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As a professional enterprise specializing in the integration and service of core equipment for road engineering, Asian Construction Equipment Group Co., Ltd. (abbreviated as​ ACE Group) has been deeply involved in the full lifecycle service of asphalt mixing plants for many years.  We understand that the installation and lifting process is a crucial prerequisite for ensuring optimal equipment performance and extending its service life. Asphalt mixing plants have complex structures and numerous heavy components; the quality of their installation and lifting directly determines subsequent production efficiency, product quality, and operational safety. Based on this, and drawing upon ACE Group’s extensive project experience, this guide has been compiled to systematically explain the core processes, technical points, and management requirements for the installation and lifting of asphalt mixing plants, providing professional reference for industry colleagues and project implementation.

I. Preliminary preparations: Laying a solid foundation for construction.

(一) Site survey and foundation acceptance

Before commencing installation and lifting operations, a comprehensive and detailed site survey must be conducted.  Key survey aspects include: site topography and ground leveling, geological bearing capacity testing (which must meet the equipment foundation design load requirements, generally not less than 200 kPa), surrounding environment (such as safety distances to nearby buildings, high-voltage lines, and major roads), and a detailed survey of underground utilities (water supply and drainage, gas, and communication cables). The survey results must be compiled into a dedicated report, which will serve as the basis for optimizing the equipment layout and lifting plan, ensuring that the site’s spatial dimensions, bearing capacity, and access conditions meet the operational requirements of the mixing plant main structure, auxiliary equipment, and lifting equipment.

Simultaneously, the concrete mixing plant foundation was strictly inspected according to the design drawings and the “Code for Acceptance of Construction Quality of Concrete Structures” (GB 50204-2015).  Key aspects checked included: foundation geometric dimension deviations (allowable deviation ±5mm), top surface elevation (allowable deviation ±3mm), surface flatness (allowable deviation 2mm/m), and concrete strength (required to reach 100% of the design strength). The foundation surface must be free of structural defects such as cracks, honeycomb, pitting, and exposed reinforcement. The positional deviation of the anchor bolt pre-reserved holes must be controlled within ±2mm. Only after the inspection is passed and the acceptance documents are signed can the subsequent installation process begin, providing a solid foundation for stable equipment installation.

(二) Review of construction drawings and technical briefing

Led by the technical lead, the construction team, supervision unit, equipment suppliers, and relevant personnel from the client side will conduct a review of the construction drawings.  The core focus of the review will be on: the rationality of the overall layout of the mixing plant, the accuracy of the installation coordinates of each component, the feasibility of the connection node structures, the safety of the lifting process, and compatibility with surrounding facilities.  Any design conflicts, dimensional deviations, or technical ambiguities in the drawings will be identified and resolved promptly. For critical aspects such as the lifting path of large modular components and high-altitude docking accuracy, the drawing plans will be optimized based on the results of on-site surveys.

After the drawings are reviewed and approved, the technical supervisor conducts a specialized technical briefing for the construction team, clarifying the technical parameters, quality control standards, safety operating procedures, progress milestones, and emergency response measures for each construction stage.  The briefing content is detailed down to critical details such as the lifting angles of specific components, tightening torque, and precision tolerance ranges.  This is done through a combination of written briefing records and on-site practical demonstrations to ensure that every construction worker clearly understands the work requirements, laying a solid foundation for the smooth progress of the construction project.

(三) Preparation of construction equipment and tools

Based on the production capacity of the asphalt mixing plant (e.g., 2000 type, 4000 type), the weight of core components (e.g., the weight of the mixing unit can reach 50-150 tons), and the installation process requirements, construction equipment and tools are precisely configured.  Lifting equipment selection must meet a safety factor of 1.2 times the maximum lifting weight. Commonly used equipment includes: truck cranes (50-200 tons), crawler cranes (for ultra-heavy components or complex sites), flatbed trailers (for component transportation), and forklifts (for handling small components). All lifting equipment must be certified by a third party, be within its validity period, and be equipped with safety devices such as torque limiters and height limiters.

At the same time, prepare specialized installation tools and consumables, including: high-precision torque wrenches (torque accuracy ±3%), spirit levels (accuracy 0.5 mm/km), theodolites (angular accuracy 2″), jacks, winches, specialized lifting equipment (steel wire ropes, shackles, balance beams), and sealing materials (high-temperature resistant sealant, rubber gaskets), etc. All tools must be pre-calibrated, and consumables must meet the design material requirements to ensure the continuity and reliability of the construction process.

II、Core Lifting and Installation Process: Precise and Efficient Positioning

(一) Lifting and installation sequence planning

Following the core principles of “prioritizing main components over secondary ones, larger components over smaller ones, lower components over upper ones, and internal components over external ones,” the lifting sequence is scientifically planned to avoid interference from overlapping operations and the risk of rework. The specific sequence is as follows:

1. Mixing plant base (the core load-bearing foundation, prioritized for precise positioning);

2. Aggregate batching system (hoppers, supports, and other large components);

3. Powder supply system (powder tanks, screw conveyor main body);

4. Asphalt supply system (asphalt tanks, heating devices);

5. Mixing plant main body and cover;

6. Dust removal system (large dust collector main body);

7. Control room, electrical cabinets, and other small, high-precision components;

8. Various conveying pipelines, connectors, and accessories.

(二) Specialized Lifting Methods and Key Technical Points

1. Lifting of heavy components (mixer base, main body, large powder silos):  The preferred method is dual-crane lifting or single-crane multi-point balanced lifting. For dual-crane lifting, cranes of the same model and performance should be selected, and a synchronous control system must be used to ensure synchronized lifting and movement. Lifting points should be symmetrically arranged, and the load distribution should be even (each crane’s load should not exceed 80% of its rated capacity). For single-crane multi-point lifting, the lifting point positions should be determined through finite element analysis, and a balance beam should be used to distribute the load and prevent local deformation of the component.During the lifting process, guide ropes were used to control the component’s position and prevent collisions. The lifting speed was controlled to within 0.5 m/min, and a 10-20 cm adjustment space was reserved during positioning, allowing for precise alignment using a traction device.

2. Lifting of long structural components (aggregate belt conveyors, long-distance screw conveyors):  Depending on the length and rigidity of the components, either integral or segmented lifting methods are selected. Integral lifting requires precise calculation of the center of gravity and the installation of temporary reinforcement supports (such as I-beam reinforcement) to prevent bending deformation during lifting; segmented lifting requires pre-assembly and trial fitting on the ground, marking precise alignment lines, and then lifting each segment into place sequentially. Flange or welded connections are used during segmented connection to ensure that the coaxiality deviation is controlled within 0.5 mm/m.

3. Lifting of small, precision components (sensors, electrical components, instruments):  A lifting method involving manual assistance and small lifting equipment (electric hoists, winches) should be used. Flexible slings should be used as lifting gear to avoid damaging the component surfaces.  Personnel must wear anti-static gloves, and direct dragging of components is strictly prohibited. Components should be secured immediately after positioning to prevent falling or collision damage.

III. Meticulous Installation Process: Ensuring Optimal Performance

(一) Installation of the mixing unit

1. After the base is in place, use shims to adjust the levelness.  Both longitudinal and transverse levelness deviations should be controlled within 0.2 mm/m. When tightening the anchor bolts, use a diagonal and even tightening method, ensuring the torque value meets the design requirements (generally 800-1000 N·m for M30 bolts). After tightening, recheck the levelness.

2. After the main unit is hoisted into place, it should be precisely aligned with the base, adjusting the coaxiality deviation to ≤0.3mm, and then the connecting bolts should be tightened. When installing the transmission device and reducer, ensure that the coaxiality deviation of the motor, reducer, and main unit input shaft is ≤0.2mm, and the coupling gap is controlled between 2-4mm.  Add the specified type of lubricating oil (generally industrial gear oil GL-5) according to the equipment manual, filling it to the oil level mark.  There should be no abnormal vibration or noise during trial operation.

3. The mixing blades must be installed strictly according to the angle markings (the typical design angle is 30°-45°), and the gap between the blades and the liner should be controlled at 5-10mm to ensure uniform mixing; when installing the discharge gate, adjust the flatness of the sealing surface to ≤0.5mm, install high-temperature resistant sealing strips, and conduct a leakage test during trial operation to ensure there is no leakage of asphalt or aggregate.

(二) Installation of the aggregate batching system

1. During the installation of the aggregate bins, ensure that the verticality deviation of the bin body is ≤1 mm/m, the bin partitions are tightly sealed, and there are no gaps between adjacent bins to prevent aggregate mixing; the inclination angle of the bin body should be determined according to the type of aggregate (generally 60°-65° for crushed stone and 65°-70° for sand) to ensure smooth and unobstructed flow of aggregates without any retention.

2. During the installation of the belt conveyor, the longitudinal horizontal deviation of the frame shall be ≤1mm/m, and the transverse vertical deviation shall be ≤2mm/m. The tension of the conveyor belt is controlled by adjusting the position of the rollers. During no-load test operation, the belt deviation shall be ≤5mm/10m; the weighing device must be installed to ensure that the weighing hopper is level, the sensors are subjected to uniform force, and the wiring connections are secure. After calibration, the weighing error shall be controlled within ±0.5%, meeting the requirements of “Weighing Display Controller” (GB/T 7724-2017).

3. The aggregate hopper and discharge gate must be installed with a secure and sealed connection. The discharge gate should open and close smoothly, the electric actuator’s response time should be ≤0.5s, and the limit switches must be accurately positioned to prevent over-opening or over-closing.

(三) Installation of the powder supply system

1. When installing the powder storage tank, the foundation must be leveled and compacted. A level instrument should be used to calibrate the verticality of the tank body, with a deviation of ≤1mm/m. The tank body should be secured using a combination of anchor bolts and wind-resistant guy wires (the strength of the guy wires needs to be reinforced in areas with wind speeds ≥6 on the Beaufort scale). The tank body must be equipped with a dedicated grounding device, with a grounding resistance of ≤4Ω, to prevent the risk of dust explosion caused by static electricity accumulation.

2.  During the installation of the screw conveyor, ensure that the longitudinal levelness deviation of the casing is ≤0.5 mm/m, and that the gap between the screw blades and the casing is uniform (2-3 mm) to prevent material jamming.  A high-precision tension sensor should be used for the weighing device, and the weighing error should be controlled within ±0.3%. After installation, perform three full-scale load calibrations to ensure accurate measurement.

3. The conveying pipelines are connected using flanges, with wear-resistant rubber gaskets used for sealing. The bolts are tightened evenly in a diagonal pattern. The pipeline layout is designed to minimize the path length and reduce the number of elbows (elbow radius of curvature ≥ 3 times the pipe diameter) to lower the resistance to powder conveying; pneumatic ball valves are used, with a switching accuracy of ≤ 0.1s, ensuring precise control of the powder conveying volume.

(四) Installation of the asphalt supply system

1. The asphalt tank installation must ensure a tank body levelness deviation of ≤1 mm/m. The foundation should be equipped with a moisture-proof layer and an insulation layer. The outside of the tank body should be wrapped with rock wool insulation material with a thickness of ≥50 mm. The internal heating device (heat transfer oil heating pipes) must be securely installed and evenly distributed. Temperature sensors should be installed in the middle and bottom of the tank, with a measurement accuracy of ±1℃, to ensure that the asphalt temperature is stably controlled within the production range of 130-160℃.

2. The asphalt conveying pipelines are made of stainless steel (304 or 316L), with a heating device and insulation layer on the outside.  The connections use a double sealing method of welding and flanges, and the welded joints undergo penetrant testing (PT) to ensure there are no defects such as pores or cracks. The pumping system uses a dedicated asphalt gear pump, with flow rate and head matching the asphalt plant’s capacity. During trial operation, the pump body shows no leakage, and the pressure remains stable (fluctuation range ≤ 0.2 MPa).

3. The asphalt spray nozzle is installed directly opposite the aggregate discharge point of the mixing plant, and the nozzle angle is adjusted to 45°-60° to ensure even spraying of asphalt onto the aggregate surface.  An electromagnetic flow meter is used for metering, with a metering error controlled within ±0.5%, and it is linked to the control system to achieve precise closed-loop control of asphalt usage.

IV. Key Points for Quality Control Throughout the Entire Process

(一) Quality inspection of incoming components

All incoming components must be accompanied by factory certificates of conformity, material certificates, and performance test reports. ACE Group, in conjunction with the supervising unit, will conduct special inspections:

1. Visual inspection: verifying that components are free from defects such as deformation, corrosion, and cracks, and that the surface coating is intact;

2. Dimensional inspection: ensuring that critical dimensions (such as connection flange thickness and bolt hole spacing) are within a tolerance of ±2mm.

3. Performance Testing: The mixing drum body undergoes ultrasonic testing (UT), with a 100% weld qualification rate; the gearbox undergoes no-load test run, operating smoothly and quietly with a temperature rise of ≤40℃; the sensors are calibrated for accuracy, and the error meets design requirements.  

Any parts that fail inspection are strictly prohibited from being used on site and must be returned to the supplier for replacement.

(二) Dynamic Control of Installation Accuracy

During the installation process, a closed-loop control model of “real-time monitoring – adjustment – verification” was adopted, with key precision indicators tracked throughout:

1. Foundation elevation and levelness: Verified after each process step; deviations exceeding limits were corrected using shims or secondary grouting;

2. Component verticality and coaxiality: Monitored in real time using a theodolite and laser alignment instrument, and re-verified after adjustment;

3. Connection gap and sealing accuracy: Checked using feeler gauges, with a sealing surface gap of ≤0.1mm to ensure no leakage.

All precision data must be recorded and archived to form quality traceability documents.

(三) Quality control of connecting parts

Bolt connections must be tightened strictly according to the design torque, using a torque wrench in three stages (initial tightening, re-tightening, and final tightening).  Thread locking compound must be applied to bolts in critical areas (main machine base, tank fixing bolts) to prevent loosening; welded connections must be performed by certified welders, with beveling treatment before welding and slag removal after welding, followed by non-destructive testing (UT/PT) to ensure weld quality; sealed connections require the selection of sealing materials compatible with the medium, even application of sealant during installation, and pressure testing after tightening (asphalt pipelines are tested at 1.5 times the working pressure, with no leakage for 30 minutes).

V. Comprehensive Security Management Measures

(一) Personnel Safety Management

Before construction began, ACE Group organized specialized safety training for all personnel.  The training covered topics such as lifting and hoisting safety procedures, working at height regulations, electrical safety procedures, fire and explosion prevention requirements, and emergency response procedures.  A test was administered after the training, and only those who passed were allowed to work.  Workers were required to wear appropriate personal protective equipment (safety helmets, safety harnesses, non-slip shoes, and protective gloves).  Personnel working at height were required to obtain a work-at-height permit, and safety harnesses were to be secured using the “high-point attachment, low-point use” method.  Working without a permit or engaging in unsafe practices was strictly prohibited.

(二) Safety precautions at the construction site

The construction site is enclosed with a fence, dividing it into work areas, office areas, and material storage areas. Safety warning signs are displayed (including warnings for lifting operations, working at heights, and fire hazards).  Working platforms at height are equipped with guardrails (height ≥ 1.2m) and safety nets, and safety protection sheds are installed below the working areas.  Unauthorized personnel are strictly prohibited from entering the work areas. The construction site is equipped with sufficient fire-fighting equipment (dry powder fire extinguishers, fire sand, fire hoses) and first-aid supplies, and emergency exits are provided to ensure smooth emergency response.

(三) Equipment Safety Management

Before using lifting equipment, a comprehensive inspection is required: the wire ropes must be free of broken strands and excessive wear (wear less than or equal to 3%), the brakes must be sensitive and reliable, and the limit switches must be effective; electrical equipment must be protected against rain, moisture, and electrical leakage, the distribution box must be equipped with a leakage protection device (leakage action current ≤ 30mA), and the wires must be protected by conduits; a dedicated person must monitor the equipment during operation, and if any abnormality is found, the equipment must be stopped immediately for inspection; regular maintenance and servicing should be performed, and worn parts should be replaced to ensure the safe and reliable operation of the equipment.

(四) Safety Management and Control for Specialized Operations

High-altitude work must avoid overlapping operations; if overlapping is unavoidable, isolation and protective layers must be installed. Lifting operations require a dedicated person to direct the work, and the command signals must be standardized (using both hand gestures and walkie-talkies). Open-air lifting operations are strictly prohibited in winds of force 6 or higher, or during rain or snow. Electrical work requires power to be switched off, and a “Do Not Energize” sign must be displayed.  Before starting work, a voltage test must be performed to ensure that there is no electricity before proceeding. During asphalt system installation, open flames are strictly prohibited near the work area, and a combustible gas detection device must be installed at the construction site to prevent asphalt leaks from causing fires.

VI. Description of Usage Scenarios

This guide is applicable to the installation and lifting operations of new construction, expansion, and renovation projects for various types of asphalt mixing plants (fixed, mobile, batch, and continuous) manufactured by ACE Group and other companies in the industry.  It covers the construction scenarios of asphalt mixing plants supporting various road engineering projects, including municipal roads, highways, airport runways, and port terminals. It can serve as a core basis for construction units to prepare construction plans, for technical personnel to provide technical guidance, and for operators to perform operations. It can also be used by project owners as a reference for supervising and managing project quality and safety.

VII. Frequently Asked Questions and Answers for Customers

Q1: How long does it typically take to install and assemble asphalt mixing plants of different capacities?

A1: The installation and hoisting period mainly depends on the production capacity of the concrete mixing plant and the on-site construction conditions.  The typical project timelines for ACE Group are as follows: for small mixing plants (2000 type and below), the period is approximately 15-20 days; for medium-sized mixing plants (3000-4000 type), the period is approximately 25-35 days; for large mixing plants (5000 type and above), the period is approximately 40-60 days. If the site is restricted, requires night work, or encounters adverse weather conditions, the period may be extended accordingly. We will develop a precise schedule based on the actual site conditions during the early stages of the project to ensure timely completion.

Q2: During the installation process, how can we ensure the installation accuracy of the concrete mixing plant to avoid problems such as excessive vibration and high noise during subsequent operation?

A2: ACE Group controls installation accuracy through a “three-tiered guarantee”: first, it uses high-precision measuring equipment (laser alignment instruments, electronic levels) for real-time monitoring to ensure that key indicators remain within the design specifications; second, it implements a “process handover inspection” system, where each accuracy-related process must be reviewed and approved by the technical supervisor before proceeding to the next step;third, after the equipment is installed, conduct no-load and load test runs.  Use vibration sensors and noise detectors to monitor the equipment’s operating status. If abnormal vibration or noise occurs, troubleshoot and adjust the equipment promptly (such as adjusting the main unit’s levelness and optimizing the coaxiality of the transmission system) to ensure stable operation.

Q3: How should we deal with the risk of deformation of large components (such as the mixing unit) during the lifting process?

A3: We will take comprehensive preventive measures before lifting: firstly, we will determine the optimal lifting points through finite element analysis and use a special balancing beam to distribute the load and avoid local stress concentration; secondly, we will adopt temporary reinforcement measures for heavy components (such as welding reinforcing bars) to improve the rigidity of the components; and thirdly, we will select lifting equipment with matching performance, control the lifting speed and posture, and avoid impact loads. If any signs of deformation are detected during the lifting process, we will immediately stop lifting and address the issue by adjusting the lifting points, adding reinforcement measures, or changing the lifting plan to ensure the safety of the components before continuing the operation.

Q4: What after-sales support services will your company provide after the installation is complete?

A4: ACE Group provides comprehensive after-sales support services:

1. After installation, a professional team will conduct equipment commissioning (including no-load and load testing) to ensure that all equipment performance meets the standards; 2. We provide specialized training for the owner’s operators, covering equipment operation, daily maintenance, and troubleshooting;

3. We provide a one-year free warranty service, with dedicated personnel conducting regular inspections during the warranty period to promptly resolve any equipment operating issues;

4. We establish a long-term service mechanism, providing lifelong technical support and spare parts supply services to ensure the long-term stable operation of the equipment.

Q5: The construction site is located near a residential area. How can we control construction noise and dust pollution?

A5: For construction sites near residential areas, we will implement specific environmental protection measures:

1. Noise control: We will use low-noise construction equipment, set up noise barriers, and schedule work times appropriately (avoiding 10:00 PM to 6:00 AM and lunch breaks).  We will also minimize horn use during lifting operations to reduce noise impact;

2. Dust control: The construction site ground will be hardened, material transport vehicles will be covered with tarpaulins, and mist cannons and sprinkler systems will be used to suppress dust.  Enclosed measures will be taken during the handling of powdery materials to prevent dust dispersion and ensure compliance with local environmental emission standards.

VIII. Conclusion

The installation and lifting of asphalt mixing plants is a technically intensive and complex engineering project, and its quality and safety directly determine the equipment’s operational efficiency and the overall project benefits.Drawing on years of industry experience, Asian Construction Equipment Group Co., Ltd. has built an integrated implementation system encompassing “precise planning in the early stages, refined process control, and comprehensive service support throughout the entire lifecycle.” By strictly adhering to the technical specifications and management requirements outlined in this guide, we can effectively guarantee the safety, standardization, and efficiency of installation and lifting operations. In the future, Asian Construction Equipment Group Co., Ltd. will continue to focus on technological innovation, constantly optimizing installation and lifting processes to provide customers with more professional and reliable asphalt mixing plant integration services, contributing to the high-quality development of road engineering.

As a professional manufacturer and service provider in the field of road construction equipment, Asian Construction Equipment Group Co., Ltd. (abbreviated as​ ACE Group) is deeply committed to the research, development, production, and technical service of mobile asphalt mixing plants, focusing on the core needs of efficient, environmentally friendly, and convenient engineering construction.  With its core characteristics of flexible relocation and rapid commissioning, the mobile asphalt mixing plant has become essential equipment for road maintenance, construction in remote areas, and continuous operation across multiple project sections.This article systematically analyzes the structural composition, working principles, core technical characteristics, and engineering application advantages of mobile asphalt mixing plants from the perspective of Asian Construction Equipment Group Co., Ltd. products and technologies. It addresses frequently asked technical questions from industry clients, providing professional technical references and systematic solutions for engineering applications.

I. Core Structural Components

1. Aggregate supply system

The aggregate supply system is a fundamental component that ensures the continuous and stable production of the concrete mixing plant.  ACE Group utilizes a modular integrated design to precisely meet the efficient supply requirements of different aggregate gradations. The core configuration is as follows:

• Aggregate Bins: Equipped with 3-6 independent bins, allowing for the classified storage of different grades of aggregates such as crushed stone and sand. The bin capacity is matched to the production capacity, ranging from 50 to 150 tons. The bins are constructed from wear-resistant steel plates and feature an anti-stick coating on the inner walls, along with a vibration-based arch-breaking device to effectively prevent aggregate arching and blockage, ensuring continuous material flow.

• Aggregate weighing device: Equipped with high-precision weighing sensors and an intelligent metering control system, with a weighing range of 0-8000kg and a metering accuracy of ±1% to ±2%. It integrates a dynamic compensation algorithm to correct metering deviations in real time, ensuring that the aggregate proportion accuracy meets engineering technical specifications.

• Aggregate conveying device: Large units are equipped with heavy-duty belt conveyors (conveying capacity 100-300 t/h), integrated with anti-deviation and anti-spillage mechanisms; small units or those operating in confined spaces utilize shaftless screw conveyors, which feature a compact structure and stable conveying performance, effectively meeting the needs of mobile and relocatable operations.

