction will
be achieved in deeper zones of the layer
 While changing from higher to lower energy
settings at later stage, compaction will be achieved
from lower to upper zones of the layer

 If machine is used for too many passes in lower

energy setting before being put to higher energy
setting, higher energy will break down the
compaction already achieved in upper zones of layer

- Never put the machine in lower energy setting for

more than two passes, before being put it to higher
energy setting
 Result of Over Compaction
- If maximum density has been achieved; over
compaction will result to change the working
principle of machine from ground contact vibration
to impact operation

- It will crush the surface material or make it loose

- It will damage the vibratory roller leading to
expensive repair
Loading and Transportation
of WMM / Bituminous Mix
- Steps To Be Taken To Avoid Segregation
 Loading of Bituminous Mix in Tipper

Improper method of loading Proper method of loading

bituminous mix from Hot mix bituminous mix from Hot mix plant
plant to Tipper to Tipper

 The loading of bituminous mix from Hot mix plant

in Tipper should be carried out in multiple cone
system
 Multiple cone system
- The first loading is done near cabin end
- Second loading is done at tail gate end
- Third / last loading is done at top of first and
second loading
- It is desirable to have three or four cones
depending on size of tipper
Thank You