How to Set Up a Portable Asphalt Plant

Whether hot-mix asphalt (HMA) production occurs on a permanent site or a temporary, remote site, asphalt plant needs vary from relocatable plants, to skid-mounted plants, to portable plants, based on location.

Setting up a portable unit at a remote site may seem daunting if producers are first-timers to the process, or even seasoned professionals who haven’t performed set-up in a while.

Regardless, setting up a portable plant, whether it’s the Asphalt Drum Mixers Inc. (ADM) EX Series Model 8844—or a competitive, portable plant of similar size—the same basic rules apply.

Remember to think of safety first. Read the manual and understand any safety issues before performing any work.

It’s important to refer to the set-up manual of the particular brand of portable asphalt plant. However, the following instructions will provide an excellent overview of the process, whether these instructions are being used as a primer or merely a refresher.
There are four main steps in setting up a portable asphalt plant.

1. Prepare the site;
2. Erect the equipment;
3. Install electrical cables and plumbing; and
4. Test and calibrate equipment.

1. Prepare the Site

After selecting the site location, take a few things into consideration before setting the plant. These are, among others: foundations, wind direction, stockpile location, equipment and truck traffic, and your neighbors.

Foundations

When it comes to portable plants, the type of foundations you may need can vary depending on the supports provided by the manufacturer, the soil conditions, and length of time the plant will be at the location. Fully portable asphalt plants, like the ADM EX Series counterflow asphalt plant, allow for a quick setup, directly on the ground, and in most cases, eliminate the need for any type of foundation support or cribbing. Other options for foundation support are optional full-width sand shoes, wood or steel cribbing such as railroad ties, large stones, or concrete pads. You will want to select the support that will allow you to do a quick set-up without compromising a stable support.

Wind Direction and Dust Control

One of the most overlooked considerations for an asphalt plant set-up is for wind and dust control. As materials and the ground become dry, dust may be created around the asphalt-plant site and can become a nuisance if not controlled properly. The wind may blow the smaller materials and dust around the site and this dust may damage sensitive electrical parts, increase cleaning and maintenance of filters and bearings, and equipment. Locate the plant so that any possible dust is carried away from the equipment, control house, and other buildings and neighboring lands. A dust control program that includes frequent watering of bare drives and lots, frequent maintenance, and personal protection equipment (PPE) should be implemented.

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Stockpiles

Good stockpiling procedures are crucial to the production of top quality asphalt mix. Proper stockpiling is important to allow for proper water drainage and to minimize material size segregation.

Firm, clean surfaces should be made ready and precautions should be taken to keep stockpiles separated to prevent intermingling that often leads to loss of proper gradation. Separation of the material is achieved by keeping stockpiles widely spaced, using bulkheads between stockpiles, or by storing aggregate in bins. Where bulkheads are used, they should be strong enough to withstand aggregate weight and should extend the full depth of the stockpiles.

Stockpile locations should provide ease of access to both the loader operator and the delivery vehicle while also minimizing cross traffic.

Equipment and Truck Traffic

Efficiency is at the core of any profitable system, so designing smooth traffic flow for your equipment, delivery trucks, and personnel should be top priority. Traffic flow should be designed to minimize travel time, cross traffic, blind spots, and collisions. Allow for short straight lines where possible to minimize time, fuel consumption, and wear on equipment, and to lower emissions. Eliminating cross traffic and blind spots minimizes collisions and other accidents as well as reducing stops and traffic jams.

Neighbors

Odds are that if you are installing a portable plant you don’t plan on being around too long. But whether your project lasts two months or two years, it’s always a good idea to be a good neighbor.

Always be conscious about your actions and how they affect others around you. Proper plant and lot maintenance, minimized truck traffic, reduced noise, and controlling fugitive dust will help keep your neighbors happy. Maintaining a good reputation with your neighbors will go a long way now and with future projects.

2. Erect the Equipment

Before any work is performed, please read and understand any safety issues relative to the equipment.

In most cases, the first piece of equipment to be erected is the surge system. There are different types of portable surge systems: some that require cranes and some that are self erecting, such as the ADM self-erecting silo. Simply maneuver the truck rig and silo unit into position marked by the installation drawings and lift the silo and drag slat conveyor using the supplied hydraulic pump unit. Follow manufacturer’s instructions for operating the hydraulic pump unit.

If the portable silo is not self-erecting, then a crane will be required to lift it and the drag slat conveyor into place. It is best practice to consult and hire a professional when erecting equipment with a crane. Check the shipping bill or contact the equipment manufacturer for equipment weights to properly size the crane for lifting.