2. Powder supply system

Addressing the characteristics of powdered materials such as cement, mineral powder, and fly ash, which are prone to arching and dust generation, ACE Group has optimized the design of its powder supply system to ensure both stable conveying and environmental compliance.  The core configuration is as follows:

• Powder Silo:  Features a sealed silo structure with a capacity of 20-80 tons, equipped with a pneumatic arch-breaking device and a material level sensor. The arch-breaking device can automatically start and stop based on the material level feedback signal, ensuring smooth powder discharge; the material level sensor continuously collects data on the remaining material in the silo, providing data support for precise material replenishment.

• Powder weighing device:  Utilizes a suspended weighing hopper equipped with high-precision sensors, with a weighing range of 0-3000kg and a weighing accuracy of ±0.5% to ±1%. The weighing hopper is fitted with a dustproof sealing cover and an automatic cleaning mechanism, effectively reducing powder leakage and residue, ensuring stable weighing accuracy.

• Powder conveying device: The mainstream configuration uses a closed screw conveyor, which offers the advantages of stable conveying and convenient maintenance; for long-distance conveying scenarios, a pneumatic conveying system can be used, which achieves enclosed conveying of powder through compressed air, with a conveying distance of up to 50 meters or more, effectively controlling dust pollution.

3. Asphalt supply system

The core technical aspects of the asphalt supply system are precise temperature control and guaranteed metering accuracy. ACE Group employs a full-process insulation design to ensure stable asphalt performance. The core configuration is as follows:

• Asphalt Tank: With a capacity of 50-120 tons, the tank features a double-layered insulation structure (inner layer heated by thermal oil, outer layer insulated with rock wool), and is equipped with temperature sensors and an automatic heating control system. This ensures precise and stable control of the asphalt temperature at 130-160℃, guaranteeing excellent asphalt fluidity.

• Asphalt transfer pipeline:  Uses seamless steel pipes with an outer layer of heat-transfer oil heating jackets, complemented by an electric tracing auxiliary insulation system. The pipeline temperature is monitored in real time to effectively prevent asphalt solidification and blockage.  Quick-connect couplings are used at pipeline joints for easy disassembly and reassembly during relocation.

• Asphalt metering device: Equipped with an imported high-precision electromagnetic flow meter, achieving a metering accuracy of ±0.5%, and integrating both mass and volume measurement and calibration functions.  It can automatically adjust the asphalt flow rate according to the formula parameters, ensuring precise and controllable asphalt-to-aggregate ratio in the mixture.

4. Mixing unit

The mixing unit is the core component that determines the quality of the mixed materials. ACE Group utilizes a twin-shaft forced mixer design, which can precisely adapt to the mixing requirements of different working conditions. The core configuration is as follows:

• Mixing Tank: Available in capacities of 2000L, 3000L, and 4000L. The tank body is made of high-strength, wear-resistant steel plates, and the inner lining features a quick-release design. The internal design of the mixing tank optimizes material flow to ensure thorough mixing and tumbling of materials.

• Mixing System: Equipped with a high-power motor and a hardened gear reducer, it features high transmission efficiency and strong operational stability. The mixing arms and blades are made of wear-resistant alloy material, and the blade arrangement has been optimized through fluid dynamics simulation.  It utilizes a dual-mode control system of “low-speed mixing + high-speed discharge,” resulting in a 20% increase in mixing efficiency and a discharge time shortened to 15-25 seconds.

• Discharge device:  It adopts a hydraulically driven discharge gate with a double sealing structure, effectively preventing leakage of the mixed material. The opening and closing of the discharge gate are precisely controlled by a PLC system, providing a dual safety mechanism of automatic discharge and manual emergency operation.

5. Intelligent control system

ACE Group’s independently developed intelligent control system achieves fully automated control of the entire concrete mixing plant process, effectively improving production efficiency and operational convenience.  Its core components are as follows:

• Control Panel:  Features an ergonomic design with a high-definition touchscreen and physical control buttons, displaying real-time production parameters, equipment operating status, and other key information. The user interface is simple and intuitive, supporting both Chinese and English languages to meet the needs of different operators.

• Core Control Unit: Utilizes an industrial-grade PLC controller (Siemens or Mitsubishi brands optional), equipped with proprietary control software developed in-house. It features functions such as recipe storage (up to 100 sets), production data statistics, and fault warning and diagnosis.  It supports remote monitoring and maintenance, allowing real-time viewing of production status and remote troubleshooting via a mobile app or computer.

• Sensing and Detection System: Equipped with multiple types of high-precision sensors for temperature, pressure, flow rate, and material level, the system features high detection accuracy and fast response speed. Sensor data is transmitted to the control unit in real time. When parameters exceed the set thresholds, the system immediately triggers an audible and visual alarm and automatically executes safety protection measures such as shutdown and material cutoff.

6. Precise weighing system

The weighing system adopts a hierarchical weighing design architecture, which is a key component in ensuring the accuracy of material proportioning and the quality of the mixed materials.  Its core components are as follows:

• Aggregate scale: Measuring range 0-8000kg, accuracy ±1%~±2%, adopts a dual-sensor support structure to effectively reduce the impact of material shock on weighing accuracy.

• Powder weighing scale: Measuring range 0-3000kg, accuracy ±0.5%~±1%, equipped with a dust cover and automatic cleaning mechanism to prevent powder adhesion from affecting weighing accuracy.

• Asphalt scale/flow meter:  Utilizes a dual measurement and verification mechanism for both mass and volume, ensuring accurate asphalt usage with a measurement accuracy of ±0.5%.

• Finished product weighing scale: Measuring range 0-10000kg, used to verify the weight of each batch of mixed materials, ensuring production batch stability and providing a basis for production data traceability.

7. Environmentally friendly dust removal system

ACE Group adheres to the concept of green manufacturing and has implemented an integrated two-stage dust removal and exhaust gas treatment system, fully meeting national environmental protection standards.  The core components are as follows:

• Primary dust removal: A cyclone dust collector is used to separate large dust particles with a diameter of ≥ 10μm using centrifugal force, achieving a dust removal efficiency of over 90%.  It features a simple structure and convenient maintenance, allowing for quick removal of accumulated dust.

• Secondary dust removal: A pulse jet bag filter (with high-temperature resistant needle-punched felt filter bags) is used to efficiently filter fine dust particles with a diameter of ≥0.5μm, achieving a dust removal efficiency of ≥ 99.5%.  An automatic cleaning system is included to regularly clean the filter bags and ensure stable filtration performance.

• Induced Draft and Exhaust Gas Treatment: Low-noise induced draft fans are used, along with silencing devices, to effectively reduce operating noise. High-end models can be optionally equipped with exhaust gas desulfurization and denitrification devices to further reduce harmful gas emissions and meet stringent environmental control requirements.

8. Finished product storage silo

The finished product silo is used for the temporary storage of asphalt mixture. Its main functions are to ensure production continuity and maintain the temperature stability of the mixture.  The core components are as follows:

• Storage function: With a capacity of 50-150 tons, it features a sealed steel structure design, effectively preventing the mixed materials from getting damp or contaminated.

• Insulation system: The silo body uses a rock wool insulation layer combined with an electric heating system to maintain the mixed material temperature stably at 120-140℃, reducing heat loss and ensuring optimal performance during paving construction.

• Discharge device:  Features a pneumatically controlled discharge gate and a flow regulating mechanism, allowing for precise control of the discharge speed according to the needs of the transport vehicle.  The discharge opening is equipped with a spill-proof baffle to reduce material waste and environmental pollution.

II. Working Principle

1. Material feeding and metering stage

After the loader delivers the aggregate to the aggregate bin, the control system, based on preset formula parameters, instructs the aggregate conveying device to transport the aggregate to the aggregate weighing hopper for precise weighing; the powder is transported to the powder weighing hopper via a screw conveyor or pneumatic conveying device for weighing; and the asphalt is transported through insulated pipes to the metering device for flow/mass measurement.  Once all materials have been weighed, the weighing hopper gates open simultaneously, accurately discharging the materials into the mixing drum of the main mixer.

2. Mixing stage

After the mixing unit is started, the twin-shaft mixing blades rotate forward, performing forced mixing of the materials.  The optimized arrangement of the blades ensures that the materials tumble vertically and mix horizontally within the cylinder, guaranteeing thorough blending of aggregates, powders, and asphalt. The mixing time can be preset to 30-60 seconds depending on the type of mixture, and can be manually fine-tuned via the control system under special operating conditions. If additives are required, they can be precisely sprayed through dedicated pipelines during the mixing process.

3. Unloading and storage phase

After mixing is complete, the mixing drum rotates in the reverse direction, and the hydraulic system drives the discharge gate to open, discharging the uniformly mixed asphalt mixture into the finished product silo or directly into transport vehicles.  After unloading, the mixing drum resumes forward rotation to clean out any remaining material, preparing for the next mixing cycle. The mixture in the finished product silo is kept at the required temperature by a heating system to ensure the needs of subsequent paving operations are met.

4. Environmental treatment stage

During the mixing process, the dust-laden air generated is drawn into the dust removal system by the negative pressure of the induced draft fan.  It first passes through a cyclone separator to remove large dust particles, and then enters a pulse jet bag filter for deep filtration to remove fine dust. The filtered clean air is discharged through the exhaust stack after meeting emission standards. The collected dust can be regularly cleaned and recycled. The small amount of asphalt-containing wastewater generated during the production process is treated by a dedicated wastewater treatment device and can be recycled for equipment cleaning, achieving zero wastewater discharge.

III. Advantages of Core Engineering Applications

1. Flexible transitions, adaptable to multiple work scenarios.

ACE Group’s mobile asphalt mixing plant adopts a fully modular design architecture, with each functional unit integrated onto a trailer chassis or crawler-type walking mechanism.  During relocation, there is no need to disassemble core components; the equipment can be quickly moved by a tractor or by its own self-propelled mechanism.  Assembly and disassembly time is reduced to within 24 hours, significantly lowering relocation and transportation costs. This feature makes it particularly suitable for road construction in remote mountainous areas, continuous operation across multiple project sections, and emergency road repairs, allowing for rapid deployment and operation to ensure project progress stays on schedule.

2. Easy to install, with a short commissioning period.

The equipment is pre-installed and debugged before leaving the factory, requiring only simple procedures such as module connection, pipeline connection, and site leveling for on-site commissioning. Compared to traditional fixed concrete batching plants that require large-scale civil engineering construction, the ACE Group mobile concrete batching plant requires only 3-7 days for on-site installation and commissioning, significantly shortening the project preparation period and helping customers quickly increase production capacity.  Furthermore, it does not require long-term site occupation and can be quickly removed after completion of work, reducing site rental costs.

3. High efficiency and stability, with controllable production quality.

Equipped with an advanced twin-shaft mixing system and intelligent control system, the plant boasts a production capacity of 80-240 tons per hour, meeting the production needs of various-sized projects.  Fully automated control ensures precise coordination of all processes, resulting in minimal aggregate gradation deviations and stable, controllable mix quality.  Furthermore, the equipment utilizes high-quality core components (such as imported sensors and wear-resistant mixing blades), leading to a low failure rate and significantly longer continuous operating time, effectively improving production efficiency.

4. Environmentally friendly and compliant with policy requirements.

Utilizing a comprehensively optimized environmentally friendly design, the two-stage dust removal system effectively controls dust emissions, with dust concentration below 10 mg/m³, meeting the latest national environmental standards.  The fully enclosed material conveying and storage structure reduces dust pollution.  Optional exhaust gas treatment and wastewater recycling systems are available to reduce harmful gas emissions and enable water resource recycling. The equipment operates with noise levels below 85 dB, making it suitable for operation in environmentally sensitive areas such as residential neighborhoods.

5. Intelligent operations and maintenance reduce management costs.

The independently developed intelligent control system supports real-time production data statistics, automatic fault warning, and remote monitoring and maintenance functions. Operators can quickly access recipes and view production reports via the touchscreen, facilitating production management.  When equipment malfunctions, the system can accurately locate the fault and issue a warning, allowing technicians to quickly troubleshoot the problem through remote assistance, thus reducing downtime.  Furthermore, the modular design facilitates component maintenance and replacement, lowering long-term operating and maintenance costs.

IV. Core Application Scenarios

1. Road construction scene in a remote mountainous area

Addressing the challenges of inconvenient transportation, difficult material delivery, and limitations on bringing in traditional equipment in remote mountainous areas, ACE Group’s mobile asphalt mixing plant offers flexible relocation capabilities, allowing for quick deployment without extensive dismantling. The equipment can utilize local aggregate resources for production, significantly reducing the cost of long-distance transportation of mixed materials.  Its rapid deployment capability also ensures timely progress in mountain road construction, making it suitable for the construction and expansion of low-grade roads in mountainous regions.

2. Multi-section continuous operation scenarios

Large linear engineering projects such as highways and national and provincial trunk roads are often divided into multiple construction sections. Traditional fixed asphalt mixing plants have high relocation costs and long transfer times.  ACE Group’s mobile asphalt mixing plant can be quickly moved between different sections, with disassembly and reassembly time reduced to within 24 hours. This eliminates the need for repeated construction of infrastructure, effectively reducing equipment investment and relocation costs for multi-section projects, and ensuring the continuity of construction and consistency of asphalt mix quality across multiple sections.

3. Emergency road repair scenarios

When roads are damaged by natural disasters such as floods and earthquakes, or when potholes and cracks appear in roads requiring emergency repairs, ACE Group’s mobile asphalt mixing plant can respond quickly and be deployed nearby.  It can be installed, commissioned, and put into operation in a short time, providing a stable supply of asphalt mixture for emergency repairs and helping to quickly restore road traffic capacity. This is suitable for scenarios such as emergency repairs of municipal roads and emergency maintenance of national and provincial trunk roads.

4. Road maintenance engineering scenarios

Routine maintenance operations on urban and rural roads are characterized by dispersed work sites, small work volumes per operation, and high mobility.  ACE Group’s mobile asphalt mixing plant is compact and highly portable, allowing it to move with maintenance crews and produce small batches of asphalt mix on-site. This makes it ideal for various maintenance procedures such as road milling and resurfacing, crack filling, and pothole repair, improving maintenance efficiency and reducing costs.

5. Operating scenarios in environmentally sensitive areas

Environmentally sensitive areas such as residential areas, scenic spots, and water source protection zones have strict requirements regarding construction dust and noise emissions.  ACE Group’s mobile asphalt mixing plant is equipped with a two-stage dust removal and exhaust gas treatment system, resulting in dust emission concentrations of ≤ 10mg/m³and operating noise levels below 85dB.  It also utilizes a fully enclosed material conveying structure, effectively controlling dust pollution and making it suitable for construction scenarios with high environmental requirements, such as urban road renovation and scenic road upgrades.

6. Temporary construction site scenarios

Temporary infrastructure projects, such as temporary access roads for large-scale construction projects, temporary roads in industrial parks, and roads for construction camps, are characterized by short construction periods and do not require long-term site occupation.  ACE Group’s mobile asphalt mixing plants can be quickly deployed and put into operation, meeting the demand for asphalt mix during temporary road construction. After completion, they can be quickly removed, avoiding the site remediation issues associated with dismantling traditional fixed equipment and reducing the construction costs of temporary projects.

V. Frequently Asked Questions (FAQ) for Customers

Q1: What preparations are needed when relocating an ACE Group mobile asphalt mixing plant?

A1: The following technical preparations must be completed before the transition:

① Empty any remaining materials from the hoppers and clean dust and debris from the equipment surfaces;

② Disconnect the power supply, air supply, and pipeline connections, and seal and protect the interfaces;

③ Check the fixing status of each modular component to ensure that the connecting bolts are tightened;

④ Check the performance of the chassis, tires, and braking system according to the relocation method (towing/self-propelled);

⑤ Plan the transportation route in advance and verify whether the route’s load capacity and width meet the equipment transportation requirements. Under normal circumstances, a professional team of 2-3 people can complete the relocation preparation work within one day.

Q2: What are the suitable operating temperatures for the equipment? How can asphalt performance be ensured in low-temperature environments?

A2: The normal operating temperature range for the equipment is -10℃ to 40℃. In low-temperature environments (below 0℃), the following technical measures can be used to ensure asphalt performance:

① The asphalt tank and conveying pipelines are equipped with double insulation (heat transfer oil heating + electric tracing), and real-time temperature monitoring is implemented;

② Enhanced insulation measures are applied to the finished product silo, and auxiliary heating devices are activated when necessary;

③ Mixing process parameters are optimized, and the mixing time is appropriately extended by 5-10 seconds to ensure uniform material mixing;

④ Before starting the equipment, all pipelines and the mixing tank are preheated to prevent asphalt from solidifying upon contact with low-temperature components.

Q3: Can the equipment’s production capacity be adjusted according to project requirements? How is the quality stability of different mixed materials ensured?

A3: The equipment’s production capacity can be flexibly adjusted through the control system.  The specific production rate can be set within the rated capacity range (80-240 t/h) according to the type of mixture and project progress requirements.  The core technical measures to ensure the stable quality of different mixture formulations are as follows:

① The control system supports the storage of over 100 recipes, eliminating the need for recalibration during recipe switching; recipes can be directly recalled and used;

② The high-precision weighing system integrates dynamic compensation functionality to correct measurement errors in real time;

③ The mixing blades are optimized using fluid dynamics principles to ensure thorough mixing of materials with different particle sizes;

④ Key parameters such as mixture temperature and weight are monitored in real time during production, and the system automatically triggers alarms and implements corrective measures if parameters are abnormal.

Q4: What are the maintenance cycle and key maintenance points for the equipment?

A4: The core maintenance cycle and technical points are as follows:

① Daily maintenance: Clean dust from the dust collection system, check the sealing of all pipelines, and lubricate the mixing shaft bearings;

② Weekly maintenance: Calibrate the accuracy of the weighing sensors, tighten all connecting bolts, and check the wear condition of the mixing blades;

③ Quarterly maintenance: Replace hydraulic oil and lubricating oil, check the operating status of the reducer, and clean the inner lining of the asphalt tank;

④ Annual maintenance: Conduct a comprehensive inspection of the electrical system performance, replace worn liners and blades, and calibrate the accuracy of the control system. ACE Group provides regular maintenance technical guidance and on-site services to ensure the long-term stable operation of the equipment.

Q5: Compared to traditional stationary concrete batching plants, what is the energy consumption of mobile equipment? Is it more energy-efficient?

A5: The energy consumption per unit of the ACE Group mobile concrete mixing plant is comparable to traditional fixed equipment, approximately 8-10 kg of standard coal per ton of mixed material, and it offers even better energy-saving benefits under certain operating conditions.

① Modular design shortens material conveying distances and reduces energy consumption of the conveying system;

② The intelligent control system automatically adjusts the motor’s operating power according to the production load, avoiding unnecessary energy consumption;

③ The insulation system uses high-efficiency insulation materials to reduce heat loss and lower the energy consumption of the heating system;

④ The equipment can be positioned close to the work area, shortening the transportation distance of the mixed materials and indirectly reducing the overall energy consumption of the project.

Q6: Does the equipment comply with the latest environmental standards? If local environmental regulations are upgraded, can the equipment be modified to meet the new standards?

A6: The equipment has passed third-party environmental testing before leaving the factory, with dust emission concentration ≤ 10mg/m³ and noise ≤ 85dB, complying with the latest national standards such as the “Emission Standard of Air Pollutants for Asphalt Concrete Mixing Plants” (GB 40850-2021). If local environmental protection requirements are upgraded, the following technical modifications can be implemented to meet the new standards:

① Upgrading the dust removal system and adding an activated carbon adsorption device to treat odors;

② Installing exhaust gas desulfurization and denitrification devices to reduce NOx and SO₂ emissions;

③ Upgrading the wastewater treatment system to achieve higher standards for water resource recycling.  ACE Group can provide customized retrofit solutions to ensure that equipment consistently meets environmental control requirements.

VI. Conclusion

Asian Construction Equipment Group Co., Ltd. is always guided by customer needs, relying on continuous technological innovation and product optimization to provide efficient, flexible, and environmentally friendly mobile asphalt mixing plant system solutions for the road engineering industry. From equipment research and development and manufacturing to installation, commissioning, and operation and maintenance services, the company provides comprehensive technical support throughout the entire process with its professional technical team, helping customers reduce construction costs, improve project quality, and ensure project progress.  For detailed equipment technical parameters, customized solutions, or on-site testing services, please contact Asian Construction Equipment Group Co., Ltd..We will provide you with comprehensive professional technical support.

As a core component of the environmental protection system in asphalt mixing plants, the filtration performance of dust collector bags directly affects the compliant operation of the equipment and the achievement of environmental emission standards.  Asian Construction Equipment Group Co., Ltd. (abbreviated as​ ACE Group), specializing in the research, development, and maintenance services of environmental protection equipment for asphalt mixing plants, has developed this standardized replacement guide based on years of practical engineering experience. This guide strictly adheres to industrial safety regulations and environmental protection requirements, detailing the entire process and key operational points for replacing dust collector bags.  Its aim is to provide relevant maintenance personnel with professional, safe, and efficient practical guidance, ensuring the stable operation of the dust collection system, extending equipment lifespan, and helping mixing plants achieve green production.

I. Preliminary Preparations (Safety and Basic Security Phase)

1. Shutdown, power outage, and safety precautions

Before performing any maintenance work, a strict shutdown and lockout procedure must be followed: first, shut down the asphalt mixing plant step by step according to the operating procedures. After the main unit and dust removal system have completely stopped, disconnect the main power supply to the dust collector, fan, and other related equipment, and hang a “Under Maintenance, Do Not Energize” safety warning sign to prevent accidental startup and potential accidents. Operators must wear complete protective equipment according to regulations, including anti-static work clothes, dust-resistant gloves, impact-resistant safety glasses, and a dust mask (KN95 or higher level is recommended) to prevent dust inhalation and mechanical injuries.

2. Site cleanup

Thoroughly clean the exterior of the dust collector casing, the area around the manhole door, and the work area, removing debris, accumulated dust, and unrelated tools to ensure unobstructed access.  During the cleaning process, high-pressure air blowing can be used in conjunction with brooms and rags.  Special attention should be paid to cleaning dust and debris from the sealing surface of the manhole door to prevent contaminants from falling into the dust collector during replacement, which could affect subsequent sealing performance and bag filter efficiency.

3. Inspection of the main structure of the dust collector

A comprehensive inspection should be conducted on key structural components such as the dust collector casing, tube sheet, suspension brackets, and pulse jet cleaning system: check the casing for deformation, weld cracks, or corrosion and leakage; specifically verify the flatness of the tube sheet (allowable deviation ≤2mm/m), ensuring that the edges of the tube sheet holes are free of burrs, cracks, and deformation to prevent dust leakage due to poor contact between the filter bags and the tube sheet after installation; check the stability of the suspension brackets, and if there is any looseness or corrosion, reinforce or replace them promptly to ensure the stability of the filter bag suspension.

4. Selection and pretreatment of new filter bags

Based on the flue gas temperature, dust characteristics (dust concentration, particle size), and operating conditions of the asphalt mixing plant, select dust collector filter bags of suitable material and specifications (high-temperature and acid-alkali resistant FMS or PTFE composite filter materials are recommended, suitable for temperatures ≤260℃).  New filter bags must have a product qualification certificate and be inspected individually before installation to ensure there are no defects such as damage, holes, or loose threads, and that the filter bag expansion rings have good elasticity. During the pre-treatment stage, place the new filter bags in a clean and well-ventilated environment for more than 24 hours to eliminate packaging odors and moisture generated during transportation and storage, thus avoiding any impact on filtration performance.

5. Preparation of specialized tools

Prepare a complete set of specialized tools, including: a torque wrench (matching the clamp bolt specifications), Phillips/flathead screwdrivers, a special bag removal tool, non-slip ropes (with a load capacity of ≥50kg), a copper brush (to avoid scratching the panel), sealing strips (for backup), cleaning cloths, and a dedicated storage bag for used bags.  All tools must be checked for proper working condition in advance and arranged in an orderly manner to ensure efficient replacement work.

II. Core Replacement Steps (Precise Operation Phase)

1. Remove the old cloth bag.

After opening the dust collector’s access door, ventilate the area for 15-30 minutes to reduce the internal dust concentration. When entering the interior for work, a safety harness must be worn, and a designated person must be present for supervision.The removal process depends on the bag’s fixing method: For clamp-type fixing, use a torque wrench to loosen the clamp bolts, remove the clamp, and then grasp the top of the filter bag and pull it vertically upwards to detach the bag’s retaining ring from the tube sheet hole; for tie-down type fixing, use bag removal pliers to untie the binding ropes, taking care to avoid leaving any rope fragments behind.If the manhole opening is too narrow to remove the filter bag in one piece, the “upper binding and sectional cutting” method can be used: first, secure the upper part of the filter bag with a rope, pull out one-third of its length through the manhole opening, and then cut it horizontally from the bottom using a special tool. Remove the bag in sections to avoid damaging the tube sheet and adjacent components during the pulling process. The removed old filter bags must be immediately placed in sealed storage bags to prevent dust dispersion and then disposed of according to hazardous waste treatment regulations.

2. Cleaning of the ceiling panel and mounting surface.

After removing the old filter bags, use a copper brush and a vacuum cleaner to clean the surface of the tube sheet, the holes, and the surrounding areas to remove dust, debris, and fragments of the damaged filter bags, ensuring no dust remains.  The edges of the tube sheet holes should be polished and trimmed to remove burrs. Wipe the sealing surface of the tube sheet with a cloth dampened with industrial alcohol. After drying, check for flatness. If there are any uneven areas, use shims to level them, ensuring a proper fit for the new filter bags.

3. Precise installation of the new filter bag.

Slowly unfold the pre-treated new filter bag, ensuring the bag’s expansion ring is facing the tube sheet.  Using both hands, hold the top of the filter bag and lower it vertically into the hole in the tube sheet, ensuring the expansion ring is fully seated in the groove of the tube sheet hole.Key operating points for the fixing method: When using clamp-type fixing, insert the clamp onto the upper opening of the filter bag, ensuring it is tightly against the lower surface of the tube sheet. Tighten the bolts with a torque wrench to the specified torque (generally 8-12 N·m), ensuring even force distribution on the clamp to prevent damage to the filter bag due to overtightening or leakage due to looseness. When using tie-down fixing, use high-temperature-resistant rope to evenly tie 3-4 turns along the edge of the tube sheet hole, with the knot positioned below the tube sheet, ensuring the tie-down is secure and does not loosen. During installation, ensure the filter bags are perpendicular to the tube sheet, and the spacing between adjacent filter bags is controlled at 5-10 cm to prevent damage from friction caused by airflow turbulence during operation.

4. Bag position calibration

After the single-compartment filter bags are installed, observe the distribution of the filter bags from multiple angles through the manhole door. Gently adjust any misaligned filter bags using a long rod tool to ensure they are neatly arranged and evenly spaced. Verify that all filter bags are suspended at the same height (allowable deviation ≤3cm). If there are height discrepancies, adjust the expansion ring insertion depth or replace the suspension accessories to level them. Check the distance between the bottom of the filter bags and the dust collector hopper wall to ensure it is ≥20cm to prevent dust accumulation from causing filter bag blockage.

5. Installation quality verification and reinforcement

Each filter bag’s installation quality was checked individually: verifying that the expansion ring and the hole in the tube sheet were tightly fitted, and that the filter bag did not loosen when gently pulled by hand; checking that the filter bag was free from twisting, creasing, or damage; and confirming that there were no missing clamp bolts or tie ropes.  Key areas were reinforced: the bottom of the filter bag was reinforced with high-temperature stitching or fitted with wear-resistant rings to prevent damage from collision with hard objects in the hopper during operation; the sealing strips on the edge of the tube sheet were inspected, and replaced promptly if aged or damaged, to improve overall sealing performance.

III. Post-implementation support (Stable operation phase)

1. System restoration and trial run

After the replacement work is completed, thoroughly clean the inside of the dust collector and remove all tools, debris, and dust from the work area. Close the manhole door, ensuring that the sealing strip is properly compressed.  Restore power according to the asphalt mixing plant startup procedure. First, start the dust collector fan for 5 minutes of no-load operation, checking for any abnormal noises or leaks; then, start the main unit for a load test run, gradually increasing the load to normal operating conditions.

2. Monitoring and debugging of operating parameters

During the trial operation period, key parameters of the dust removal system will be monitored: the pressure difference between the inlet and outlet of the dust collector (normal range 500-1500 Pa), flue gas emission concentration (which must meet the requirements of GB 20426-2021 “Emission Standard of Air Pollutants for Asphalt Concrete Industry,” with particulate matter emission concentration ≤ 10 mg/m³), fan operating current, and equipment vibration. If a sudden increase in pressure difference occurs (>2000 Pa), it may indicate that the filter bags are installed too tightly or are blocked, requiring a shutdown for inspection. If the emission concentration exceeds the standard, the filter bags should be checked for damage or improper sealing, and corrective actions should be taken promptly.

3. Standardized operation and maintenance management

Establish a complete lifecycle maintenance record and develop a standardized inspection system: daily inspections should record the operating status of the filter bags (checking for damage or detachment) and pressure differential changes; the dust collector hopper should be cleaned weekly to prevent excessive dust accumulation from compressing the filter bags; adjust the cleaning cycle according to operating conditions, generally performing pulse cleaning every 4-8 hours to ensure thorough cleaning without damaging the filter bags.  It is recommended to conduct a comprehensive inspection of the filter bags every 6 months, and promptly replace batches of filter bags in compartments with a damage rate exceeding 5% to ensure the long-term stable operation of the dust collection system.

Asian Construction Equipment Group Co., Ltd. has always adhered to the philosophy of “precise operation and maintenance, green empowerment.” This guide is compiled based on practical engineering experience and can be flexibly adjusted according to the specific parameters of different asphalt mixing plants and dust removal equipment.  For customized operation and maintenance solutions, high-quality compatible filter bags, or professional technical support, please contact the Asian Construction Equipment Group Co., Ltd. technical service team. We will provide you with comprehensive environmental equipment operation and maintenance services to help your company achieve safe, efficient, and compliant production.

As a company that has been deeply involved in the research, development, production, and service of asphalt mixing plant equipment for many years, Asian Construction Equipment Group Co., Ltd. (abbreviated as ACE Group) has always adhered to the philosophy of “customer-centricity and technology-driven.” We deeply understand that asphalt mixing plants, as core infrastructure for road construction and maintenance, have their stable and efficient operation directly determining construction progress, project quality, and project profitability.  Based on years of frontline service experience, we have compiled and optimized the core system for daily maintenance of asphalt mixing plants and have written this guide to provide our customers with professional, practical, and targeted maintenance solutions, helping them maximize the value of their equipment throughout its entire lifecycle.

I. Introduction

With the high-quality advancement of infrastructure construction in my country, the application scenarios of asphalt mixing plants are continuously expanding, playing a crucial role in everything from expressways and municipal main roads to rural road renovations.  As the core equipment for producing high-quality asphalt mixtures, its operating status is closely linked to the efficiency, cost, and quality of construction projects. However, it is important to note that asphalt mixing plants operate under harsh conditions of high temperature, dust, and heavy loads for extended periods. Core components are prone to wear and tear, pipeline aging, and parameter drift. If daily maintenance is neglected, minor problems can easily escalate into major malfunctions, leading to downtime losses and potentially affecting project progress and quality.Therefore, establishing a scientific and comprehensive daily maintenance system is crucial for ensuring the stable operation of equipment, and it is also one of the core focuses of ACE Group’s services to its customers.

II. The Core Value of Daily Maintenance for Asphalt Mixing Plants

Routine maintenance is not simply about “fixing things,” but rather a systematic management process that spans the entire lifecycle of the equipment. Its core value is reflected in the following four dimensions, which also serve as the core principles for ACE Group’s maintenance solutions for its clients:

1. Extend the entire lifecycle of the equipment.

An asphalt mixing plant consists of several core modules, including the mixing unit, drying drum, burner, screening system, weighing system, and conveying system, all of which operate collaboratively and are interconnected. Through extensive practical case studies, ACE Group has verified that scientific daily maintenance can effectively identify and address potential equipment problems. For example, regularly lubricating the mixing unit bearings with specialized grease can effectively reduce metal friction and wear; and promptly cleaning the caked material from the inner wall of the drying drum prevents operational imbalances caused by uneven wall thickness. This approach prevents small problems from accumulating into major malfunctions, significantly extending the equipment’s service life and improving the return on investment.

2. Ensure stable production efficiency.

Equipment stability is a prerequisite for efficient production. During peak construction periods, even one hour of equipment downtime can lead to cascading delays in subsequent processes. Through routine maintenance, the optimal operating condition of each component can be ensured: for example, regularly cleaning blockages in the screening system ensures smooth aggregate screening and prevents insufficient material supply from affecting the efficiency of the mixing process; timely inspection and adjustment of conveyor belt tension prevents belt slippage and misalignment that can interrupt material transport, thus minimizing unplanned downtime and ensuring continuous and stable production.

3. Reduce overall operating costs.

The losses caused by equipment failure include not only repair costs but also hidden costs such as downtime losses, material waste, and premium prices for emergency spare parts. ACE Group reminds its customers that routine maintenance is a “low-cost, high-return” investment: for example, timely replacement of worn mixing blades can prevent uneven mixing of materials due to excessive blade clearance, reducing waste; regular inspection of oil and air lines for leaks can prevent fuel and compressed air leaks, lowering energy costs. Statistics show that customers who consistently perform routine maintenance can reduce their annual equipment maintenance costs by more than 30%.

4. Ensure the quality of construction work.

The quality of asphalt mixture directly determines the load-bearing capacity and service life of the road, and the stability of equipment operating parameters is crucial to ensuring the quality of the mixture.  Routine maintenance, through regular calibration of the weighing system, ensures that the proportion of aggregates, asphalt, and fillers meets design requirements; regular inspection of the burner’s air-fuel ratio ensures uniform heating of aggregates in the drying drum, preventing performance degradation of the mixture due to temperature fluctuations. ACE Group firmly believes that high-quality equipment maintenance is a vital guarantee of project quality.

III. Core Aspects of Daily Maintenance for Asphalt Mixing Plants

Combining the structural characteristics of the equipment with years of service experience, ACE Group has organized its daily maintenance procedures into five core modules: lubrication, cleaning, inspection and adjustment, replacement of wear parts, and electrical system maintenance. These modules are interconnected, forming a complete maintenance system.

1. Precise lubrication and maintenance

Lubrication is crucial for reducing mechanical wear and tear, and the following principles should be followed: “precise oil selection, timely replenishment, and regular inspection.”

• Lubrication of core components: For key moving parts such as the mixing unit bearings, gearbox, drying drum support rollers, and drive chains, use lithium-based grease or gear oil that meets the requirements specified in the equipment manual, and add or replace them periodically (e.g., lubricate the mixing unit bearings every 50 hours, and replace the gear oil in the gearbox every 2000 hours);

• Lubrication System Inspection: Check the oil level and oil quality of the lubrication station daily. If the oil is cloudy, contains impurities, or the oil level is below the warning line, filter or replace the oil promptly. Regularly check the oil pipes and nozzles for blockages or leaks to ensure the lubrication system is functioning properly.

2. Comprehensive cleaning and maintenance

Equipment cleaning not only prevents dust and oil from corroding components, but also facilitates the timely detection of potential malfunctions.

• Screening and Conveying System: Clean the surface and surrounding areas of the screening machine’s screen daily to prevent screen blockage; regularly clean the hoppers and inner walls of the belt conveyors and screw conveyors to prevent material adhesion and accumulation;

• Dust removal and heating system: Regularly clean the filter bags of the bag filter dust collector, check for any damage to the filter bags, and ensure that the dust removal effect meets the standards; clean the caked material and deposits on the inner wall of the drying drum to prevent affecting heating efficiency and drum balance;

• Electrical control and hydraulic systems: Regularly clean dust from inside the electrical control cabinet and check that the cooling fans are working properly; clean oil and dust from the surface of the hydraulic power unit’s oil tank, and check for clogging of the hydraulic oil filter.

3. Thorough inspection and precise adjustment

Regular inspection and adjustment are the core methods for ensuring stable equipment parameters, and these should cover all critical aspects of the equipment:

• Fastening Inspection: Daily check that all connecting bolts, anchor bolts, and fasteners are not loose, especially on components with significant vibration such as the mixing unit and drying drum. Tighten any loose fasteners immediately.

• Transmission system adjustment: Regularly check the tension of the transmission belts and chains; if they are loose, adjust or replace them promptly; check the coaxial alignment of the sprockets and pulleys to prevent misalignment and abnormal noises during operation;

• Weighing System Calibration: The weighing system (aggregate scale, asphalt scale, and powder scale) shall be calibrated at least once a week using standard weights to ensure that the measurement error is within the equipment’s allowable range;

• Combustion system adjustment: Regularly check the combustion status of the burner, observe the flame color and shape, and adjust the air-fuel ratio promptly to ensure complete combustion of the fuel and prevent black smoke emissions and excessive fuel consumption.

4. Replace vulnerable parts promptly.

Wear-prone parts are the “hot spots” for equipment wear and tear; a logbook should be maintained and these parts replaced promptly to avoid triggering cascading failures.

• Mixing system: Regularly inspect the wear of the mixing blades and liners. Replace them promptly when the wear exceeds the design threshold (e.g., when the blade thickness is reduced by 1/3).

• Conveying system: Check the conveyor belt for surface wear and edge damage. If cracks or delamination occur, repair or replace the belt promptly; check the idlers and rollers for smooth rotation, and replace them immediately if jamming or abnormal noises are detected;

• Screening system: Check the screen for damage and deformation. If there are holes or material leakage, replace the screen immediately;

• Sealing components: Regularly inspect the O-rings and gaskets in the oil and air lines, and replace them promptly if they show signs of aging or leakage.

5. Specialized maintenance of electrical systems

The electrical system is the “nerve center” of the equipment, and its safety and stability must be given top priority:

• Line inspection: Regularly check the insulation of cables and wires for damage or aging, and check for loose or overheating connections.  Repair or replace any faulty components promptly;

• Component inspection: Check the working condition of electrical components such as contactors, relays, and sensors, and clean any oxidation from the contact surfaces to ensure good contact;

• Safety protection: Check that safety devices such as emergency stop buttons, limit switches, and residual current devices are functioning correctly; regularly clean the cooling channels of the electrical control cabinet to ensure the internal temperature is maintained below 40℃.

IV. Implementation Strategies for Daily Maintenance of Asphalt Mixing Plants

High-quality maintenance content requires a scientific implementation strategy to be effective. ACE Group, based on its service experience, has developed a five-pronged maintenance implementation system for its clients: “Planning – Execution – Personnel – Documentation – Evaluation.”

1. Develop a customized maintenance plan.

Based on equipment model, service life, operating conditions (such as high temperature and high dust environments), and construction progress, a personalized maintenance plan is developed. This plan clearly defines daily, weekly, monthly, and quarterly maintenance tasks, operating standards, responsible personnel, and completion deadlines.  Specific maintenance plans are developed for critical components (such as the mixing unit and weighing system), and safety operating procedures during maintenance (such as fall protection for working at heights and power-off procedures for electrical work) are also clearly defined.

2. Strictly implement the maintenance plan.

Arrange for professional personnel to carry out maintenance work according to the plan, avoiding the situation of “prioritizing production over maintenance”; establish a closed-loop mechanism of “inspection-maintenance-verification,” maintaining daily equipment inspection records, and meticulously documenting maintenance time, projects, personnel, results, and problems found; for major safety hazards discovered during maintenance, immediately shut down the equipment, report the issue, develop a rectification plan, and track the implementation of corrective actions until completion.

3. Strengthen professional training for maintenance personnel.

The professional competence of maintenance personnel directly determines the quality of maintenance.  ACE group recommends that clients regularly organize professional training for their maintenance staff, covering topics such as equipment structure and principles, maintenance procedures, fault diagnosis techniques, and safety precautions.  They also suggest inviting technical personnel from the equipment manufacturer to provide on-site practical guidance to improve personnel familiarity with the equipment, and encouraging maintenance personnel to obtain relevant professional certifications and establishing a skills assessment mechanism.

4. Establish a comprehensive equipment database.

A complete lifecycle file is established for each piece of equipment, covering equipment procurement contracts, technical documents, installation and commissioning records, and acceptance reports; operating records (such as operating time, production output, and operating parameters); maintenance records (such as maintenance items, cycles, and consumable replacement information); repair records (such as fault type, repair plan, and replaced parts); fault analysis reports, and performance evaluation reports.  Through this archived data, the equipment’s operating status can be accurately traced, providing data support for optimizing maintenance plans.

5. Conduct regular equipment performance assessments.

A comprehensive performance evaluation of the equipment is conducted quarterly or semi-annually, testing core indicators such as production capacity, stability of mixture quality, energy consumption levels, and failure rate.  Based on the evaluation results, shortcomings in maintenance work are analyzed, and the maintenance plan is optimized (e.g., adjusting maintenance cycles, adding maintenance items).  For aging or underperforming components, upgrade and modification plans are developed in advance to avoid impacting production.

V. Frequently Asked Questions from Customers

Based on ACE Group’s daily service experience, we have compiled the most frequently asked questions from customers regarding the daily maintenance of asphalt mixing plants and provide professional answers:

1. Do maintenance schedules need to be adjusted under different operating conditions?

Yes, it is necessary. If the equipment is operating in harsh conditions such as high temperatures, high dust levels, and continuous heavy loads (e.g., construction in high temperatures during summer, aggregate processing near mines), the maintenance cycle needs to be shortened (e.g., daily lubrication cycle shortened by 1/3, cleaning frequency increased to twice a day). If the equipment is used infrequently and the operating conditions are good (e.g., intermittent construction in small municipal projects), the maintenance cycle can be appropriately extended under the guidance of professional personnel, but the inspection and calibration of core components cannot be omitted.

2. What key points should be considered when replacing wear and tear parts?

It is necessary to select original or high-quality replacement parts that match the equipment model (such as the dedicated wear parts provided by ACE group) to avoid equipment damage caused by incompatible parts; before replacement, the installation area must be cleaned and polished to ensure a proper fit; after replacement, a test run should be conducted to verify the working condition of the component; at the same time, keep a record of wear part replacements and establish a consumption ledger to facilitate timely replenishment.

3. During the maintenance process, which safety points require particular attention?

Before electrical maintenance, the power must be switched off and a “Do Not Energize” sign must be posted, and the work must be performed by a qualified electrician; for work at height (such as cleaning the drying drum or inspecting the dust collector), safety belts must be worn and safety protection facilities must be erected; when cleaning high-temperature components (such as the drying drum and burner), wait until the equipment has cooled to a safe temperature to avoid burns; during maintenance, keep away from moving parts of the equipment to prevent entanglement and injury.

4. How can we determine if the maintenance work is effective?

This can be verified through three key indicators: whether the equipment failure rate has decreased (e.g., a reduction of more than 50% in monthly failure incidents); whether production efficiency is stable (e.g., achieving the target output of mixed materials per unit time, without production reductions due to equipment problems); and whether the quality of the mixed materials is qualified (e.g., the proportion accuracy and temperature stability meet the design requirements).  Simultaneously, by comparing energy consumption and spare parts costs before and after maintenance using equipment historical data, the return on investment of the maintenance efforts can be evaluated.

VI. Overview of Applicable Scenarios

This guide is applicable to the daily maintenance of various types of asphalt mixing plants, and is especially suitable for the following scenarios. ACE Group can provide customized services based on specific requirements:

1. Construction of concrete mixing plants to support the construction of new highways/major municipal roads.

These scenarios demand extremely high levels of production efficiency and mix quality, requiring a strong focus on weighing system calibration, burner maintenance, and ensuring continuous equipment operation.  A high-frequency maintenance model of “daily inspections + weekly specialized maintenance” is recommended, and ACE Group can provide on-site technical personnel for comprehensive guidance.

2. Maintenance of upgraded and renovated older concrete mixing plants

After upgrading and retrofitting older equipment, special attention is required to ensure the seamless operation of both new and old components.  Particular focus should be placed on maintaining the connection points between upgraded components (such as new electronic control systems and precision weighing modules) and the original parts. ACE Group can provide customized maintenance plans after the upgrade to ensure the equipment performs at its full potential.

3. Concrete mixing plants in remote areas/harsh environments (such as high-altitude or high-temperature desert regions)

In these types of scenarios, equipment maintenance is challenging, and spare parts procurement cycles are long. Therefore, it is necessary to strengthen preventive maintenance, stockpile core consumable parts in advance, and optimize lubrication and sealing solutions (such as using high and low-temperature resistant lubricants). ACE Group can provide a combination of remote fault diagnosis and regular on-site maintenance services.

4. Batching plants for small-scale municipal engineering projects/rural road maintenance

These types of devices are used infrequently, and maintenance personnel may lack sufficient expertise.  Therefore, we recommend a “lightweight maintenance plan” to simplify daily operations. ACE Group can provide on-site training and regular maintenance services to ensure the equipment operates stably during peak construction periods.

VII. Conclusion

Routine maintenance of asphalt mixing plants is a systematic and long-term task that directly impacts equipment operational stability, project quality, and corporate profitability. Drawing on years of technical expertise and service experience in the asphalt mixing plant field, Asian Construction Equipment Group Co., Ltd. consistently prioritizes the stable operation of its customers’ equipment. The maintenance system, core content, and implementation strategies outlined in this guide are all derived from practical field service experience.

In the future, Asian Construction Equipment Group Co., Ltd. will continue to provide comprehensive maintenance support to its customers, including customized maintenance plan development, professional technical training, genuine spare parts supply, remote fault diagnosis, and on-site maintenance services.  This will help customers maximize the value of their equipment through scientific maintenance management, ensuring the high-quality advancement of infrastructure construction. If you have any questions or needs regarding the daily maintenance of your asphalt mixing plant, please feel free to contact Asian Construction Equipment Group Co., Ltd. professional service team.

As a leading enterprise in China’s transportation infrastructure construction equipment field, Asian Construction Equipment Group Co., Ltd. (abbreviated as​ ACE Group) has been deeply involved in the research and development and manufacturing of asphalt mixing equipment for over 20 years, consistently focusing on the industry’s technical pain points and solving problems through independent innovation. With the deepening of my country’s new urbanization construction and the strategy of building a strong transportation nation, the requirements for the quality stability, production efficiency, and green and low-carbon properties of asphalt mixtures in major projects such as roads and bridges continue to rise.The core component of an asphalt mixing plant — the mixing mechanism — directly determines the homogeneity of the finished product, production energy consumption, and equipment lifespan. It is also a key bottleneck restricting the breakthrough of domestically produced high-end mixing equipment. Based on this, ACE Group assembled a dedicated R&D team and, after three years of technical research, completed a multi-dimensional optimization and upgrade of the mixing mechanism, forming a core technology system that combines independent intellectual property rights with engineering practicality, providing strong support for the high-quality development of the industry.