• Always use safety equipment and safety harnesses when necessary or required.
• Always use proper rigging techniques when lifting any equipment.
• Always check the crane, hooks, and clevises and lift cable slings for correct lifting capabilities.
• Always use a man-lift, scissors-lift, or cage when required, to connect or remove the lift cable slings from the lifting eyes.
• Remove the other shipped items from the trailer. Position them in a safe and clear zone away from the silo erection area.
• Locate the necessary nuts, washers, and bolts for assembly of the unit. Count and size all bolt holes for correct bolts necessary.

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Silo

• Install legs to silo with the silo on its side. Some silos may have the legs installed at the factory.
• For large or wide silos, bolt the legs onto the silo base and install the cross braces before tightening leg bolts.
• If rigging allows it, install any bolt on handrails or batch hopper (bolt-on type).
  Ladder-cage assembly installation can be performed before or after the silo is lifted into position.
• Tighten and secure all hardware.Connect lift cable slings to the lifting eyes on the silo top.
• If a second crane is used, connect lift cable slings to the lifting eyes on the silo base.
• Be aware, the weight of the silo may cause the cables to go slack as they are lifted over center.
• Lift the silo and place on the foundation plates.
• Weld and/or bolt all four legs to the foundation plates.
• Remove the cable hooks and release the crane cables.
• Rig, lift, and mount the drag cradle, batch hopper, and hand railing if not previously mounted.
• Bolt down to silo using bolts supplied.
• Remove the cable hooks and release the crane cables.

Drag Slat Conveyor

• In preparing to lift the drag slat conveyor, position the unit so that only a single lift is required to put the conveyor directly into the foundation position.
• Depending on the size of the drag slat conveyor and the size of the crane(s), lift the drag slat conveyor with the lifting eyes on both ends of the conveyor. Be aware, the top end is heavier.
• Lift drag conveyor, position head section on saddle, and place drag base on the foundation plate.
• Weld and/or bolt drag base to the foundation plate.
• Remove the cable hooks and release the crane cables.
• Install or secure any drag supports that may be included.
• Install any items such as bypass chute, guard rails, stairs, etc. that will require the use of the crane.
• Remove the cable hooks and release the crane cables.

The Drum Unit

• For safety reasons, do not allow anyone to enter the area below the drum unit until it is pinned and secure.
• Use the foundation prints to find the measurements for positioning the unit.
• Measure and mark the position of the unit from the drag chute.
• Maneuver the truck rig and drum unit over the exact position so that the discharge point lines up to the drag slat conveyor receiving point.
• Lift and level the unit into place using the crank-down or hydraulic legs that came with the unit.
• Some equipment may have fixed legs that require manual placement and shimming to level the unit.
• Secure and pin all support legs to frame and bolt and/or weld legs to foundation plate if installed.
• Install the receiving chute on the drag slat conveyor and the discharge chute on the drum unit.
• Install and/or fold down the receiving chute or slinger conveyor, breeching box, hand railing platforms, ladders, and any other required items.

Weigh Conveyor

• Use the foundation prints to find the measurements for positioning the unit.
• Measure and mark the position of the unit from the receiving chute on the dryer or fast conveyor.
• Maneuver the truck rig and conveyor unit close to position.
• Unfold or lift the weigh conveyor head unit into working position.
• Maneuver the truck rig and conveyor unit so that the material will fall into the center of the receiving chute.
• Then, unbolt the scalping screen from the conveyor. At no time must the scalping screen touch the weigh conveyor.

Aggregate Feed System

• Use the foundation prints to find the measurements for positioning the unit.
• Measure and mark the position of the unit from the weigh conveyor.
• Maneuver the truck rig and bin unit close to position.
• Unfold the collecting conveyor and place at the correct angle to match the weigh conveyor.
• Install conveyor supports and or chains to hold conveyor in position.
• Maneuver the truck rig and bin unit into position so that when the collecting conveyor discharges onto a screen, it discharges onto the top one-third section of the screen cloth.
• Lift and level the bins using the crank or hydraulic legs provided, and bolt and/or weld the legs onto the foundation pads if installed.
• Install or position into place any ladders, platforms, bin dividers, bin extensions, and other required equipment.
• If equipped, install or position the folding bulkheads and tie down cables into working position so that the ramps can begin being filled.

Baghouse

• Use the foundation prints to find the measurements for positioning the unit.
• Measure and mark the position of the unit from the drum unit.
• Maneuver the truck rig and baghouse unit into position.
• Install or position ductwork on the both the drum unit and baghouse. This may require the use of a crane. Seal all duct unions using provided materials.
• Install or position into place any ladders, platforms, railing, airlocks, blowers, dust augers, stacks, and other required equipment.

Asphalt Storage Tank

• Use the foundation prints to find the measurements for positioning the unit.
• Measure and mark the position of the AC tank unit from the drum unit.
• Maneuver the truck rig and conveyor unit close to position.
• Mount the asphalt pump on the back of the asphalt tank when both units are supplied by ADM.
• The asphalt tank and pump should be mounted as closely as possible to the AC injection lines.
• The asphalt tank must be supported solidly.

Fuel Tank

• Use the foundation prints to find the measurements for positioning the unit.
• Measure and mark the position of the unit from the center line of the drum unit.
• Maneuver the truck rig and conveyor unit close to position.
• The fuel tank must be at least 50 feet from the burner.
• The fuel tank should be equipped with a fuel filter.
• The supplied pump must also have a filter.
• All lines must be sized to the recommendations of the burner manufacturer.

RAP System

• Use the foundation prints to find the measurements for positioning the unit.
• Measure and mark the position of the unit from the receiving chute on recycle collar.
• Maneuver the truck rig and conveyor unit close to position.
• Unfold or lift the conveyor head unit into working position.
• Maneuver the truck rig and conveyor unit so that the material will fall into the center of the receiving chute.
• Lift and level the RAP bin(s) using the crank or hydraulic legs provided, and bolt and/or weld the legs onto the foundation pads if installed.
• Install or position into place any ladders, platforms, bin dividers, bin extensions, and other equipment required.
• If equipped, install or position the folding bulkheads and tie down cables into working position so that the loading ramps can begin being filled.

3. Install Electrical Cables and Plumbing—Electrical

• Move generator into position. Select a location near the plant and fuel source but where noise will be minimal for operations. The farther the location, the less the sound will be, but the larger the power cable might need to be.
• Install and connect the main power cable, and test the generator for proper voltage.
• Begin with the farthest cable, lay out the high voltage motor wire along provided cable trays, and plug into main MCC, typically at the control room.
• Secure the cable along the way with proper wire ties.
• Continue until all motors are plugged into their proper outlets.
• Lay out the 110V control cables along the cable trays securing them so that they do not lie on top of the high voltage wires.
• Secure the cable along the way with proper wire ties.
• Continue until all control cables are plugged into their proper outlets.
• Lay out the low voltage signal cables along the provided cable trays assuring that they do not lie alongside the high voltage cables, crossing only when necessary.
• Secure the cable along the way with proper wire ties.
• Continue until all signal and low voltage cables are plugged into their proper outlets.
• Some cables may need to be hardwired.

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Plumbing

• Simplify plumbing connections for the asphalt and fuel tanks using hoses with quick connections.
• Hot oil-heated flex hose packages with quick connections available from ADM can provide quick connections from the asphalt pump to the plant.
• Fuel hoses with spill-proof quick disconnects can make fuel connections safe, quick, and easy.
• Always check all plumbing for leaks, wear, and damage to avoid any unwanted spills.
• If your plant is not equipped with quick connections, use the plumbing diagrams provided by the manufacturer to connect the equipment.

4. Test and Calibrate

• Once the equipment is installed and all electrical connections are made, it’s time to test and calibrate. (The following steps may need to be performed by a licensed electrician.)
• With all breakers in the “off” position, check power at the top of the main breaker.
• If power is correct, turn on main breaker and check power at the bottom of the main.
• Continue this for all breakers in the circuit to assure all connections and power are correct.
• After assuring power is correct, continue testing by turning all motors and checking rotations.
• Once all electrical is tested, perform calibrations of the asphalt pump, weigh conveyor, cold feed bins, surge system scales, and other systems such as level indicators, temperature sensors, and others.
• Follow the manufacturer’s instructions for proper testing of the system on your plant.

When asphalt producers follow the portable asphalt plant set-up instructions that manufacturers provide, producers are able to get plants set up safely, properly, and in a reasonable time frame to get their operations up and running.

Carlos Cardenas

Carlos Cardenas is a sales engineer for ADM Asphalt Drum Mixers Inc. with 25 years of expertise in the asphalt plant manufacturing industry. For more information, contact him at (260) 637-5729.