DHB Asphalt Drum Mix Plant

I. Current Industry Situation and the Strategic Significance of Technological Breakthrough

In recent years, my country’s transportation infrastructure construction has achieved leapfrog development. In 2023, the total length of newly built and reconstructed highways nationwide exceeded 120,000 kilometers, and the annual consumption of asphalt mixtures exceeded 500 million tons, driving the continuous growth of market demand for mixing equipment. However, significant shortcomings still exist behind the industry’s development: although most domestic enterprises have mastered the basic manufacturing technology of medium and large-sized mixing equipment, in the field of ultra-large equipment with a capacity of tens of millions of tons and a capacity of over 400t/h, foreign brands occupy more than 65% of the market share due to their core technological advantages, and domestic equipment faces the dilemma of being “large but not strong”.The core problem lies in the fact that the design theory and manufacturing process of the mixing mechanism lag behind the international advanced level, resulting in large fluctuations in the uniformity of the mixture, insufficient asphalt coating, severe equipment wear, and high energy consumption, which directly affect the quality of the project and the construction cost.

ACE Group deeply understands that optimizing and upgrading mixing mechanisms is not only an inevitable choice to enhance the core competitiveness of products, but also a strategic measure to promote the localization of high-end equipment and ensure the quality and safety of national transportation infrastructure construction. By breaking through the bottlenecks in mixing theory and structural design through technological innovation, the gap with international brands can be effectively narrowed, providing the industry with high-performance, low-energy-consumption, and long-life domestic solutions, demonstrating the technological responsibility and industrial commitment of national enterprises.

II. Multi-dimensional Technical Standards and Core Requirements for Asphalt Mixture Mixing

Modern engineering has upgraded the performance requirements for asphalt mixtures from the traditional macroscopic homogeneity to a multi-dimensional homogenization standard of “precise particle size distribution, sufficient asphalt coating, uniform microscopic dispersion, and stable temperature field.” This places stringent requirements on the design of mixing mechanisms.

1. Particle size distribution uniformity: Coarse and fine aggregates must strictly follow the design ratio to achieve uniform distribution in three-dimensional space, forming a dense and stable skeleton structure to ensure the load-bearing capacity and durability of the mixture;

2. Asphalt coating integrity: High-intensity shearing action breaks down the water film and adsorption layer on the aggregate surface, ensuring that the asphalt binder completely coats the aggregate particles and forms an asphalt film of uniform thickness;

3. Microscopic dispersion stability: Effectively breaks up aggregate agglomeration, ensuring that fillers, admixtures and other components are uniformly dispersed in the asphalt matrix, thus constructing a stable suspension-compact system;

4. Temperature field consistency: During the mixing process, local overheating should be avoided to prevent asphalt aging, or local undercooling to prevent insufficient coating. Ensure that the temperature fluctuation of the mixture outlet is controlled within ±3℃.

5. Green and low-carbon adaptability: While meeting the mixing quality requirements, it minimizes energy consumption and equipment wear, meeting the green development requirements of engineering construction.

III. Innovative Design and Technological Breakthroughs of ACE Group’s Mixing Mechanisms

Addressing the industry’s technical pain points, the R&D team at ACE Group, based on fluid mechanics and particle dynamics simulation analysis and combined with over a thousand experimental verifications, has developed a three-dimensional optimization system of “fluid state optimization + structural upgrade + material innovation,” achieving a leap in the performance of the mixing mechanism.

(一) Innovation in material flow movement mode: design of circulation-shear composite flow pattern

Traditional twin-shaft mixers, operating in either counter-current or purely circumferential flow patterns, suffer from issues such as material retention, insufficient shear strength, and uneven liner wear. ACE Group has innovatively developed a “circulation-shear composite flow” technology, achieving three major breakthroughs through an asymmetric phase angle mixing arm arrangement and optimized guide vane design:

1. It adopts a zoned design of “main mixing zone + auxiliary shearing zone”. The main mixing zone uses a spiral mixing arm to push the material to form a closed circulation, ensuring macroscopic uniformity; the auxiliary shearing zone is equipped with high-strength shearing teeth to form a local turbulent field and enhance the microscopic dispersion effect.

2. Optimize the phase angle of the stirring arm arrangement, controlling the phase difference between adjacent stirring arms to 45°, avoiding material stagnation zones at the shaft ends and corners of the housing, and increasing the material circulation rate by 30%;

3. An innovative guide vane angle adjustment mechanism can dynamically adjust the material flow rate according to the aggregate gradation and asphalt grade, adapting to different working conditions and improving mixing adaptability by 40%.

Compared with the traditional method, the composite flow design improves the wear uniformity of the liner by 50%, extends the service life of the equipment by 35%, and increases the shear strength by 25%, effectively solving the problem of insufficient asphalt coating.

(二) Precise optimization of core structural parameters

Based on a multi-objective optimization algorithm, ACE Group accurately calibrates the key parameters of the mixing mechanism:

(1).Blade helix angle: Adopting a variable helix angle design of 17°-19°, it takes into account both axial conveying efficiency and radial mixing intensity, increasing the axial conveying speed of materials by 20% and avoiding local accumulation;

(2).Stirring arm spacing and angle: The spacing between adjacent stirring arms is optimized to 120mm, and the angle is set to 75° to form a continuous stirring trajectory, reducing the material residence time to less than 2s;

(3).Main and auxiliary shaft speed matching: Utilizing variable frequency speed control technology, the speed difference between the main and auxiliary shafts is stabilized at 17%-18%, forming an efficient shear field and reducing the coefficient of variation of asphalt film thickness by 40%.

(4).Innovative Liner and Blade Materials: Utilizing NM450 wear-resistant alloy steel and a ceramic composite coating, a “stepped self-cleaning liner” was developed, extending service life by 60% and reducing uneven mixing caused by material adhesion. Upgraded Sealing and Heat Dissipation Structure: Adopting a double-seal + negative pressure dustproof design, combined with a forced air cooling system, reduces equipment failure rate by 30%, adapting to harsh working conditions such as high temperatures and dust.

(三) Integration of intelligent control technology: adaptive adjustment system for operating conditions

ACE Group has deeply integrated intelligent sensing technology with the mixing mechanism to develop a “condition-adaptive adjustment system”: equipped with an infrared temperature sensor, a material level sensor, and a torque sensor, it monitors parameters such as the temperature of the mixture, the material level, and the mixing resistance in real time;

A database of mixing parameters is established based on big data algorithms. The speed, mixing time, and blade angle can be dynamically adjusted according to aggregate moisture content, gradation changes, asphalt viscosity, etc., to achieve “one machine adapting to multiple working conditions”.

It integrates remote diagnostics and predictive maintenance modules, which can provide early warnings of wear and tear on vulnerable parts through equipment operation data analysis, thereby reducing operation and maintenance costs.

IV. Engineering Application Case: Epoxy Asphalt Paving Project for Steel Deck of a Cross-Sea Bridge

A provincial-level eight-lane expressway reconstruction and expansion project, with a total length of 89 kilometers, requires the supply of 1.2 million tons of asphalt mixture, with stringent requirements for the uniformity, durability, and production efficiency of the mixture. The project adopted a mixing plant equipped with a new composite fluid mixing mechanism. After six months of practical application, third-party testing data showed:

· The standard deviation of Marshall stability decreased from 1.3kN to 0.7kN, with a coefficient of variation ≤5%, which is better than the industry limit of 10%.

· The average thickness of the asphalt film was 68μm, and the coefficient of variation was optimized from 16% to 8%.

· The actual production efficiency of a single machine reaches 420t/h, which is 5% higher than that of traditional equipment, and the unit energy consumption is reduced to 8.2kg standard coal/t, a 15% reduction in energy consumption;

· The equipment can operate continuously without failure for up to 720 hours, reducing the failure rate by 32% and extending the replacement cycle of vulnerable parts to 8,000 hours.

· The road surface achieved a 100% pass rate in the first inspection of core indicators, and there were no early damages, ruts, or other defects within three months of opening to traffic.

V. Technical Summary and Future Outlook

By innovating the flow pattern, optimizing the structure, and integrating intelligence into the mixing mechanism, ACE Group has successfully addressed the industry pain points of traditional mixing equipment — namely, poor uniformity, high energy consumption, and rapid wear — achieving simultaneous improvements in mixing quality, production efficiency, and green, low-carbon practices. This technological breakthrough not only demonstrates ACE Group’s independent innovation capabilities but also drives the transformation of domestically produced high-end asphalt mixing equipment towards “precision, intelligence, and greenness,” providing reliable domestic equipment support for transportation infrastructure construction.

In the future, Asian Construction Equipment Group Co., Ltd. will continue to deepen its technological research and development: First, it will focus on the integration of intelligent control and digital twin technology to build a visualized management system for the entire life cycle of the mixing process; second, it will explore the application of new environmentally friendly materials and mixing mechanisms to further reduce energy consumption and carbon emissions; and third, it will expand the research and development of ultra-large capacity (above 600t/h) mixing equipment to overcome the technical challenges of mixing under extreme working conditions.

Asian Construction Equipment Group Co., Ltd. will always take technological innovation as its core driving force, adhere to the product philosophy of “independent and controllable, high performance, green and low carbon”, and continuously provide the industry with more competitive high-end equipment and solutions, injecting a continuous stream of technological power into the construction of a transportation powerhouse.

Asian Construction Equipment Group Co., Ltd. (abbreviated as​ ACE Group) has been deeply involved in the road engineering field for many years. Relying on advanced construction equipment and a mature technical system, it has accumulated rich practical experience in the construction of hot-mix asphalt pavement. This specification, based on the current “Technical Specification for Construction of Highway Asphalt Pavement” (JTG F40–2004) and the latest industry technical standards, combined with practical data from hundreds of the company’s road engineering cases, systematically outlines the key technical points, critical control parameters, and special working condition handling solutions for the entire process of hot-mix asphalt pavement construction. It aims to provide construction teams with scientific, standardized, and practical technical guidance to ensure that project quality meets the core requirements of “high strength, high smoothness, and high durability.”

I. Construction Preparation Phase (Core Controls: Foundation Guarantee and Parameter Calibration)

1.1 Raw material quality control (source control, performance compliance)

• Asphalt materials: Base asphalt (70#, 90#) or modified asphalt (SBS, SBR type) that meet the design requirements should be given priority. Before entering the site, key indicators such as penetration (25℃, 0.1mm), softening point (ring and ball method, ℃), ductility (10℃/5℃, cm), and film oven aging test (mass loss rate, penetration ratio) must be tested. The test results must meet the corresponding grade requirements of JTG F40–2004 specification. It is strictly forbidden to use asphalt with indicators exceeding the standard or deteriorated.

• Aggregate selection: Coarse aggregates are hard rocks such as basalt and granite produced by impact crushing, with a crushing value ≤26%, Los Angeles abrasion loss ≤28%, needle-like and flaky particle content ≤15%, mud content ≤1%, and particle angularity (flow time) ≥30s; Fine aggregates are manufactured sand or clean natural sand, with gradation meeting design requirements, mud content ≤3%, and apparent relative density ≥2.60; Aggregate gradation must be verified through standard sieve analysis tests to ensure a smooth continuous gradation curve without obvious discontinuities in gradation.​

• Mineral powder compatibility: The mineral powder should be ground from limestone, with a hydrophilicity coefficient <1, a fineness modulus (passing rate on a 0.075mm sieve) ≥75%, and a moisture content ≤1%. The use of fly ash or cement as substitutes for mineral powder is strictly prohibited to avoid affecting the bonding performance between asphalt and aggregates.

1.2 Construction equipment commissioning (precise calibration, stable performance)

· Paver: Select a high-grade paver with automatic leveling and vibratory compaction functions (such as Volvo ABG or Dynapac SD series). Before construction, calibrate the vibration frequency (2000~3000 times/min) and screed angle (preset according to the loose paving thickness), and check the matching of the auger distributor speed and paving speed to ensure uniform mixture distribution and no segregation. Equip with a non-contact leveling beam or laser leveling system, with accuracy error controlled within ±1mm.

· Road rollers: Equipped with double-drum vibratory rollers (working weight ≥12t) and rubber-tired rollers (working weight ≥26t). Vibratory rollers require calibration of amplitude (0.3~0.8mm) and vibration frequency (30~50Hz). Rubber-tired rollers require strict control of tire pressure between 0.5~0.7MPa, with uniform tire wear and no localized damage. All rollers must have their travel speed calibrated (0~6km/h steplessly adjustable) to ensure uniform speed during compaction.

· Mixing equipment: An intermittent asphalt mixing plant (production capacity ≥ 240 t/h) is used, equipped with a computer-controlled automatic metering system (metering accuracy: asphalt ±0.3%, aggregate ±0.5%). During commissioning, the feeding speed of the cold aggregate bins and the screening efficiency of the hot aggregate bins need to be verified to ensure gradation stability; the fuel system and heating devices should be checked to ensure that the heating temperature of the aggregate and asphalt meets the standards.

1.3 Substrate pretreatment (base layer meets standards, interlayer bonding)

· Base layer acceptance: The flatness deviation of the base layer surface is ≤3mm/3m (measured with a 3m straightedge), the compaction degree is ≥98% (measured by sand filling method), and the deflection value meets the design requirements (≤design deflection value); the surface is free of defects such as loose material, cracks, and pits. Locally loose areas must be repaired with cement-stabilized crushed stone, and cracks with a width ≥5mm must be treated with sealant.

· Tack coat construction: After the base layer passes inspection, spray slow-cracking emulsified asphalt (PC-2 type) evenly, with the dosage controlled at 0.7~1.5L/m² (calculated based on the solid content of emulsified asphalt). After spraying, use a spreader to evenly spread 3~5mm stone chips (dosage 3~5kg/m²) to ensure that the penetration depth of emulsified asphalt is ≥5mm. After demulsification and curing, proceed to the next process.

· Sealing Coat Construction: For heavy-load roads such as highways and Class I roads, a synchronous chip seal coat (chip size 5~10mm, asphalt dosage 1.2~1.6kg/m², chip seal dosage 8~12kg/m²) or a slurry seal coat (thickness 3~5mm) needs to be added on top of the prime coat. After sealing, it must be cured for at least 24 hours to ensure interlayer bond strength ≥0.6MPa (pull-out test).

II、Mixing stage (core control: uniform gradation, temperature meets standard)

2.1 Selection and Parameter Setting of Mixing Equipment

An intermittent mixing plant with secondary screening function should be selected, equipped with an asphalt heat transfer oil heating system and an aggregate drying drum (thermal efficiency ≥85%). The computer control system must have automatic recording functions for batching, temperature, and mixing time, allowing traceability of production data for each batch of mixture.

• Temperature control standards: Aggregate heating temperature 160~190℃ (10~20℃ higher than asphalt heating temperature); asphalt heating temperature (base asphalt 150~170℃, modified asphalt 160~180℃); mixture delivery temperature (base asphalt mixture 145~165℃, modified asphalt mixture 160~180℃); The mixture temperature must not exceed 195℃ (critical aging temperature).

2.2 Key Points for Mixing Quality Control

• Mixing time: 5–10 seconds for the dry mixing stage (to ensure uniform preheating of the aggregate), 35–45 seconds for the wet mixing stage (stirring after adding asphalt), with a total mixing time of no less than 45 seconds, ensuring the mixture is free of white speckles and asphalt clumps, and has a uniform color.

• Gradation and Asphalt-Aggregate Ratio Control: Before starting work each day, the gradation of the hot aggregate bins must be tested, and the feeding ratio of the cold aggregate bins adjusted according to the test results; the asphalt and aggregate usage should be recorded for each batch, with an allowable deviation of ±0.3% for the asphalt-aggregate ratio; at least one Marshall test of the mixture should be conducted daily to test indicators such as stability, flow value, and void ratio to ensure compliance with design requirements.

• Waste disposal: If problems such as excessive temperature, deviation of gradation, or uneven mixing occur during the mixing process, the mixture must be disposed of as waste and is strictly prohibited from being used for road paving.

III. Mixed Material Transportation Stage (Core Controls: Insulation to Prevent Segregation, Continuous Supply)

3.1 Technical requirements for transport vehicles

Dump trucks with a rated load capacity of ≥20t should be used. The inner walls of the truck bed must be evenly coated with a diesel-water mixture release agent (volume ratio 1:3). The amount applied should be such that the mixture does not stick to the material; excessive application is strictly prohibited as it may cause the asphalt film to peel off. Vehicles must be equipped with double-layered rainproof and heat-insulating tarpaulins (inner layer of insulation cotton, outer layer of waterproof cloth), ensuring the tarpaulin is completely covered and free from damage or air leakage.The number of transport vehicles should be rationally configured according to the mixing plant’s production capacity and paving speed, ensuring that there are always 3–5 vehicles waiting to unload in front of the paver to avoid the paver stopping due to lack of material. Each vehicle’s cab should be equipped with a thermometer to monitor the mixture temperature in real time.

3.2 Transportation and Unloading Control

• Control vehicle speed during transportation, avoiding sudden acceleration and braking to reduce segregation of the mixture; the transportation time of the mixture should not exceed 1 hour (at normal temperature), and in high-temperature weather (≥35℃), the transportation time should not exceed 40 minutes, with the temperature drop controlled at ≤10℃/h.

• Upon arrival at the site, the asphalt mixture must be immediately tested for temperature: ≥135℃ for base asphalt mixtures and ≥150℃ for modified asphalt mixtures. Mixtures failing to meet these standards must be discarded. During unloading, transport vehicles must maintain a distance of 10–30cm from the paver, which should push the vehicles forward slowly, strictly prohibiting collisions with the paver. The tarpaulin should be gradually uncovered during unloading to prevent a sudden drop in mixture temperature.

IV. Paving Operation Stage (Core Controls: Smooth and Uniform, Suitable Temperature)

4.1 Preparations before paving

• Clean the base surface to ensure it is free of dust and debris; based on the design elevation and paving thickness, use a total station to set up control points at intervals of 5–10m, and hang steel strand baselines (tension ≥15kN) to ensure that the paving elevation deviation is ≤±2mm.

• Paver preheating: The screed preheating temperature should be ≥100℃ (base asphalt) or ≥120℃ (modified asphalt), and the preheating time should be no less than 30 minutes to avoid the mixture sticking or unevenness deviation caused by a low-temperature screed.

4.2 Paver Parameter Settings and Operation

• Paving speed: 2~6m/min for base asphalt mixture, 1~3m/min for SMA mixture. Maintain a constant speed and do not change speed or stop the machine at will. The speed fluctuation range is ≤±0.5m/min.

• Loose paving coefficient: determined through test sections, 1.15~1.35 for ordinary dense-graded asphalt concrete (AC), 1.1~1.2 for SMA mixture, loose paving thickness = design thickness × loose paving coefficient, with deviation controlled within ±5mm.

• Paving temperature: Base asphalt mixture ≥130℃, modified asphalt mixture ≥150℃, SMA mixture ≥160℃. The mixture temperature should be checked every 20 minutes during paving to ensure it meets the standards.

• Auxiliary operations: Mechanical paving is the main method, with manual assistance for edge trimming and segregation treatment; when trimming manually, heat-resistant gloves must be worn, and it is strictly forbidden to step on the high-temperature mixture to ensure a smooth surface.

V. Rolling and shaping stage (core control: compaction degree meets the standard, no wheel tracks)

5.1 Compaction Process and Equipment Combination

Rolling operations must strictly follow a three-stage process of “initial compaction → secondary compaction → final compaction,” scientifically combining equipment characteristics with the type of mixture to ensure a steady improvement in compaction quality.

• Initial compaction stage: Static compaction is performed using a double-drum roller, with a total of two passes. The core objective of this stage is to quickly eliminate paving marks and lay a smooth foundation for subsequent compaction. The temperature control standards are: not lower than 120℃ for base asphalt mixtures and not lower than 140℃ for modified asphalt mixtures.

• Secondary compaction stage: A combination of vibratory roller and rubber-tired roller is used. The vibratory roller operates with high-frequency, low-amplitude parameters (vibration frequency 35~45Hz, amplitude 0.3~0.5mm), compacting 4~6 times; the rubber-tired roller simultaneously performs 2~3 kneading compactions. Through the synergistic effect of the two compaction methods, the maximum compaction degree of the mixture (≥97%) is achieved. The temperature control during this stage is: not lower than 100℃ for base asphalt mixtures and not lower than 120℃ for modified asphalt mixtures.

• Final compaction stage: Static compaction is performed again using a double-drum roller, for a total of 2 passes. The core task is to eliminate wheel tracks generated during the secondary compaction process and ensure that the road surface smoothness meets the standard (requirement ≤1.5mm/3m). The temperature control standard is: not lower than 70℃ for base asphalt mixture and not lower than 80℃ for modified asphalt mixture.

5.2 Key Points of Compaction Operation

• Compaction sequence: Strictly adhere to the technical principles of “edges first, then center; static compaction first, then vibratory compaction; slow compaction first, then fast compaction.” The compaction direction must be consistent with the paving direction; lateral compaction is strictly prohibited to prevent pavement displacement or cracking. When operating a double-drum roller, overlap by 1/3 of the drum width; for a rubber-tired roller, overlap by 1/2 of the drum width to ensure thorough compaction without any omissions or blind spots.

• Speed control: The rolling speed must be kept constant and stable at each stage to avoid sudden acceleration or braking, which would affect the compaction effect. The specific speed standards are: 2~3km/h for the initial compaction stage, 3~5km/h for the intermediate compaction stage, and 4~6km/h for the final compaction stage, with the speed fluctuation range not exceeding ±0.5km/h throughout the entire process.

• Prohibited requirements: Before the road surface temperature cools down to below 50°C, the road roller is strictly prohibited from turning, making a U-turn, or parking on the road surface for a long time to prevent damage to the road structure; during the entire rolling process, water must not be sprayed or any auxiliary materials spread on the road surface to avoid affecting the bonding performance and compaction quality of the asphalt mixture.

VI. Joint Treatment (Core Control: Smooth, dense, and crack-free)

6.1 Longitudinal joints

• Hot joint: Two pavers work in echelon, with the subsequent paving layer overlapping the previous one by 10–15cm. The overlapping area is kept warm (≥100℃). During compaction, the roller applies static pressure once along the joint, then compacts outwards to ensure a tight joint.

• Cold joints: If continuous paving cannot be completed on the same day, the loose parts at the edge shall be cut off before construction on the next day (cutting depth ≥5cm) to make the joint vertical and flat; apply tack coat (emulsified asphalt dosage 0.3~0.5L/m²), and after the emulsion breaks, the new mixture shall be manually paved, and the flatness shall be checked with a 3m straightedge to ensure that the joint is smooth.

6.2 Transverse joints

• Joint type: Vertical flat joints are required; oblique joints are strictly prohibited. After paving, use a cutting machine to vertically cut the edges, remove loose mixture, and apply tack coat.

• Compaction Treatment: Preheat the mixture at the joint to ≥65℃. First, use a double-drum roller for transverse compaction (perpendicular to the road centerline), with a compaction strip width of 20~30cm, gradually advancing towards the new paving layer. Then switch to longitudinal compaction to ensure the joint compaction is consistent with the main pavement, without any stepped appearance.

VII. Quality Inspection and Acceptance (Core Control: Indicators Meet Standards, Appearance is Qualified)

7.1 Detection of Key Control Indicators

• Compaction degree: Core drilling was used for testing, with one point sampled per 2000m². The compaction degree at a single point was ≥97%, and the representative value was ≥98%. Simultaneously, a nucleus-free density meter was used for rapid testing to assist in controlling construction quality.​

• Thickness: Measured using core drilling method. Single-point thickness deviation ≥ design thickness — 5mm, extreme value ≥ design thickness — 10mm, representative value ≥ design thickness — 3mm.

• Smoothness: Measured with a 3m straightedge, maximum gap ≤3mm; for highways, a continuous smoothness meter is used, IRI value ≤2.0m/km.

• Permeability coefficient: Tested using a permeability meter; SMA mixture ≤ 120 ml/min, ordinary asphalt mixture ≤ 300 ml/min.

• Texture depth: Tested using the sand-laying method; ≥0.55mm for ordinary asphalt mixtures, ≥0.7mm for SMA mixtures.

7.2 Appearance Quality Acceptance

The surface is free of obvious wheel tracks, cracks, shoving, segregation, looseness, or other defects; joints are smooth with no vehicle bouncing; pavement edges are neat, and elevation meets design requirements. Any localized quality defects discovered are immediately repaired using methods such as cutting and repaving to ensure overall quality meets standards.

VIII. Handling Special Operating Conditions (Core Control: Risk Mitigation and Quality Assurance)

8.1 Construction in Rainy Weather

Laying the asphalt mixture is strictly prohibited in rainy weather or when the base layer is damp. If rain occurs during construction, paving must be stopped immediately. The already laid mixture should be quickly compacted and covered with a rainproof tarpaulin. Rain-soaked mixture must be discarded and must not be used for road paving. After rain, the moisture content of the base layer must be retested. Construction can only resume after the moisture content (≤10%) (for cement-stabilized base layers) and the surface is dry.

8.2 Low-Temperature Construction

Construction is generally prohibited when the ambient temperature is below 10℃ (for ordinary asphalt) or below 15℃ (for modified asphalt). If construction is absolutely necessary, the plant temperature of the mixture must be increased (base asphalt +10℃, modified asphalt +15℃), transportation time shortened (≤30 minutes), and the paving and compaction pace accelerated to ensure the final compaction temperature does not fall below the control standard. During low-temperature construction, the number of rollers should be increased, and the interval between initial and secondary compaction should be shortened to prevent the mixture temperature from dropping too quickly, resulting in substandard compaction.

8.3 High-Temperature Construction

When the ambient temperature is ≥35℃, adjust the construction time (avoiding the midday heat). Strengthen insulation and sun protection during the transportation of the mixture to reduce temperature loss. After paving, accelerate the compaction speed to ensure compaction is completed within the specified temperature range. Increase the frequency of mixture sampling in hot weather, focusing on monitoring asphalt aging to prevent performance degradation due to excessively high temperatures.

IX. Opening to Traffic and Maintenance

After asphalt pavement is compacted, it needs to cool naturally to ambient temperature (generally 24 hours after construction) before being opened to traffic. Driving on the uncooled pavement is strictly prohibited to avoid damage. Initially, heavy vehicles (≤20t) are restricted to a speed of ≤40km/h. Normal traffic can resume once the pavement has fully stabilized (generally after 7 days). Regular pavement inspections should be conducted after opening to traffic, and debris should be removed promptly. Any minor cracks, potholes, or other defects should be immediately addressed with preventative maintenance to extend the pavement’s lifespan.

Conclusion

Hot-mix asphalt pavement construction is a systematic and meticulous project that must strictly adhere to the core principles of “qualified raw materials, compliant equipment, standardized processes, and thorough testing.” Asian Construction Equipment Group Co., Ltd. , driven by technological innovation and focused on project quality, has developed this specification that combines years of construction practice and technological accumulation to provide comprehensive technical reference for related projects.During construction, process parameters must be optimized through test sections based on actual project conditions (such as climate conditions, material properties, and road grade). The “three quicks and two timely actions” principle (quick unloading, quick paving, quick compaction; timely testing, timely repair) must be strictly implemented to ensure the project quality meets design standards and usage requirements.

In the field of asphalt pavement engineering, technical terminology is the core carrier of technical communication, equipment operation, and engineering construction. As a high-tech enterprise specializing in the R&D and manufacturing of asphalt mixing equipment and engineering technical services, Asian Construction Equipment Group Co., Ltd. (abbreviated as ACE Group)

 deeply understands the importance of standardized and precise terminology application in ensuring project quality and improving construction efficiency. This article, combining industry standards and ACE Group’s technical practices, systematically sorts out, optimizes, and expands the core technical terminology related to asphalt mixing plants, covering four core dimensions: materials, mixtures, construction, and equipment, providing authoritative reference for industry colleagues.

I. Materials (ACE Group’s Preferred Standard Compatible Materials)

1. Asphalt: A blackish-brown solid/semi-solid viscous substance obtained through crude oil distillation, solvent extraction, or coal processing, or naturally occurring. It is the core binder of asphalt mixtures. ACE Group recommends using petroleum asphalt that conforms to the GB/T 15180 standard, suitable for different climate zones and engineering strength requirements. It covers three major categories: natural asphalt, petroleum asphalt, and coal tar pitch. Its penetration, ductility, softening point, and other indicators must be precisely matched with the process parameters of the mixing equipment.

2. Coarse aggregate: Aggregates such as crushed stone, crushed gravel, screened gravel, and slag with a particle size greater than 2.36mm in asphalt mixtures are the core components constituting the aggregate skeleton structure. The coarse aggregates compatible with ACE Group’s mixing equipment must meet the technical requirements of a crushing value ≤26% and an abrasion value ≤28%, with a predominantly cubic particle shape to ensure the stability of the skeleton interlocking.

3. Fine aggregate: This refers to natural sand, manufactured sand, and stone chips with a particle size less than 2.36mm in asphalt mixtures. Its core function is to fill the gaps between coarse aggregates and improve the density of the mixture. ACE group recommends using fine aggregates with high cleanliness and a mud content ≤3%, with an angularity index ≥30s for better adhesion to asphalt.

4. Filler: Mineral powder with a particle size of less than 0.075mm, common types include cement, lime, fly ash, and finely ground limestone powder. ACE Group’s mixing equipment and its matching powder supply system can precisely control the filler dosage, requiring a specific surface area ≥300m²/kg, which can significantly improve the cohesion and water stability of asphalt mixtures.

5. Modified asphalt: Asphalt binder with properties optimized by adding modifiers such as rubber, resin, polymers (e.g., SBS, SBR), and finely ground rubber powder, or by undergoing slight oxidation processing. ACE Group’s intelligent mixing equipment can achieve precise metering and uniform dispersion of modifiers, and is compatible with mainstream products such as SBS modified asphalt and rubber modified asphalt, meeting the anti-rutting and anti-aging requirements of high-grade highways.

6. Emulsified asphalt: A uniformly dispersed system (asphalt emulsion) made by high-speed shear emulsification of petroleum asphalt (or coal tar pitch) and water under the action of emulsifiers and stabilizers. It is classified into spray type (for tack coat and primer coat) and mixing type (for ambient temperature mixtures) according to application scenarios. ACE Group’s ambient temperature mixing equipment is compatible with emulsified asphalts with different demulsification rates, ensuring uniform mixing.

7. Cationic emulsified asphalt: Positively charged emulsified asphalt prepared with cationic emulsifiers has strong adhesion to acidic aggregates (such as granite), fast demulsification speed, and is suitable for tack coat and prime coat construction. ACE Group’s asphalt distributor truck can achieve precise spraying.

8. Anionic emulsified asphalt: negatively charged emulsified asphalt prepared with anionic emulsifiers has good compatibility with alkaline aggregates (such as limestone), high mixing stability, and is often used for mixing asphalt mixtures at room temperature.

9. Modifiers: External admixtures that improve the performance of asphalt, including polymers such as SBS (styrene-butadiene-styrene block copolymer), SBR (styrene-butadiene rubber), and PE (polyethylene), as well as finely ground rubber powder and fibers. ACE Group’s mixing equipment is equipped with a dedicated modifier addition device, enabling metering with an accuracy of 0.1%.

10. Stabilizers: Additives used to improve the storage stability of emulsified asphalt (such as calcium chloride and bentonite) to prevent asphalt particles from segregating. ACE Group recommends using stabilizers that meet the JT/T 375 standard to ensure that the emulsion shelf life is ≥6 months.

11. Solvent: A volatile liquid (such as gasoline, kerosene, diesel) used to dilute petroleum asphalt to produce liquid petroleum asphalt. ACE Group’s mixing equipment is equipped with a solvent storage and metering system to ensure accurate and controllable dilution ratio.

II. Mixed Materials (ACE Group Mixing Equipment Adaptation System)

1. Asphalt mixture: The general term for mixtures formed by mixing mineral aggregates (coarse aggregates, fine aggregates, and fillers) with asphalt binders in a designed ratio. It is the core road construction material for asphalt pavements. ACE Group’s mixing equipment can achieve precise proportioning and production of different types of mixtures.

2. Asphalt Concrete Mixture: Asphalt concrete, also known as asphalt concrete, is a mixture of coarse aggregate, fine aggregate, and filler aggregates arranged in a continuous gradation, mixed with asphalt to produce a mixture that meets technical standards (represented as LH when graded using a round-hole sieve). ACE Group’s forced intermittent mixing equipment can achieve a mix proportion deviation of ≤±2% for this type of mixture, meeting the requirements for high-grade highway surface layers.

3. Dense-graded Asphalt Concrete: A mixture with continuous aggregate gradation and dense interlocking particles, resulting in a residual void ratio of <10% after compaction. Type I dense-graded asphalt concrete (void ratio 3%–6%, 2%–6% for pedestrian roads) is suitable for main road surfaces; Type II semi-dense-graded asphalt concrete (void ratio 4%–10%) is suitable for secondary roads. ACE Group’s intelligent control system can monitor the void ratio in real time.

4. Semi-open graded asphalt mixture: also known as asphalt macadam mixture (represented by LS when graded by round hole sieve), it is made by mixing coarse aggregate, fine aggregate and a small amount of filler (or no filler) with asphalt. The residual void ratio after compaction is >10%. It is suitable for road base or subbase. ACE Group’s mixing equipment can adjust the mixing time to ensure uniformity.

5. Open-graded asphalt mixture: The aggregate gradation is mainly coarse aggregate with a low content of fine aggregate. The particles are dispersed and the porosity after compaction is >15%. It has drainage and noise reduction functions and is often used for the surface layer of drainage pavement. ACE Group equipment can accurately control the fine aggregate content to meet the gradation requirements.

6. Gap-graded Asphalt Mixture: The aggregate gradation is missing one or more particle size grades (such as missing 4.75~9.5mm particles), forming a skeleton-void or skeleton-dense structure, such as OGFC (open-graded drainage asphalt wearing course). ACE Group’s mixing equipment supports custom gradation curve settings.

7. Emulsified asphalt aggregate: This is an ambient temperature mixture made by mixing emulsified asphalt and aggregates at room temperature. It has a compaction residual void ratio of >10%, is energy-saving and environmentally friendly, and is suitable for low-grade highways or maintenance projects. ACE Group’s ambient temperature mixing plant can achieve high-efficiency production.

8. Modified asphalt mixture: Asphalt mixtures using modified asphalt as binder have excellent resistance to rutting and cracking. ACE Group’s mixing equipment is equipped with a dedicated modified asphalt heating and mixing system to ensure stable performance of the mixture.

9. Colored Asphalt Mixture: A mixture made by adding colored pigments and special modifiers, suitable for landscape roads and sidewalks. ACE Group equipment is compatible with precise metering of pigment addition.

10. Recycled Asphalt Mixture: A mixture made by adding recycled asphalt pavement material (RAP material). ACE Group’s recycled mixing equipment can adjust the RAP material content from 0 to 50%, and is equipped with a heating and screening system for the recycled material, making it energy-saving and environmentally friendly.

11. Extra coarse asphalt macadam mixture: maximum aggregate size ≥37.5mm (45mm for round hole sieve), suitable for road subbase. ACE Group’s large-scale mixing equipment can be adapted to the heating and mixing of large-diameter aggregates.

12. Coarse-grained asphalt mixture: The maximum aggregate size is 26.5mm or 31.5mm (30-40mm for round hole sieve), suitable for the lower layer of the road surface. The aggregate screening system of ACE Group Equipment can accurately control the gradation.

13. Medium-grained asphalt mixture: The maximum aggregate size is 16mm or 19mm (20mm or 25mm for round hole sieve). It is suitable for the intermediate layer of the road surface and is the core structural layer material of high-grade highways.

14. Fine-grained asphalt mixture: The maximum aggregate size is 9.5mm or 13.2mm (10mm or 15mm for round hole sieve), suitable for the surface layer of road.

15. Sandy Asphalt Mixture: Maximum aggregate size ≤ 4.75mm (5mm for round hole sieve), also known as asphalt stone chips or asphalt sand, suitable for sidewalks, bicycle lanes or road seals.

III. Construction-related (Adaptation to ACE Group’s standardized construction processes)

1. Hot-mix asphalt pavement: Asphalt and aggregates are mixed at 150-180℃ and paved at 120-150℃. This is the mainstream construction technology for high-grade highways. ACE Group’s hot-mix mixing plant can precisely control the mixing temperature and paving temperature.

 2. Asphalt mixture pavement at ambient temperature: pavement made by mixing emulsified asphalt or diluted asphalt with aggregates at ambient temperature (5-35℃), which is convenient to construct and energy-saving and environmentally friendly.

3. Prime coat: To enhance the adhesion between the asphalt surface layer and the non-asphalt base layer (such as cement-stabilized crushed stone base layer), a thin, penetrating layer of emulsified asphalt, coal tar pitch, or liquid asphalt is poured onto the base layer surface, with a penetration depth ≥5mm.

4. Tack Coat: A thin layer of asphalt material applied to enhance the bond between asphalt layers and between asphalt layers and cement concrete pavement or bridge deck. The application rate is controlled between 0.3 and 0.6 kg/m².

5. Sealing Coat: A thin layer of asphalt mixture laid to seal the voids on the road surface and prevent moisture intrusion. The layer laid on the surface of the surface course is called the upper sealing coat (anti-skid, anti-aging), and the layer laid below the surface course is called the lower sealing coat (waterproof, bonding). ACE Group’s mixing equipment can produce slurry sealing coat and chip seal coat mixtures.

6. Slurry seal: The seal is formed by mixing stone chips, fillers (cement, fly ash, etc.), emulsified asphalt, admixtures and water in a certain proportion to form a fluid dynamic mixture, which is then evenly spread on the road surface. ACE Group’s slurry seal machine can achieve integrated construction.

7. Crushed stone seal: This is a seal layer formed by first spreading asphalt binder, then evenly spreading crushed stone and compacting it. It is suitable for preventive maintenance of road surfaces. ACE Group’s asphalt distributor and crushed stone spreader can work together.

8. Liquid petroleum asphalt: A product made by diluting petroleum asphalt with solvents such as gasoline, kerosene, and diesel. It is also known as light asphalt or diluted asphalt and is suitable for tack coat and primer coat construction. ACE Group equipment is compatible with its storage and metering.

9. Paving temperature: The temperature during asphalt mixture paving. The paving temperature of hot-mix asphalt mixture is ≥120℃. ACE Group pavers are equipped with a temperature monitoring system to ensure construction quality.

 10. Compaction temperature: The temperature during asphalt mixture compaction. Initial compaction temperature ≥ 110℃, final compaction temperature ≥ 70℃. ACE Group road rollers can adjust the compaction process according to temperature requirements.

11. Curing period: The time from the completion of asphalt pavement construction to the opening of traffic. The curing period for hot-mix pavement is ≥4 hours, and for normal temperature pavement it is ≥24 hours. The specific time needs to be adjusted according to the temperature and the type of mixture.

12. Recycling Construction: The process of using a milling machine to recycle old asphalt pavement material (RAP material), which is then screened, heated, and mixed with new aggregates and new asphalt to form recycled mixture for repaving the road surface. ACE Group’s recycling mixing plant can achieve efficient utilization of old materials.

13. Milling: The operation of breaking and cutting old asphalt pavement with a milling machine, recycling old materials and repairing the pavement base. ACE Group’s matching milling machine can accurately control the milling depth (0-100mm).

IV. Equipment (ACE Group’s core products and components)

1. Asphalt Mixture Mixing Equipment: Also known as asphalt mixing plant/mixing equipment, it is the core equipment for preparing road surface mixtures by heating, metering, and mixing asphalt, aggregates, powders, and additives according to the designed proportions. ACE Group’s mixing plants cover three major series: forced intermittent, continuous, and recyclable, possessing advantages such as intelligent control, high efficiency and energy saving, and environmental compliance.

2. Forced Intermittent Asphalt Mixing Equipment: Employing a “batch batching-forced mixing” mode, each batch independently completes aggregate screening, heating, metering, and mixing, enabling precise control of the mix proportions (deviation ≤ ±1%) and quality. It is the preferred equipment for high-grade highway construction. ACE Group’s equipment of this type is equipped with a PLC intelligent control system, supporting remote monitoring and data traceability.

3. Continuous Asphalt Mixing Equipment: Production equipment for continuous heating, batching, and mixing of aggregates, with high production efficiency (up to 400t/h), suitable for large-scale road engineering. ACE Group equipment is equipped with a variable frequency speed control system to achieve flexible adjustment of output.

4. Recycled Asphalt Mixture Mixing Equipment: This equipment integrates the functions of recycling, screening, heating, and mixing of recycled materials. It can add 0-50% RAP material. ACE Group ‘s equipment is equipped with a dual heating system (low-temperature heating of recycled materials + high-temperature heating of new materials) to prevent aging of recycled materials and to save energy and protect the environment.

5. Mobile asphalt mixing plant: The equipment modules can be quickly disassembled, transported, and assembled, making it suitable for temporary projects or remote construction sites. ACE Group ‘s mobile equipment has a small footprint, a short installation period (≤7 days), and performance consistent with stationary equipment.

6. Fixed Asphalt Mixing Plant: A large-scale mixing equipment fixedly installed on site, with strong production capacity (100-600t/h), suitable for long-term, large-scale projects. ACE Group ‘s fixed equipment can customize aggregate bins and asphalt tank capacity according to needs.

7. Indoor Asphalt Mixture Production Line: The mixing equipment, material yard, and loading and unloading processes are integrated into a closed workshop to achieve full-process indoor operation, effectively control dust and noise pollution, and meet environmental protection requirements. ACE Group ‘s indoor production line is equipped with a high-efficiency dust removal and sound insulation system.

8. Aggregate heating system: The core component of the asphalt mixing plant, which uses a burner to heat the aggregate to 160-190℃. ACE Group equipment is equipped with an energy-saving burner (thermal efficiency ≥92%), which supports multiple energy sources such as diesel, natural gas, and biomass fuel.

9. Asphalt Storage Tanks: Insulated containers used for storing asphalt. ACE Group ‘s storage tanks are equipped with electric heating or steam heating systems, and the insulation temperature is controlled at 130-150℃ to prevent asphalt from solidifying. The capacity ranges from 50 to 500t.

10. Powder Supply System: Composed of powder silos, screw conveyors, and weighing scales, it is responsible for the storage, transportation, and accurate metering of fillers. ACE Group ‘s system is equipped with an anti-bridging device to ensure a stable powder supply.

11. Dust Removal Equipment: To handle the dust generated during the mixing process, ACE Group ‘s equipment adopts a two-stage dust removal system of “cyclone dust collector + bag dust collector”. The dust emission concentration is ≤10mg/m³, which meets the national environmental protection standards.

12. Intelligent Control System: The PLC control system independently developed by ACE Group integrates functions such as formula management, metering control, temperature monitoring, fault alarm, and data statistics. It supports dual operation via touch screen and computer and can realize remote operation and maintenance.

13. Asphalt Sprayer Truck: A vehicle specially designed for uniformly spraying tack coat, primer, and liquid asphalt. ACE Group ‘s sprayer truck is equipped with an intelligent flow control system, with a spraying accuracy of ≤±3% and an adjustable spraying width (2～6m).

14. Paver: A specialized piece of equipment that spreads asphalt mixture evenly on the road surface. The paving thickness (0-300mm) and width (2-12m) can be adjusted. ACE Group pavers are equipped with an automatic leveling system to ensure road surface flatness (standard deviation ≤2mm/3m).

15. Road Roller: Equipment used to compact the paved mixture, achieving a specified density (≥96%) and strength through rolling. ACE Group’s road rollers include steel-drum rollers (static/vibratory) and rubber-tired rollers, which can be used in combination depending on the type of mixture.

16. Milling machine: Specialized equipment for milling and crushing old asphalt pavement. ACE Group’s milling machine is equipped with a hydraulic drive system, and the milling depth is precisely adjustable. The old material recycling rate is ≥95%.

Conclusion

Technical terminology is the foundation for technological inheritance and innovation in the asphalt mixing plant industry. Asian Construction Equipment Group Co., Ltd. consistently focuses on “standardization, intelligence, and greening,” integrating the application of standardized terminology into the entire process of equipment research and development, manufacturing, and engineering services. This article summarizes core terms covering key technical nodes in the industry, providing precise reference for engineering technicians, equipment operators, and project managers.

In the future, Asian Construction Equipment Group Co., Ltd. will continue to deepen its expertise in the asphalt mixing equipment field, continuously optimize its product technology and service system, and promote the standardization of industry terminology and technical specifications. For further information on the application scenarios of terminology in actual engineering projects, equipment selection and adaptation solutions, or customized technical services, please feel free to communicate with the Asian Construction Equipment Group Co., Ltd. technical team at any time, and work together to build high-quality asphalt pavement projects.

As my country’s highway infrastructure construction develops towards high quality and precision, asphalt mixing plants, as core equipment in road construction, directly affect project quality and construction efficiency through their installation accuracy and system stability. As a professional road equipment R&D and manufacturing enterprise, Asian Construction Equipment Group Co., Ltd. (abbreviated as ACE Group) has been deeply involved in the asphalt mixing plant field for many years. Based on extensive engineering experience and technological innovation, it has formulated this “Standardized Installation Technical Specification for Asphalt Mixing Plants”.This specification is for reference only. Actual installation operations require flexible adjustments based on specific project conditions (such as geological conditions, equipment model differences, and local environmental requirements). If necessary, consult the ACE Group team for customized guidance. This specification focuses on the key technical points, quality control, and safety requirements of the entire installation process. It aims to provide a scientific, standardized, and practical technical reference for the installation of various models of ACE Group asphalt mixing plants, helping to ensure that each set of equipment meets design performance indicators, providing reliable production guarantees for customers, and promoting the improvement of quality and efficiency in road construction projects.

I. General Provisions

(一) Purpose of the Procedure

As a core production equipment in road construction, the installation quality of asphalt mixing plants directly determines the production efficiency, product qualification rate, and equipment lifespan of the asphalt mixture. To standardize the entire installation process of ACE Group asphalt mixing plants, unify technical standards, clarify operational requirements, prevent safety risks, and ensure that the equipment achieves its designed capacity and environmental protection targets after installation, this procedure is hereby formulated. This procedure applies to the installation engineering of new construction, relocation, and renovation projects of all models of ACE Group asphalt mixing plants.

(二) Scope of Application

This procedure covers all stages of installation, including pre-installation preparation, main equipment installation, auxiliary system deployment, electrical integration, commissioning, and acceptance. It is applicable to ACE Group’s engineering and technical personnel, cooperating construction units, and on-site workers, serving as a technical reference for installation operations. It should be noted that safety, environmental protection, and special equipment management regulations may differ in different regions. Actual operation should prioritize compliance with current local regulations. The content of this procedure does not replace specific compliance requirements.

(三) Core Principles

Installation work must adhere to the principles of “safety first, technical compliance, precise positioning, and closed-loop management,” and strictly implement the national “Installation and Acceptance Specifications for Asphalt Concrete Mixing Equipment” and the requirements of the ACE Group Technical Manual to ensure that the installation process is safe and controllable and that the installation quality meets the standards and achieves excellence.

II. Pre-installation Preparations

（一）Site and foundation engineering

1. Site Selection and Planning: The site must be flat, with geological bearing capacity meeting equipment operation requirements, far from densely populated areas, and away from underground pipelines and areas susceptible to natural disasters. The site must be rationally planned with raw material storage areas, finished material stacking areas, equipment operation areas, and maintenance access routes to ensure smooth passage for transport vehicles and sufficient operating space for construction machinery; a complete drainage system should be installed to prevent water accumulation from eroding the foundation structure.

2. Foundation Design and Construction: Based on the equipment foundation drawings provided by ACE Group and the geological survey report, a detailed foundation design will be conducted. The strength and impermeability grade of the foundation concrete must meet the design requirements, and the size and depth of the anchor bolt pre-drilled holes must be precisely controlled. After construction, the foundation surface must be kept flat, and the curing period must meet the requirements for concrete strength development. During the curing period, it is strictly forbidden to pile heavy objects or apply external forces.

3. Foundation Acceptance: After the foundation construction is completed, load-bearing capacity testing and dimensional verification are required, and a professional test report must be issued. Special attention should be paid to checking the anchor bolt embedment positions, foundation elevation, and the verticality of reserved holes. Equipment installation can only proceed after the foundation has passed inspection.

(二) Equipment unpacking inspection and storage

1. Arrival Inspection: Upon arrival of the equipment, a joint acceptance inspection will be conducted by technical personnel from ACE Group, the supervision unit, and the construction unit. The model and quantity of the main unit, components, and spare parts will be verified against the “Equipment Packing List,” with a focus on checking the appearance integrity of easily damaged parts. Professional testing methods will be used to inspect the quality of key components to prevent hidden damage during transportation.

2. Document Verification: Verify the equipment’s factory certificate of conformity, material inspection report, electrical schematic diagram, installation manual, and other technical documents to ensure that the documents match the equipment model and that all signatures and seals are complete. Simultaneously collect relevant qualification documents and test reports for special equipment and archive them as required.

3. Equipment storage: After unpacking, the equipment should be stored according to the type of components. The main components should be protected against rain and moisture. Electrical components and seals should be stored in a dry warehouse. Metal parts should be treated to prevent rust. Precision instruments should be stored separately and protected against moisture and shock.

(三) Preparation of Tools and Materials

1. Specialized tool configuration: Equipped with lifting equipment that meets the requirements for equipment hoisting and installation, testing tools with accuracy meeting measurement standards, welding equipment adapted to equipment assembly needs, and electrical testing instruments. All tools must be metrologically calibrated and have valid labels affixed to ensure that their performance and accuracy meet the operational requirements.

2. Requirements for auxiliary materials: Anchor bolts, gaskets and other connecting parts must meet the strength grade requirements; sealant must be a temperature-resistant and oil-resistant product suitable for the equipment’s operating conditions; lubricating oil must strictly follow the model specified by ACE Group; and insulation materials must meet the requirements for thermal conductivity and protective performance.

III. Main Equipment Installation Specifications

(一) Installation of the main mixing tower

1. Base Installation: Using professional lifting equipment, the base of the mixing plant is hoisted to the designated position on the foundation and initially fixed with anchor bolts. The base is then leveled using a leveling tool. Once the level is achieved, a secondary grouting method is used to fill the gap between the base and the foundation. The strength of the grout must meet the design requirements. After the grout has reached the required strength, the anchor bolts are tightened according to the specifications.

2. Tower Assembly: Install the main tower sections in a bottom-up order, layer by layer. The flange connection surfaces of adjacent sections must be cleaned and sealed properly, and high-strength bolts must be used for fastening. After each tower section is installed, use professional instruments to measure its verticality and correct any deviations promptly to ensure the overall verticality of the tower meets design standards.

3. Mixing System Installation: Hoist the mixer to the designated location inside the main mixing building and securely fix it to the tower body using connectors. Precisely connect the mixer’s inlet, outlet, and all pipes to ensure a leak-free seal at the connections; install the mixing motor and reducer, and adjust the tension of the transmission components to ensure smooth operation of the transmission system.

(二) Drying drum installation

1. Bracket Installation: Install the appropriate bracket according to the size and weight requirements of the drying cylinder. The bracket foundation must be stable and level. Use lifting equipment to hoist the drying cylinder onto the bracket and secure it firmly with positioning pins and bolts to ensure the drying cylinder is placed stably.

2. Burner Installation: Accurately install the burner at the designated location on the drying cylinder, ensuring the installation position meets design requirements. Connect the fuel supply pipeline and control system to the burner. After installation, a rigorous sealing check must be performed to prevent fuel leakage and potential safety hazards.

3. Transmission System Debugging: Install the drive motor, reducer, and transmission components of the drying drum, and adjust the tension of the transmission device to ensure that the drying drum can rotate smoothly and steadily. Start the motor for a no-load test run to check the stability of the drying drum operation and troubleshoot any abnormal vibrations or noises.

(三) Vibrating screen installation

1. Frame Fixing: Hoist the vibrating screen frame to the designated installation location and securely fix it to the foundation using anchor bolts or welding. Use a leveling tool to adjust the frame’s levelness to ensure stable installation. A vibration damping device must be installed between the frame and the foundation to ensure the vibration reduction effect meets design requirements.

2. Screen Installation: Select and install a suitable screen according to the aggregate screening requirements. The screen must be taut, secure, and free from damage or looseness. Install the vibratory motor and adjust the angle of the motor eccentric block to achieve the required vibration frequency and amplitude, ensuring that the screening efficiency meets the standards.

IV. Installation of auxiliary equipment and pipelines

(一) Installation of the batching system

1. Silo Installation: Install various raw material silos (stone silos, powder silos, asphalt tanks, etc.) according to design specifications, ensuring that the silos are installed securely and that the spacing between each silo meets the requirements for operation and maintenance. Powder silos need to be equipped with dust collectors and arch-breaking devices, and asphalt tanks need to be equipped with heating devices and temperature control systems to ensure the silos function properly.

2. Feeding Equipment Installation: Install a suitable feeder (belt scale, screw conveyor, electromagnetic vibrating feeder, etc.) at the bottom of the silo. Adjust the discharge port position of the feeding equipment to ensure that the material can smoothly enter the next process. Connect the electrical control system of the feeding equipment to achieve precise control of the feeding rate.

(二) Installation of the conveyor system

1. Belt Conveyor Installation: Lay the belt conveyor according to the process flow, ensuring the frame is installed flat and firmly, and that the idlers and rollers meet the specifications. Adjust the belt tension to prevent belt deviation during operation; install necessary safety protection devices to ensure safe equipment operation.

2. Powder Conveying Pipeline Installation: Install various types of powder conveying pipelines. The pipeline material must meet the requirements for wear resistance and sealing. Pipeline connections must be tight, and seals must be used to prevent powder leakage. Necessary valves and elbows should be installed on the pipelines to ensure smooth powder conveying.

3. Installation of Asphalt Conveying Pipelines: Asphalt conveying pipelines must be insulated to prevent the asphalt from solidifying during transport. Specialized sealing materials must be used for pipe connections to ensure a tight seal. An asphalt pump and heating equipment must be installed to ensure the asphalt can be smoothly delivered to the mixing system.

(三) Installation of dust removal system​

1. Dust Collector Installation: Select and install a suitable dust collector based on the batching plant’s production capacity and environmental standards. The installation location should facilitate operation and maintenance, ensuring smooth connections between the dust collector’s inlet and outlet pipes. The dust collector must be linked to the control system to achieve automated adjustment of the dust removal function.

2. Ventilation duct installation: Lay ventilation ducts to effectively connect the dust collector to each dust-generating point in the mixing plant. The ventilation ducts must have sufficient strength and sealing to ensure effective dust collection; the duct layout must be reasonable to avoid sharp bends or the risk of blockage.

3. Exhaust Fan Installation: Install an exhaust fan at the end of the ventilation system. The fan’s airflow and pressure must meet the design requirements of the dust removal system. Adjust the fan’s direction and speed to ensure stable negative pressure in the ventilation system. The fan installation must be equipped with vibration damping devices to reduce operating noise.

V. Electrical System Installation and Commissioning​

(一) Installation of electrical control cabinet

1. Cabinet Fixing: The electrical control cabinet must be installed in a dry, well-ventilated control room. The cabinet must be installed vertically and level, firmly fixed to the ground, and reliably grounded. The spacing between cabinets must meet the requirements for operation and maintenance space, facilitating future maintenance.

2. Wiring Specifications: Wiring inside the control cabinet must be carried out according to the electrical schematic and wiring diagram. Wire and cable types must meet design requirements. Wiring of different voltage levels and purposes must be laid separately and clearly labeled. Terminals must be securely crimped, and wiring insulation performance must meet standards.

(二) Wiring between the motor and the sensor

1. Motor Wiring: An insulation resistance test must be performed before wiring the motor to ensure good motor performance; the wiring method must strictly follow the requirements on the motor nameplate, and protective measures must be taken for cable laying. The motor casing must be reliably grounded, and large motors must be equipped with overload protection devices.

2. Sensor Installation: Temperature, pressure, and weight sensors must be installed in designated locations to ensure accurate measurement data. Sensor wiring shielding must be effectively grounded, and signal transmission cables must be kept away from power cables to avoid signal interference. Sensors must be calibrated before installation to ensure measurement accuracy meets design requirements.

(三) Installation of grounding and lighting systems

1. Grounding System Installation: A complete grounding system shall be constructed using a combined grounding method, including grounding electrodes, grounding wires, and grounding busbars. The installation depth and material of the grounding electrodes must meet standards, the grounding wire connections must be secure and reliable, and the grounding resistance must meet safety requirements. Equipment metal casings, electrical control cabinets, motors, etc., must all be reliably grounded.

2. Lighting System Installation: Sufficient lighting fixtures shall be installed in the mixing plant’s operating area and control room. The lighting intensity must meet the needs of operation and maintenance, and the protection level of the fixtures must be appropriate for the operating environment. Lighting circuits must be laid independently and equipped with emergency lighting devices to ensure lighting needs are met in the event of a sudden power outage.

VI. Equipment Commissioning and Trial Operation

(一) No-load commissioning

1. Individual Unit Commissioning: After completing equipment installation and electrical wiring, start each unit in the order of “electrical first, then mechanical; auxiliary equipment first, then main unit”. Observe the equipment operation status, check the motor rotation, transmission component operation and lubrication effect, troubleshoot abnormal vibration or noise, and ensure that the individual unit operating parameters meet the design requirements.

2. Interlocking Debugging: After the individual machine debugging is qualified, start the entire set of equipment for interlocking no-load debugging. Simulate the actual production process, check the interlocking control functions between the equipment, verify the smoothness of the material conveying path and the accuracy of valve action, and ensure the reliability of the emergency stop function.

(二) Load Trial Operation

1. Trial Production Preparation: Prepare qualified raw materials according to the design mix ratio and check that the quality of the raw materials meets the specifications. Adjust the equipment operating parameters to ensure that all systems are in a ready state; formulate a trial production plan, clarifying the operating procedures and safety precautions.

2. Trial Production Operation: Gradually increase the input of raw materials and carry out trial production operations according to plan. Monitor the equipment operating status in real time, record key operating parameters (temperature, pressure, output, etc.), and check the equipment sealing performance and wear condition; conduct quality testing on the produced asphalt mixture to ensure that the product quality meets the standards.

3. Problem rectification: Problems discovered during the trial operation (such as material leakage, abnormal noise, parameter deviation, etc.) will be addressed by the technical personnel of ACE Group, who will lead the development of rectification plans, complete the rectification within a specified time limit, and retest until the problem is completely resolved.

VII. Acceptance and Delivery

(一) Acceptance Standards and Contents

1. Installation quality acceptance: In accordance with this procedure and relevant national standards, check the installation accuracy (levelness, verticality, concentricity, etc.), the firmness and sealing performance of the connection parts, and verify the standardization of electrical wiring and the integrity of the equipment appearance.

2. Performance index acceptance: Test the equipment’s production capacity, product quality pass rate and energy consumption level, check whether environmental protection indicators (dust emissions, noise, etc.) meet the requirements, and ensure that the overall performance of the equipment meets the design standards.

3. Document Acceptance: Verify the technical documents required for acceptance (equipment unpacking and acceptance record, foundation inspection report, installation and construction record, commissioning report, raw material certificate of conformity, etc.) to ensure that the documents are complete, the data is accurate, and they meet the archiving requirements.

(二) Preparation of Acceptance Report

After acceptance, the Asphalt Mixing Plant Installation Acceptance Report shall be jointly prepared by ACE Group, the construction unit, and the supervision unit, which shall specify the acceptance content, acceptance method, acceptance results and rectification status, and attach supporting materials such as equipment photos and test reports, and shall be signed and confirmed by the participating units.

(三) Delivery and Training

1. Equipment delivery: After acceptance is completed and all issues are rectified, the equipment handover procedures will be completed, and the equipment technical data (installation manual, operation manual, maintenance manual, spare parts list, etc.) and acceptance report will be handed over to the user. Both parties will sign the delivery confirmation document.

2. Personnel Training: ACE Group’s technical personnel conduct systematic training for user operators and maintenance personnel, including equipment structure and principles, operating procedures, troubleshooting methods, and key points of daily maintenance. After the training, an assessment is conducted to ensure that relevant personnel have the ability to operate and maintain the equipment independently.

VIII. Supplementary Provisions​

1. This specification is subject to interpretation and revision by the Engineering and Technology Department of Asian Construction Equipment Group Co., Ltd.. Any matters not covered herein shall be handled in accordance with current national standards and equipment technical manuals. The content of this specification is for reference only and will be updated to reflect industry technological developments and engineering practices during revision.

2. Installation work must strictly adhere to safe operating procedures. The construction unit must provide complete safety protection facilities, and all personnel must be certified and comply with safety management regulations. These safety requirements are for reference only; actual requirements must comply with national work safety regulations and the project’s specific safety plan.

3. After the equipment is installed, a regular maintenance plan should be developed and maintenance work should be carried out as required. The specific maintenance requirements should be in accordance with the “Maintenance and Maintenance Procedures for Asphalt Mixing Plants” of ACE Group.

IX. Conclusion

This “Standardized Installation Technical Specification for Asphalt Mixing Plants of ACE Group” is a concentrated reflection of Asian Construction Equipment Group Co., Ltd. technical strength and engineering experience. Its content is for reference only and does not constitute a final technical commitment or legal basis. The core value of this specification lies in providing a standardized and detailed reference framework for installation operations and offering full-cycle technical support for equipment installation quality. In practical application, relevant units should flexibly adjust the specifications according to the specific circumstances of the project (such as geological conditions, equipment models, local regulations, etc.), strictly adhere to current national standards and regulations, strengthen process control, pay attention to details, and ensure the safety and compliance of every procedure.In the future, Asian Construction Equipment Group Co., Ltd. will continue to track industry technology development and engineering practice needs, dynamically optimize and upgrade this specification, provide customers with more targeted technical references, and help my country’s road construction industry achieve high-quality development.

Introduction: Fuel Selection — The Core Foundation for Efficient and Environmentally Friendly Operation of Asphalt Mixing Plants

As a key piece of equipment in road construction, the choice of fuel for asphalt mixing plants directly impacts production efficiency, operating costs, and environmental compliance. Under the industry’s backdrop of “dual carbon” goals and increasingly stringent environmental regulations, selecting the optimal solution from categories such as diesel, heavy oil, natural gas, coal, biomass fuels, and PMC new solid fuels has become a core issue for enterprises to reduce costs, increase efficiency, and achieve sustainable development. Based on years of industry experience, Asian Construction Equipment Group Co., Ltd. (abbreviated as ACE Group) provides a comprehensive analysis of the technical characteristics and practical application scenarios of various fuels, offering professional selection guidance for the industry.

I. Comparison of Mainstream Fuel Technology Characteristics and Applicable Scenarios

(一) Traditional fossil fuels

diesel fuel​

Technical parameters: Calorific value 42-46 MJ/kg, combustion efficiency ≥92%, NOx emission 800-1200 mg/m³

Key advantages: Fast ignition response (≤3 seconds), no pretreatment equipment required, compatible with various small and medium-sized mixing plants, high combustion efficiency (thermal conversion efficiency can reach over 85%), and can accurately ensure the uniformity and stability of aggregate heating; wide supply network coverage, convenient access and filling, and no complicated pretreatment process required.

Significant disadvantages: High unit costs, which will drive up operating costs in the long run; high emissions of nitrogen oxides (NOx) and particulate matter (PM) during combustion, which do not meet the environmental protection requirements of first-tier cities, resulting in significant environmental compliance pressure.

Applicable scenarios: short-term emergency production, temporary operation of small mixing plants, or remote areas where natural gas or heavy oil supply is limited.

Heavy oil (industrial fuel oil)

Technical parameters: Calorific value 40-44 MJ/kg, combustion efficiency 88%-90%, sulfur content ≤350 mg/kg (national standard).

Key advantages: Low raw material cost, 30%-40% lower than diesel price; high calorific value (approximately 42,000 kJ/kg), which can meet the heat requirements of continuous high-intensity production in large-scale mixing plants with a calorific value of 160t/h.

Significant disadvantages: It requires supporting pretreatment equipment (such as filtration and heating devices), which increases the initial equipment investment and subsequent maintenance costs; the concentration of combustion pollutants is high, and there is a high risk of exceeding the standards for sulfur content and particulate matter emissions, requiring additional desulfurization and denitrification equipment.

Applicable scenarios: Large-scale mixing plants in areas with abundant resources and relatively relaxed environmental regulations, and which must have complete environmental treatment facilities.

Coal (thermal coal)

Core advantages: my country has abundant and widely distributed coal resources, low transportation costs, and the lowest unit heat cost among traditional fuels.

Significant disadvantages: Low combustion efficiency (only 60%-70%), resulting in significant energy waste. Combustion produces large amounts of pollutants such as sulfur dioxide, nitrogen oxides, and particulate matter, requiring a complete set of environmental protection equipment (desulfurization tower + denitrification device + bag filter). Slagging is prone to occur during combustion, necessitating regular furnace cleaning (1-2 times per month), leading to increased equipment downtime and severe environmental pollution. In some areas, the use of coal in coal mixing plants around urban areas has been restricted. Storage requires dedicated space, occupies a large area, and carries the risk of spontaneous combustion.

Applicable scenarios: Limited to special areas with extremely low environmental protection requirements and extremely convenient resource access. Its use is now being gradually restricted by policies.

(二) Clean and environmentally friendly fuels

Natural gas (LNG/CNG)

Technical parameters: Calorific value 36-38 MJ/m³, combustion efficiency ≥95%, NOx emission ≤200 mg/m³, sulfur content nearly zero.

Key advantages: Outstanding clean and environmentally friendly characteristics; nitrogen oxide emissions after combustion are only 1/3 of those of diesel, particulate matter emissions are almost zero, and sulfur dioxide emissions are negligible, easily meeting the “National VI” and more stringent local environmental standards; no additional investment in environmental protection equipment is required, and when paired with a modern high-efficiency burner, the combustion efficiency can reach over 90%, with stable heat output, effectively improving the production quality of asphalt mixtures.

Significant disadvantages: Supply is limited by regional pipeline network coverage; areas without natural gas pipelines require the construction of skid-mounted stations, resulting in higher initial equipment and pipeline laying costs; prices are affected by market fluctuations, transportation costs increase in remote areas, and long-term stability is slightly inferior to heavy oil.

Applicable scenarios: Cities and surrounding areas with strict environmental protection requirements, large-scale mixing plants, long-term fixed sites, especially suitable for projects with high requirements for production environment and product quality.

(三) Renewable Energy

Biomass fuel (molded pellets)

Technical parameters: Calorific value 18-22 MJ/kg, combustion efficiency 85%-88%, net CO₂ emissions ≈ 0 (carbon cycle)

Core advantages: Highly renewable, with a wide range of raw material sources (such as straw, wood chips, agricultural and forestry waste, etc.), in line with the “carbon neutrality” development trend; net carbon dioxide emissions during combustion are close to zero, making it highly environmentally friendly.

Significant disadvantages: Lower calorific value (approximately 18,000-25,000 kJ/kg), requiring larger combustion equipment and storage space; High moisture content, prone to mold growth during storage, requiring dedicated sealed storage silos, resulting in higher transportation costs and loss rates; Poor combustion stability, requiring a dedicated combustion control system.

Applicable scenarios: Areas rich in agricultural and forestry resources, and areas where environmental policies encourage the application of renewable energy. Suitable for small and medium-sized mixing plants or as an auxiliary fuel.

(四) New Alternative Fuels: PMC New Solid Fuels

Technical parameters: Calorific value 48-52 MJ/kg, combustion efficiency ≥96%, NOx emission ≤150 mg/m³

Core advantages: It combines environmental friendliness and economy, boasting a combustion rate exceeding 98%, with pollutant emissions far lower than heavy oil and diesel, meeting stringent environmental standards for nitrogen oxides and particulate matter emissions; it offers a significant advantage in calorific value, being approximately 60% cheaper than diesel, with combustion efficiency 10% higher than heavy oil and 30% lower than natural gas, while also reducing equipment carbon buildup, lowering maintenance costs and failure rates, and exhibiting superior environmental performance compared to natural gas, requiring no additional environmental treatment, resulting in outstanding long-term comprehensive benefits; it is highly adaptable to various processes and can be retrofitted to existing mixing plant equipment.

Significant disadvantages: Currently reliant on imports, with high initial procurement costs for core equipment (solid fuel burners) and substantial upfront investment; supply stability is affected by international logistics and trade policies. There are currently few domestic suppliers, and supply chain stability needs improvement.

Applicable scenarios: Large-scale mixing plants with sufficient financial strength that pursue long-term cost reduction and environmental upgrades, especially suitable for enterprises with high requirements for both operating cost control and environmental compliance.

II. Core Decision-Making Dimensions for Fuel Selection (Professional Advice from ACE Group )

Cost-benefit balance: A comprehensive calculation of the entire life cycle cost, including fuel procurement costs, equipment investment costs, maintenance costs, and environmental treatment costs, is required. For example, natural gas has high initial equipment investment but low environmental treatment costs in the later stages; heavy oil has low procurement costs but requires additional pretreatment and environmental retrofitting costs, which may not be cost-effective in the long run.

Resource availability: Prioritize fuel types with stable local supply and convenient transportation. Natural gas should be prioritized in areas with pipeline coverage; biomass fuels can be explored in areas rich in agricultural and forestry resources; diesel fuel or supporting heavy oil pretreatment equipment can be used temporarily in areas without clean fuel supply.

Policy and Environmental Requirements: Strictly adhere to local environmental regulations and industry policies to avoid production shutdowns and rectifications due to improper fuel selection. In areas with strict environmental controls, prioritize natural gas, biomass fuels, or PMC (Proton Modified Metals) solid fuels; allow for future upgrades to adapt to even stricter environmental standards.

Production scale and operating conditions: Large-scale continuous production mixing plants are suitable for fuels with high calorific value and strong stability (such as natural gas, heavy oil, and PMC new solid fuels); small-scale intermittent production plants can choose to obtain convenient diesel or biomass fuels.

Conclusion: Driving Green Upgrading of the Industry through Scientific Selection

Currently, fuel selection for asphalt mixing plants is trending towards “cleaner, more efficient, and lower-cost” options. Natural gas, with its mature technology and environmental advantages, remains the mainstream choice in areas with strict environmental controls. PMC (Polymerized Carbon) solid fuels, as an emerging alternative, are expected to become an important direction for cost reduction and efficiency improvement in the industry after policy support and technology localization. Biomass fuels, guided by renewable energy policies, are seeing their application scenarios continue to expand.

Hello everyone, friends and partners in the engineering industry!

In road construction, municipal maintenance, airport and dock construction, there is a “core piece of equipment” that always plays a central role – the asphalt mixing plant! Simply put, the smooth roads and runways we travel on rely entirely on its precise proportioning and efficient mixing of the core material, “asphalt mixture.”

As a company deeply rooted in the engineering equipment field, Asian Construction Equipment Group Co., Ltd. (abbreviated as​ ACE Group) will today use a “professional + plain language” approach to fully unlock the secrets of asphalt mixing plants: from what they are and what they can do, to their internal structure, how to select them, and how to use them—we’ll explain it all in one go. Whether you’re selecting and purchasing, operating on-site, or performing routine maintenance, you’ll gain a clear understanding after reading this!

I. understand: What is an asphalt mixing plant? How has it evolved?

Core Definition

An asphalt mixing plant (also called an asphalt concrete mixing plant) is a specialized production line for the mass production of asphalt mixtures. Its core task is clear: according to a pre-designed formula, it precisely weighs and efficiently mixes raw materials such as aggregates, asphalt, and mineral powder to ultimately produce a mixture that meets road quality requirements—without it, there would be no smooth and durable asphalt pavement!

Development Process: From “Manual Work” to “Intelligent Manufacturing”

Early on: Mixing relied entirely on manual labor or simple machinery, which was not only inefficient but also resulted in inaccurate proportions and inconsistent road surface quality. Now: It has long been upgraded to an “intelligent player”! Equipped with a PLC automated control system (equivalent to the “brain” of the equipment), online monitoring, and energy-saving and environmental protection technologies, production efficiency, mixture quality, and environmental protection levels have all achieved a qualitative leap. One person can operate the entire process from the control panel.

II. What materials can it produce? Where can it be used? — Comprehensive application scenarios

Types of mixtures that can be produced (customized to meet different needs)

Ordinary asphalt mixture (AC): The “basic” choice for everyday road construction, offering high cost-effectiveness;

Modified asphalt mixture (SBS, rubber powder modified, etc.): More wear-resistant and high-temperature resistant, suitable for highways and heavy-duty roads;

Colored asphalt mixture: Aesthetically pleasing! Commonly used in scenic roads, urban sidewalks, and bus lanes;

Special purpose mixtures (high modulus, ultra-thin wearing course, etc.): Designed for special working conditions, such as airport runways and port terminals, offering maximum strength and durability.

Main Application Scenarios

From major transportation arteries like highways and first-class roads, to municipal roads, residential parking lots, airport runways, port terminals, and even road maintenance and repair, asphalt mixing plants are indispensable – truly a “must-have” piece of equipment for transportation infrastructure construction!

III. Internal Structure Revealed: 12 Core Systems, Each with its Own Function

An asphalt mixing plant may appear large and complex, but it’s actually a “well-organized team.” Twelve core systems work in perfect harmony to produce qualified asphalt mixtures. Let’s break them down one by one:

Cold Aggregate Batching System: The raw material “sorter”—separates stones (aggregates) of different sizes into cold aggregate bins, precisely conveying them according to the formula ratio to avoid “too much or too little material”;

Drying System: The raw material “dryer”—uses drums to dry the moisture in the aggregates and heats them to a specified temperature (e.g., around 160℃). Heat exchange efficiency directly affects energy consumption;

Combustion System: The “heat source provider” of the drying system—burns fuel oil, natural gas, or pulverized coal, requiring stable heat output, high thermal efficiency, and minimal emissions;

Hot aggregate lifting system: The raw material “transporter”—The elevator transports the dried hot aggregate to the vibrating screen. It must be wear-resistant and well-sealed to prevent heat loss and material leakage.

Vibrating screen: The raw material “screener”—It sorts the hot aggregate by particle size, removing oversized particles to ensure the aggregate size meets the formula requirements.

Hot aggregate storage silo: The hot aggregate “temporary warehouse”—It stores the screened hot aggregate by particle size, with enough capacity to produce several batches of aggregate, avoiding frequent refills.

Metering and Mixing System: The “Chef” of the Mixture – Aggregates, asphalt, and mineral powder are precisely weighed separately (the error must be controlled within a few parts per thousand), and then mixed evenly using a forced mixer. This step directly determines the quality of the mixture.

Asphalt Supply System: The “Thermostatic Steward” of the Asphalt – Asphalt tanks and a heat transfer oil system work together to keep the asphalt in a liquid state (otherwise it would solidify), and precisely deliver it to the mixing tank.

Powder Supply System: The “Conveyor” of Mineral Powder – Stores and transports mineral powder or additives, preventing clumping and arching, otherwise the powder supply will be inconsistent.

Dust Removal System: The “Guardian” of Environmental Protection – A combination of cyclone and bag filter dust collectors “blocks” dust generated during production, meeting environmental emission standards and keeping the workshop clean.

Finished Product Silo: The “Insulated Warehouse” for Mixed Materials – Stores the mixed finished materials, keeping them warm (preventing clumping and hardening). Available in bottom-mounted and side-mounted types, select according to needs.

Control System: The “brain center” of the entire station—the PLC, operating console, and monitoring interface are integrated. It can automatically control production, record data, and remotely diagnose faults. High-end equipment now relies on it to achieve intelligent operation.

IV. How to choose the right style? — 4 main categories to match your needs

Asphalt mixing plants aren’t a “one-size-fits-all” solution. They can be categorized across four dimensions to help you quickly find the right model for your needs:

1.By Mixing Method (The core difference lies in “production rhythm”)

Forced Intermittent Mixing (Mainstream): “Batch mixing”—aggregates are dried first, then the mixture is mixed in batches, each batch taking 45-60 seconds. This results in stable quality and precise proportions, making it the choice for most projects.

Continuous Drum Mixing (High-Yield): “Conveyor Mixing”—drying and mixing occur continuously in the same drum, resulting in high output, but slightly lower proportioning accuracy. This is suitable for scenarios where high quality requirements are not critical and rapid delivery is needed.

2.By Transportation Method (Depending on whether the construction site is fixed):

Fixed: “Permanent Player”—Fixed in one location, equivalent to an “asphalt mixing plant,” suitable for long-term, high-volume production (such as mixing plants around cities);

Semi-Fixed: “Assembled Player”—Disassembled and loaded onto trailers, then reassembled at the construction site, suitable for temporary construction sites of large road projects;

Mobile: “Flexible Player”—Also disassembled and loaded onto trailers, but assembly is faster and relocation is convenient, suitable for small to medium-sized projects and situations requiring multiple construction sites.

3.By production capacity (depending on your required output):

Small: ≤40 tons/hour (suitable for small-area repairs, rural roads);

Medium: 40-400 tons/hour (commonly used for municipal roads and ordinary highway construction);

Large: ≥400 tons/hour (for large-scale projects such as highways and airport runways).

4.By Environmental Protection Level (Consider Environmental Configuration and Resource Utilization):

Standard Type: “Basic Environmental Protection Model”—Equipped with simple dust removal and basic emission control devices, meeting the minimum national environmental standards. Suitable for small projects with lenient environmental requirements and limited budgets.

Environmentally Friendly Type: “Upgraded Purification Model”—Equipped with high-efficiency baghouse dust collectors, desulfurization and denitrification devices, and a low-noise design. Dust and flue gas emissions are far below national standards, resulting in an odorless and dust-free workshop. Suitable for municipal projects in urban areas with strict environmental requirements.

Recycling type: “Resource recycling model” – The core highlight is its ability to be mixed with recycled asphalt mixture (RAP). After the waste pavement is recycled and crushed, it is mixed with new materials and new asphalt for reprocessing. This not only saves resources such as stone and asphalt, but also reduces waste landfill, maximizing environmental benefits and reducing raw material costs. It is suitable for road renovation, maintenance and projects with strict environmental policies (the core technology is the precise crushing, heating and blending ratio control of recycled materials).

V. Working Principle: The Birth of Asphalt Mixtures (Understand Step by Step)

The production process of an asphalt mixing plant is actually quite clear, much like “preparing a standardized meal,” with the following steps:

Cold aggregate supply + batching: Take out stones of different sizes according to the formula;

Drying and heating: Dry and dehydrate the stones, then heat them to the specified temperature;

Lifting and screening: Send the hot stones onto the screen and separate them into different particle sizes;

Hot material storage: Temporarily store the materials according to particle size for future use;

Precise weighing: Weigh the stones, asphalt, and mineral powder separately, with no error;

Forced mixing: Mix all raw materials evenly to form an asphalt mixture;

Finished product storage + transportation: Store in a finished product warehouse with insulation, then transport to the construction site by engineering vehicles.

The entire process is “commanded” by the control system, which is automated and coordinated without human intervention, ensuring that the quality of each batch of materials is consistent.

VI. Core Advantages: Why Choose a High-Quality Asphalt Mixing Plant? (Key Points from ACE Group)

High-efficiency production: Optimized heat exchange structure + high-efficiency burner + rapid mixing technology ensures high output and timely completion.

Intelligent and controllable: PLC automated control ensures precise proportioning, full monitoring of the production process, and stable mixture quality, eliminating concerns about substandard materials.

Environmentally friendly and energy-saving: Baghouse dust collection and negative pressure control reduce dust emissions; energy-saving burner + recycled material blending (RAP) technology is both environmentally friendly and cost-effective.

Durable and easy to maintain: The overall structure is optimized, and key components (such as stirring blades and drums) are designed to be wear-resistant, resulting in a long service life and simple daily maintenance.

VII. Selection Guide: 3 Steps to Choose the Right Model and Avoid Pitfalls (Practical Advice from ACE Group)

First, clarify the construction requirements: Based on the road grade (highway/municipal/rural road), daily required output, construction period (long-term/temporary), and construction site size, determine the equipment capacity and transportation method;

Next, examine the core technical performance: Focus on these 5 points—metering accuracy (accurate materials ensure good quality), mixing uniformity (prevents clumping of the mixture), automation level (saves labor), environmental indicators (dust/smoke emissions meet standards), and energy consumption (saves fuel costs);

Finally, compare brands and cost-effectiveness: Imported equipment has good performance but is expensive and has high maintenance costs; domestic equipment is now technologically mature, cost-effective, and easy to maintain. For example, ACE group’s asphalt mixing plant focuses on “precision, efficiency, and environmental protection” and is suitable for most engineering scenarios in China.

VIII. Maintenance and Care: Tips for Extending Equipment Life (Daily + Regular)

Routine Maintenance (Must be done every day after get off work)

Clean any adhering material inside the equipment (otherwise it will clump and affect the next production run);

Check the oil level and grease levels at lubrication points (for smooth machine operation and reduced wear);

Inspect belts, chains, air lines, and electrical circuits (for looseness or damage);

Perform a no-load run to confirm that the equipment is functioning normally.

Regular maintenance (periodic inspections, don’t skip them)

Chains, buckets, and sprockets of the hot material elevator (easily worn parts, replace promptly);

Seals and fan impellers of the screw conveyor (prevent material leakage and dust accumulation);

Springs and screen of the vibrating screen (broken screens will affect aggregate grading);

Scrapers of the drying drum, blades of the mixing cylinder, and main shaft (wear-resistant parts, check for wear regularly);

Temperature sensors and metering systems (ensure data accuracy);

Gearbox cleaning and lubrication (protect core transmission components).

IX. Safe Operation: These rules must be followed! (Safety First)

Personnel Regulations: Workers must wear work clothes and safety helmets. Wearing slippers and working without protective gear is prohibited.

During Production: A warning horn must be sounded before starting the machine. Maintenance is strictly prohibited while the equipment is running. During loading, pay attention to directing traffic and avoid blind spot collisions. Ensure unobstructed signal transmission between the control room and the work site.

Maintenance Work: Safety belts must be worn when working at heights. When entering equipment (such as mixing tanks), supervision is mandatory. Power must be disconnected and the equipment locked (LOTO) to prevent accidental operation.

Hazardous Materials Management: Smoking and open flames are strictly prohibited in the oil tank area. Before unloading oil or asphalt, check the tank capacity and valve status to prevent leaks.

X. Common Faults and Troubleshooting: Minor Problems You Can Handle YourselfPowder System Issues:

1. Powder System Issues:

Abnormal Level Display: This could be due to a faulty level gauge or powder buildup in the tank. Check the level gauge or clean the accumulated powder from the tank.

Slow Powder Discharge: This could be due to powder buildup on the butterfly valve or rotary feeder, or the powder tank arching. Clean the areas with powder buildup and unclog the tank.

2. Dust Collection System Issues:

Dust Leakage: This is most likely due to damaged or improperly installed filter bags, or a malfunction in the pulse-jet system. Check the filter bags, filter cages, and negative pressure. Replace any damaged filter bags.

In conclusion: ACE group, building high-quality roads with you.

This concludes the comprehensive analysis of asphalt mixing plants! We hope this has helped you gain a complete understanding of this “core equipment for road construction.” Asian Construction Equipment Group Co., Ltd. has been deeply involved in the engineering equipment field for many years, focusing on providing precise, efficient, and environmentally friendly asphalt mixing plants and related services. From selection consultation and installation to daily maintenance and troubleshooting, we provide full support.

With the high-quality development of infrastructure construction in my country, asphalt mixing plants, as the core production unit of road engineering, are directly related to project progress, personnel well-being, and the ecological environment through their safe operation. Asian Construction Equipment Group Co., Ltd. (abbreviated as​ ACE Group) has been deeply involved in the R&D of asphalt mixing equipment, intelligent operation and maintenance, and safety management services for many years, gaining profound insights into industry pain points: high-temperature and high-pressure operating environments, the characteristics of multi-media collaborative production, and the requirements for continuous operation, making safety risk prevention and control a core issue in the industry. In recent years, safety accidents in some projects caused by inadequate safety management systems and outdated technology and equipment have not only resulted in economic losses but also hindered the sustainable development of the industry. Therefore,This article, based on the engineering practice of Asian Construction Equipment Group Co., Ltd., systematically analyzes the key influencing factors of safe production in asphalt mixing plants, and constructs a full-process safety management solution, providing practical reference for the high-quality development of the industry.

1. Production characteristics and core safety risks of asphalt mixing plants

1.1 Core Production Characteristics

An asphalt mixing plant is essentially an intelligent production system with precise multi-component proportioning and high-temperature closed-loop processing. Its core characteristics are:

1. High-Temperature and High-Pressure Operating Conditions: The mixture heating temperature is maintained at 150-180℃. Key components such as the mixing bins and conveying pipelines operate under high pressure for extended periods, placing extremely high demands on the equipment’s heat resistance and sealing performance.

2. Multi-Media Collaborative Operation: It involves multiple materials such as aggregates, asphalt, modifiers, and powders, with significant differences in their physical states (solid, liquid, gaseous), requiring precise control of mixing ratios and reaction conditions.

3. Continuous intelligent production: Relying on an automated control system, it can operate continuously 24 hours a day. The equipment is highly interconnected, and a failure in any link may cause the entire production line to stop.

1.2 Key Safety Risks

Based on safety assessment data from over a thousand projects by ACE Group’s, the core risks are concentrated in five categories:

1. Fire and Explosion Risks: Asphalt volatile gases and powder dust can easily form explosive mixtures in high-temperature environments, potentially causing accidents upon contact with open flames or static sparks;

2. Mechanical Injury Risks: High-speed rotating components such as screw conveyors and mixing blades can easily cause pinching, shearing, and other injuries if protective devices are missing or improper operation is performed;

3. High-Temperature Contact Injuries: High-temperature material conveying and equipment surface heat dissipation can easily lead to burns to operators, especially at critical workstations such as feed inlets and discharge outlets;

4. Dust and chemical hazards: Particulate matter generated during aggregate crushing and powder conveying, as well as harmful chemicals in asphalt and additives, can easily lead to occupational disease risks and pollute the environment.

5. System linkage failure risks: Malfunction of automated control systems, equipment aging, or improper maintenance may lead to chain reactions such as material leakage and conveying blockage.

2. In-depth analysis of factors affecting safe production

2.1 Human Factors: The Core Variable in Safety Management

ACE Group’s practice shows that over 80% of safety accidents are directly related to human factors:

1. Insufficient skills and experience: Operators lack proficiency in operating intelligent equipment (such as PLC control systems and intelligent monitoring terminals) and have weak emergency response capabilities;

2. Weak safety awareness: There are violations of operating procedures (such as not wearing protective equipment as required, and unauthorized changes to process parameters), and insufficient vigilance regarding hidden risks (such as pipeline corrosion and circuit aging);

3. Lack of a management system: There is a lack of targeted safety operating procedures, pre-job training mechanisms, and accountability systems, resulting in safety management becoming a mere formality.

2.2 Equipment Factors: The Hardware Foundation for Safety Assurance

As the core carrier of production, the reliability of equipment directly determines the safety baseline:

1. Equipment Aging and Technological Lagging: Some older equipment lacks intelligent monitoring modules, and key components (such as safety valves and temperature sensors) experience performance degradation after long-term use, easily leading to malfunctions;

2. Inadequate Operation and Maintenance Management: There is a lack of a full lifecycle operation and maintenance plan, and daily inspections are superficial, failing to form a closed-loop management system of “monitoring-early warning-repair-acceptance”;

3. Insufficient safety equipment: Some equipment lacks key safety facilities such as emergency shutdown systems, intelligent fire and explosion prevention devices, and online dust monitoring equipment, or these facilities are malfunctioning.

2.3 Environmental Factors: External Support for Safe Operation

The production environment has a significant impact on safety risk prevention and control:

1. Temperature and Humidity: High temperature and humidity environments can easily lead to short circuits in electrical systems and corrosion of metal parts in equipment. Extreme low temperatures may affect the fluidity of asphalt, causing conveying failures.

2. Ventilation and Dust Removal Conditions: Poor ventilation in enclosed spaces can lead to excessive dust concentrations and the accumulation of harmful gases, increasing health risks and explosion hazards.

3. Adaptability of the Working Environment: Insufficient lighting and unreasonable site layout (such as disorderly material stacking and blocked emergency passages) can easily lead to misoperation and delays in emergency response.

3. ACE Group’s Safety Production Management Practice Solution

Based on the concept of “technology empowerment + management closed loop”, ACE Group’s has built a four-dimensional safety management system of “personnel-equipment-environment-management”, which has been implemented and verified in many key projects across the country, reducing the accident rate by more than 85%.

3.1 Personnel Safety Capability Enhancement System

1. Customized Training Empowerment: Develop a three-in-one training curriculum integrating theory, practice, and intelligent simulation, covering equipment operation procedures, risk identification techniques, and intelligent system applications. Provide comprehensive pre-job training for new employees and quarterly rotational training for experienced employees.

2. Scenario-Based Emergency Drills: Conduct at least two realistic emergency drills annually, based on typical accident cases (such as fires and material leaks), using ACE Group’s independently developed emergency response simulation system to enhance employees’ collaborative response capabilities.

3. Full-cycle assessment mechanism: Establish an assessment system of “theoretical examination + practical assessment + job competency evaluation”, and link the assessment results with job promotion and salary to ensure that 100% of operators are certified to work.

3.2 Equipment Lifecycle Safety Management

1. Intelligent Operation and Maintenance System Construction: Relying on ACE Group’s AIoT equipment monitoring platform, 12 key data points, including equipment temperature, pressure, and vibration, are collected in real time. Fault early warning is achieved through algorithm models (early warning accuracy reaches 92%), generating customized maintenance plans.

2. Technical Equipment Upgrade and Iteration: Advanced equipment such as intelligent fire and explosion prevention systems (including automatic temperature alarms and nitrogen fire extinguishing devices), infrared thermal imaging monitors, and automatic emergency shutdown systems are promoted and applied, achieving a 100% upgrade and renovation rate for old equipment.

3. Standardized maintenance process: Develop the “Asphalt Mixing Plant Equipment Safety Maintenance Manual”, which clarifies the core indicators for daily, weekly, monthly and annual inspections. Implement a “must be replaced when due” system for key components (such as mixing blades and conveying pipelines) to ensure that the equipment integrity rate remains above 98%.

3.3 Environmental Safety Optimization Plan

1. Intelligent Environmental Control System: Equipped with ACE Group’s high-efficiency integrated dust removal and ventilation equipment, the system monitors dust concentration in real time and automatically adjusts airflow to ensure that the dust concentration in the working environment is below the national standard limit;

2. Precise Temperature and Humidity Control: Utilizing an intelligent temperature control system, the system links air conditioning and dehumidification equipment to maintain the production workshop temperature at 18-28℃ and humidity at 40%-60%, preventing equipment malfunctions caused by environmental factors;

3. Standardized work environment layout: Standardize material storage areas, divide personnel and vehicle access channels, equip with explosion-proof lighting equipment (illuminance ≥300lx), and set up emergency passage signs and safety warning signs to ensure a safe and orderly work environment.

3.4 Full-Process Safety Management Mechanism

1. Systematized System Construction: Sixteen core systems have been established, including the “Safety Production Responsibility System,” “Intelligent Equipment Operation Procedures,” and “Emergency Response Plan,” clearly defining the safety responsibilities of each position and achieving “one responsibility per position, full coverage of all personnel.”

2. Routine Supervision and Inspection: A three-dimensional supervision mechanism of “daily patrols + special inspections + third-party evaluations” has been established. The ACE Group’s Safety Management APP is used to record hidden dangers in real time and track rectification, achieving a 100% rectification closure rate.

3. Accident Tracing and Improvement: A closed-loop mechanism of “accident investigation – cause analysis – responsibility determination – measure optimization” has been constructed. Case studies are used to conduct company-wide warning education, continuously optimizing the safety management system.

4. Conclusion

Safety management of asphalt mixing plants is a collaborative project involving technology, management, and personnel capabilities. ACE Group’s consistently adheres to the principles of “safety first, prevention foremost, technology empowerment, and closed-loop management.” By constructing a personnel capability enhancement system, an intelligent equipment operation and maintenance system, an environmental optimization and control system, and a full-process management mechanism, it achieves precise prevention and efficient handling of safety risks. In the future, ACE Group’s will continue to deepen the application of cutting-edge technologies such as intelligent monitoring and digital twins in safety production, launching more targeted safety solutions to help the industry achieve “safe, efficient, and green” development and safeguard the high-quality advancement of my country’s infrastructure construction.

With the arrival of winter and the continuous drop in temperature, construction projects have officially entered the winter construction phase. The low-temperature environment places higher demands on the quality of concrete construction. As a professional concrete supplier, Asian Construction Equipment Group Co., Ltd. adheres to the philosophy of “quality first, technology leading,” and based on the “Code for Winter Construction of Building Engineering” (JGJ/T 104–2011) and related technical standards, combined with years of winter construction experience, has developed a scientific and systematic winter concrete construction technology solution. This solution aims to comprehensively strengthen quality control in all aspects, from raw material control, mix design, production and transportation to on-site construction coordination, to ensure the construction quality and long-term durability of concrete projects in low-temperature environments.

I. Mechanism of the Influence of Low Temperatures on Concrete Performance in Winter

When the ambient temperature is between 0 and 4°C, the cement hydration rate decreases significantly, and the strength development of concrete is slow, making it difficult to achieve the strength growth requirements under standard curing conditions. When the temperature drops below 0°C, free water in the concrete begins to freeze, expanding in volume by approximately 9%, which may damage the bond interface between the cement paste and aggregates, affecting the integrity of the concrete’s microstructure. Furthermore, water freezing reduces the amount of liquid water available for cement hydration, essentially halting strength development. Therefore, taking effective antifreeze and insulation measures in the early stages of concrete setting and hardening is crucial.

II. Winter Concrete Production Technical Measures

According to specifications, winter construction begins when the average daily outdoor temperature remains consistently below 5℃ for five consecutive days. To ensure the workability and mechanical properties of concrete under low-temperature conditions, our company has adopted the following key technical control measures:

(1). Optimization of Cementitious Materials and Mix Proportion

1.1. Use early-strength or ordinary Portland cement, controlling the cement content to be no less than 300 kg/m³ and the water-cement ratio to be no greater than 0.60, to improve the early strength and frost resistance of concrete.

1.2. Add an appropriate amount of antifreeze water-reducing agent to reduce the amount of mixing water while ensuring workability, thereby increasing the critical frost resistance strength of concrete.

Note: (If necessary, written procedures must be completed in advance according to regulations.)

(2). Raw Material Temperature Control and Thermal Management

2.1. Heat the mixing water. When the air temperature is below 0℃, use steam heating to ensure the water temperature is not lower than 50℃, guaranteeing that the concrete outlet temperature meets the specifications.

2.2. Strictly control aggregate quality. The use of aggregates containing ice, snow, or frozen lumps is strictly prohibited. If necessary, preheat or cover the aggregates for insulation.

(3). Mixing Process Adjustment

3.1. Appropriately extend the mixing time. For concrete with antifreeze additives, extend the mixing time by 10–15 seconds compared to normal temperature conditions to ensure the homogeneity of the mixture and the full dispersion of admixtures.

(4). Strengthen Factory Inspection and Transportation Scheduling

4.1. Strengthen the testing of slump, air content, and temperature before leaving the factory to ensure that the concrete quality meets design requirements.

4.2. Rationally plan transportation routes and departure frequencies to shorten the time from concrete leaving the factory to placement in the formwork and control temperature loss.

III. Key Technical Coordination Requirements at the Construction Site

To ensure that the concrete is not damaged by frost during the pouring and curing stages, the client is requested to cooperate in implementing the following construction measures:

(1)Concrete Arrival Inspection

1.1. Upon arrival of each truckload of concrete, the construction unit’s quality inspection personnel should verify the delivery note information, including the project name, strength grade, mix proportion number, etc., and conduct a visual inspection.

1.2. If any abnormal setting, segregation, or temperature discrepancies are found in the concrete, unloading should be immediately suspended, and our on-site technical personnel should be notified for assistance.

(2)Pouring Process Control

2.1. It is strictly forbidden to mix concrete provided by Asian Construction Equipment Group Co., Ltd. with concrete from other manufacturers, nor is it permitted to add water or unapproved admixtures during the pouring process.

2.2. Concrete should be poured within one hour of leaving the factory. If slump loss occurs due to construction delays, adjustments should be made using a special admixture under our guidance, and the concrete should be mixed at high speed in the mixer truck for no less than 3 minutes.

2.3. The formwork should have tight joints and be firmly supported to prevent leakage or deformation from affecting the dimensions and appearance of the components.

2.4. During pouring, the concrete should be poured in layers, with each layer not exceeding 1.25 times the length of the vibrator’s working section to avoid cold joints. Vibration should be uniform, ideally until the concrete surface is covered with grout and there is no obvious settling, preventing over-vibration or under-vibration.

(3)Finishing and Thermal Curing

3.1. Any bleed water on the concrete surface should be removed, and laitance should be pressed into the interior. Roughening with a wooden trowel should be performed at least twice before and after initial setting to improve surface density and crack resistance.

3.2. Immediately after pouring, the concrete should be covered with plastic film, and thermal insulation measures (such as insulation felt, heated sheds, etc.) should be taken according to thermal calculations to ensure the concrete does not freeze before reaching its critical strength.

3.3. No personnel should work on the concrete or apply any load before the concrete strength reaches 1.2 MPa. The strength of the formwork should be sufficient to prevent damage to the edges and corners of the components when removing the side formwork.

(4)Formwork Removal Control

4.1. When removing formwork, the order of “removing the last support first, and the first support last” should be followed. Impact loads on the floor surface are strictly prohibited. The removed formwork and support system should be promptly dispersed and transported to designated storage areas, and should not be piled up on floors to avoid localized overloading.

4.2. When removing side formwork, the concrete strength should be sufficient to ensure that its surface and edges are not damaged. Generally, the strength should not be lower than 5.0 MPa. Under winter construction conditions, the specific removal time should be determined based on the strength of test blocks cured under the same conditions to avoid edge damage due to insufficient strength.

4.3. The concrete strength at the time of removal of the bottom formwork and its supports shall meet the design requirements and relevant specifications; if the design does not specify requirements, it shall meet the relevant requirements of the “Code for Construction of Concrete Structures” (GB 50666).

(5)Construction of Large-Volume Concrete and Special Structures

5.1. For large-volume concrete or vertical structures (such as columns and walls), a specific temperature control and insulation plan should be developed to control the internal and external temperature differences and prevent temperature cracks.

5.2. For structures exceeding 3m in height, auxiliary feeding devices such as chutes or conveyors should be used to avoid concrete segregation.

IV. Conclusion

Asian Construction Equipment Group Co., Ltd. will continue to provide reliable and high-quality concrete products for all projects, and will cooperate with construction units to ensure quality control during winter construction. We are willing to work closely with all parties to strictly implement winter construction technical plans, implement various anti-freezing and insulation measures, and ensure that the construction quality of concrete structures meets design and specification requirements, jointly creating high-quality projects.

Compliant operation of asphalt mixing plants（ACE Group Edition）

As a high-tech enterprise deeply rooted in the field of road construction equipment, Asian Construction Equipment Group Co., Ltd. has always focused on “safety, efficiency, precision, controllability, stability, and reliability.” Based on years of technological accumulation and engineering experience, this standardized operation manual for asphalt mixing plants has been compiled. The manual covers all key aspects of the entire process, from start-up preparation to shutdown maintenance, aiming to provide operators with scientific and standardized operational guidance. This helps to achieve standardized production processes, refined quality control, and standardized equipment operation and maintenance, fully leveraging the technological advantages and performance potential of Asian Construction Equipment Group Co., Ltd. equipment.

Chapter 1.Preparatory Procedures Before Startup

To ensure the safety and efficiency of the asphalt mixing plant production process, pre-start preparations are crucial. Before starting, a comprehensive inspection of key equipment such as the mixing host, control system, conveyor belt, vibrating screen, and asphalt pump system must be conducted to ensure that the equipment is in normal operating condition, without oil leaks, abnormal noises, or unusual vibrations. Secondly, the completeness of safety protection devices is the foundation for ensuring operational safety. Operators must meticulously check safety railings, emergency stop buttons, alarm devices, and sensors to ensure a rapid response in any emergency.Finally, the preparation of raw materials and process parameters must be complete. Aggregates should be stacked reasonably according to gradation requirements, asphalt and additives need to be preheated to the specified temperature, and metering equipment such as thermometers and flow meters should be calibrated to ensure their normal operation. The batching parameters, including the weight of each grade of aggregate, the amount of asphalt, and the proportion of additives, should be strictly entered into the control system according to the construction design requirements.

Chapter 2.System Power-On and Self-Test Procedure

Before starting the mixing plant, the operator should first turn on the power to the control cabinet to put the system into standby mode. Modern asphalt mixing plants are usually equipped with an automatic self-test program, which can check the operating status of key components such as motors, sensors, weighing systems, and alarm systems. After the self-test program is completed, it must be confirmed that the alarm system, indicator lights, and displays are working properly. If any abnormality is found, it should be investigated immediately or reported to technical personnel to prevent equipment failure or safety accidents during production.

Chapter 3. Preparation Process for Silos and Batching Weighing

Silos and weighing systems are core components for controlling the precise delivery of raw materials. Operators must thoroughly clean the silos to ensure no residual aggregate or impurities remain, and check the operation of each aggregate bin door and feeding equipment. The weighing system needs precise calibration to ensure weight measurement accuracy is within the specified range (typically ±1%). Subsequently, the batching parameters for each aggregate, asphalt, and additive are set in the control system. This step directly affects the quality of the finished mixture; therefore, operation must be strictly performed according to design requirements.

Chapter 4.Aggregate Conveying and Metering Technology

Start the conveying equipment to transport the aggregate from the silo to the mixing drum. During the feeding process, the preset proportions and feeding sequence must be strictly followed to avoid uneven aggregate flow or blockage. The control system monitors the weighing data in real time and corrects deviations promptly. After the aggregate is fed, ensure that the weighing data matches the actual amount fed to guarantee the accuracy of subsequent asphalt addition and mixing.

Chapter 5.Asphalt and Additive Addition Techniques

Before adding asphalt to the mixing drum, it must be heated to the construction temperature (generally 160~180℃), and the flow rate must be accurately metered using a pump system. Admixtures such as wetting agents or stabilizers must be added according to the design ratio and simultaneously with the asphalt to the mixing drum. The order of addition and the uniformity of mixing have a significant impact on the performance of the asphalt mixture. During operation, the flow rate and temperature must be monitored in real time to ensure that all components are fully dispersed.

Chapter 6.Research on Aggregate Drying and Heating Process

The uniformity of aggregate drying and heating is crucial for ensuring the quality of asphalt mixtures. Operators must start the drum dryer, set appropriate temperature parameters, and ensure that the aggregate moisture content is below the design requirements (typically <1%). Improper temperature settings can affect the bonding properties of asphalt; therefore, real-time monitoring using an infrared thermometer or system sensors is necessary. Simultaneously, fine aggregates should be graded using a vibrating screen and stored in a hot aggregate bin to maintain mixing uniformity.

Chapter 7.Mixing and Stirring Technology

After drying and heating, the aggregate enters the mixing drum and undergoes initial low-speed mixing to ensure uniform premixing of the aggregate and asphalt. High-speed homogenization mixing is then initiated to fully integrate the asphalt and aggregate. The general mixing time is 45-90 seconds, with the specific time determined based on the asphalt type and construction requirements. For special asphalt or functional mixtures, a secondary mixing process may be added to improve homogeneity and stability.

Chapter 8.Preparation Procedures for Discharging Finished Asphalt Mixtures

Before discharging, the operator must check the discharge port, transport equipment, and the interior of the mixing drum to ensure unobstructed flow and prevent blockages or leaks. Any residual material must be thoroughly cleaned to prevent contamination of the next batch of mixture. Simultaneously, transport vehicles or tank trucks should arrive in advance, and their temperature should be confirmed to meet loading requirements to ensure the stable quality of the asphalt mixture during transportation.

Chapter 9.Discharge Operation and Quality Control

Discharge operations must be conducted in a sequential manner, opening the discharge gates and controlling the discharge flow rate to prevent stratification or bleeding of the mixture. Simultaneously, random samples of the finished mixture should be taken to test indicators such as temperature, asphalt content, and porosity to ensure that each batch of discharge meets construction quality standards. If any abnormalities are found, operations should be stopped immediately and the cause investigated.

Chapter 10.Mixing Equipment and its Cleaning and Maintenance System

After discharging, the mixing drum should be cleaned immediately, using high-pressure water washing or a special cleaning ball, to prevent the asphalt from hardening and clumping. The conveying equipment, silos, and vibrating screens also need to be cleaned to ensure smooth operation in the next production run. This step is crucial for extending the service life of the equipment and ensuring the quality of the mixture.

Chapter 11.System Shutdown Procedures

System shutdown should be performed in the prescribed sequence: first, shut down the mixer; then, stop the conveying system; and finally, turn off the power to the control cabinet. After shutdown, check the status of all components, including temperature, motor vibration, and alarm systems. Record any abnormalities and take necessary measures to ensure the equipment is in a safe condition.

Chapter 12.Daily Inspection and Maintenance

After each shift, a comprehensive inspection of the main unit, conveying equipment, and heating system should be conducted. Key components must be lubricated, and easily worn parts such as bearings, belts, and pumps should be replaced promptly. The work area, silos, and surrounding environment should be cleaned to ensure safety and cleanliness, preparing for the next shift. Simultaneously, daily production data and equipment status should be recorded for management and analysis.

In summary：

by implementing the 12 key steps outlined above, asphalt mixing plants can achieve standardized, traceable, and low-failure-rate operation. Key control points include aggregate drying and temperature control, asphalt and additive dosage ratios, mixing homogeneity, discharge temperature, and flowability. The goal is to ensure stable asphalt mixture quality, high production efficiency, low safety risks, and provide reliable material support for road construction.

Asian Construction Equipment Group Co., Ltd. adheres to the philosophy of “customer-centric, quality-based,” and this operation manual is a concentrated reflection of our technical strength and service spirit. We firmly believe that strictly following standardized operating procedures can not only fully utilize the optimal performance of equipment but also effectively reduce production risks and improve construction efficiency. In the future, Asian Construction Equipment Group Co., Ltd.will continue to iterate its technology and optimize its services, providing the global road construction industry with more advanced equipment solutions and more professional technical support, working hand in hand with customers to build high-quality transportation infrastructure and create new value for the industry.

As the “heart” of modern road construction, the operational efficiency of an asphalt mixing plant directly determines the project’s progress, cost, and final quality. Through years of technical accumulation and practical service at Asian Construction Equipment Group Co., Ltd. , we deeply understand that simply possessing a high-performance set of equipment is far from sufficient; the key lies in maximizing its potential through scientific and meticulous operation.

Today, we are willing to summarize this valuable experience into five core techniques and share them with every operator and manager working on the front lines. This is not only an operational guide but also Asian Construction Equipment Group Co., Ltd. solemn commitment to helping you achieve maximum capacity, optimal quality, and best efficiency.

Tip 1: Optimize Start-up and Warm-up to Seize Production Advantages

Efficient production begins with a perfect start. We believe that the start-up and warm-up process is not simply a “start-up,” but a “warm-up race” concerning efficiency and quality.

(1) Thorough preparation to ensure a smooth start.

Before starting the machine, we recommend that you conduct a “double-line inspection”: On the material line, ensure that the aggregates, asphalt, and admixtures are sufficient and of the correct specifications, and that the silos are clean and free of impurities; on the equipment line, inspect key components such as the mixer, drying drum, conveying system, and asphalt pump to prevent potential problems such as oil leaks, abnormal noises, and abnormal vibrations. Thorough preparation is the first line of defense against production delays.

(2) Precise Temperature Control: Laying the Foundation for Quality

Preheating is crucial for ensuring the quality of the mixture. The drum dryer and asphalt tank must reach the preset temperature, and the temperatures of the aggregate and asphalt must remain uniform and stable. Excessive temperature differences will directly affect the uniformity of mixing and may even lead to difficulties in discharging. We recommend using advanced temperature control systems and infrared thermometers for real-time monitoring to ensure everything goes smoothly.

Asian Construction Equipment Group Co., Ltd. practical advice: Complete equipment preheating at least 30 minutes in advance to ensure production is in optimal condition from the start, preventing downtime or rework due to insufficient temperature.

Tip 2: Strictly Control Mix Proportioning and Weighing to Lay the Foundation for Quality

Precise mixing proportions are the “soul” of asphalt mixtures. Any slight deviation in the weighing system can lead to material waste and pavement quality defects.

(1) Regular Calibration: Safeguarding Accuracy

The weighing system is the core of quality control. We strongly recommend regular calibration of aggregate scales, asphalt flow meters, and additive metering devices to ensure their accuracy remains within ±1% tolerance. This is the most direct and effective way to reduce waste and improve the pass rate of the mixture.

(2) Optimizing the Order: Ensuring Uniform Mixing

Following the standard feeding order of “coarse aggregate first, then fine aggregate, then asphalt, and finally admixtures” is key to achieving uniformity in the mixture. This order effectively reduces the risk of poor asphalt adhesion or mixture segregation.

(3) Real-time monitoring and immediate correction

The automatic control system of a modern mixing plant is a powerful tool for achieving refined management. Operators should closely monitor the real-time data of the dosage of each component. Once a deviation is detected, adjustments should be made immediately to prevent the accumulation of errors and ensure consistent quality for each batch of product.

Asian Construction Equipment Group Co., Ltd. practical suggestion: Properly preserve the records of each batching operation. This not only facilitates quality traceability but also serves as a valuable data asset for subsequent process optimization and management improvement.

Tip 3: Precisely Control Mixing Time to Activate the Potential of the Mixture

The mixing process is the art of bringing various materials together. Scientifically controlling the mixing time and speed is key to activating the performance of the mixture and improving production efficiency.

(1) Low-speed initial mixing for preliminary wetting

After the aggregate and asphalt are added, a low-speed mixing process is first performed for 20–30 seconds. The goal of this stage is to ensure that the asphalt evenly coats the surface of the aggregate, completing the preliminary wetting.

(2) High-speed homogenization for perfect blending

Then, the mixing speed is switched to a high-speed mixing mode of 45–90 seconds. During this stage, the asphalt and aggregate fully penetrate and combine, forming a final mixture with stable structure and uniform performance. The specific duration needs to be adjusted flexibly according to the type of aggregate and the grade of asphalt.

(3) Customized Processes to Address Special Needs

For modified asphalt or functional mixtures, we recommend customized solutions such as secondary mixing or appropriately extended high-speed mixing time to ensure their special properties are fully realized.

Asian Construction Equipment Group Co., Ltd. practical advice: Flexible adjustment of mixing parameters can not only optimize the mixing effect but also effectively improve the overall production cycle while ensuring quality.

Tip 4: Optimize material output and transportation for seamless integration

The “last mile” of production is equally crucial. Efficient material output and coordinated transportation are key to ensuring production continuity and reducing waiting costs.

(1) Ensure unobstructed flow and prevent blockages

Regularly inspect the discharge port, mixing drum, and conveying system to ensure unobstructed flow. This is fundamental to preventing residual material accumulation and ensuring smooth discharge.

(2) Precisely control flow rate and temperature

Discharge temperature directly affects construction performance. Excessive temperature increases energy consumption and safety risks; excessively fast or slow flow rates may cause stratification or disrupt production rhythm. Precisely adjusting the discharge gate opening and conveying speed through an automatic control system is a scientific means to ensure continuous and efficient production.

(3) Coordinated Transportation to Reduce Downtime

Communicate with transport vehicles in advance to ensure that tank trucks or hoppers arrive on time and maintain a suitable temperature. Close coordination between the discharge and transportation processes can minimize the ineffective waiting time of the mixer.

Tip 5: Insist on Cleaning and Maintenance to Extend Equipment Lifespan

Equipment is the foundation for creating value. We believe that preventative maintenance is far superior to post-failure repair and is fundamental to ensuring the long-term efficient operation of equipment.

(1) Timely Cleaning to Prevent Problems

After each production run, the mixing drum should be cleaned immediately. High-pressure water or a cleaning ball should be used to remove residual asphalt to prevent it from hardening and affecting the next production run.

(2) System Maintenance to Eliminate Hidden Dangers

Regularly clean the belts, bucket elevators, and hoppers of residual material, and check the wear condition of each component. Timely replacement of easily worn parts such as bearings, seals, and belts is a necessary investment to ensure the continuous and reliable operation of the equipment.

(3) Preventive Maintenance, Routine Implementation

Regular lubrication and inspection of key components such as temperature control systems, pumps, and motors are essential. Establishing a scientific daily, weekly, and monthly maintenance system, and making maintenance work systematic and routine, can significantly reduce the failure rate and improve the overall utilization rate of equipment.

Asian Construction Equipment Group Co., Ltd. practical suggestion: Treat equipment maintenance as part of the production plan, not an extra burden. A healthy equipment condition is the most solid guarantee for efficient production.

In summary:

Efficient operation of an asphalt mixing plant does not rely on outstanding performance in a single (link/step), but rather stems from precise control of every detail and systematic management of the entire process. These five techniques are the culmination of wisdom gleaned by Asian Construction Equipment Group Co., Ltd. in serving global clients, and they permeate the complete closed loop from preparation to production to maintenance.

We firmly believe that superior equipment requires professional operation.Asian Construction Equipment Group Co., Ltd. is not only a provider of high-quality asphalt mixing equipment, but also your trusted long-term partner. We hope this experience will help you fully unleash the potential of your equipment, stand out in the fierce market competition, and jointly contribute to building a higher-quality, more efficient transportation future.

Asian Construction Equipment Group Co., Ltd. , working hand in hand with you to create an efficient future.

Bitumen drum decanters and bitumen bag decanters have their own advantages. When customers are selecting a decanter machine to purchase, it is recommended to consider the following:

1. Production Needs

Production needs include the packaging form of bitumen, as well as the desired processing capacity and speed of the bitumen decanter. For large-scale production that requires the processing a significant volume of bitumen, such as in road construction, bitumen bag decanting plant, may be a more suitable choice. For smaller bitumen requirements, where the quality and application range of bitumen are more demanding or environmental regulations are stricter, such as in waterproofing, anti-corrosion, or other industrial applications, bitumen drum decanter machinery are more appropriate.

2. Outline Dimensions

20FT and 40FT containers are widely used in international shipping. Therefore, choosing a bitumen melter in dimensions that are more suitable for international shipping saves transportation costs.

3. Service Life

To select a bitumen decanter that best suits needs, users should comprehensively consider factors such as make, quality, price, after-sales service, performance and service life, whilst carefully evaluating the cost-benefit ratio when selecting a bitumen decanting plant.

Bitumen bag decanter machine and bitumen drum decanter machine are used to process raw bitumen, remove impurities and convert it into a liquid form that is convenient for use. Both of these two types are equipped with an automatic electronic control system to ensure safe and stable operation. However, differences exist as a result of their different working principles:

1. Functions

The two types of decanters process materials of different packing form. Bitumen drum decanter machines are primarily used to heat and extract bitumen from drums, while bitumen bag decanters are mainly used to process bagged bitumen by melting solid bitumen using a thermal oil heating system.

2. Structure

Bitumen drum decanters consist of components such as a decanting chamber, lifting mechanism, hydraulic propulsion system, melting chamber, oil pipe heating system and electrical control system. The bitumen bag decanting plant, on the other hand, comprises a decanting chamber, lifting device, conveying system, melting chamber, heating system, and a fire tube intensified heating unit.

3. Work Flow

Bitumen drum decanters mainly focus on the degree of mechanical automation, and use advanced mechanical devices to quickly and efficiently extract bitumen from drums, which reduces the labor intensity of workers and improves production efficiency; bitumen bag decanting plant is designed to process a large volume of bitumen in bulk bags and its focus is on the design and optimization of the heating system, with an emphasis on the melting capacity. Bag type uses a thermal oil heating system, combined with a fire tube for enhanced heating, which can quickly melt the bagged bitumen into liquid, leading to high production efficiency.

4. Production Capacity

The optimization of the heating system gives bitumen bag decanter machinery higher melting efficiency. In cases where the overall dimensions of the bitumen decanting plants are similar, bitumen bag decanters typically present a greater processing capacity. For example, a typical ISO 20FT equipment box can accommodate 20 one-ton bags for heating treatment at a time. On the other hand, drum-packed bitumen is typically 180 kg per drum, and the processing capacity of bag decanter machinery may be limited by the drum size and quantity, potentially resulting in a relatively smaller capacity.

DJT-3000 Asphalt Melting Machine

5. Energy Saving and Environment Protection

Bitumen bag decanters often adopt an enclosed structure, which effectively reduces the volatilization and leakage of bitumen during the decanting process, thereby reducing environmental pollution. Additionally, some advanced bitumen bag decanting plants are equipped with an efficient heating and circulation system, which reduces energy consumption and may be somehow advantageous in energy-saving and environmental protection. Bitumen drum decanters also have their own characteristics on energy conservation and environmental protection. Their enclosed production structures significantly reduce environmental pollution. Furthermore, drum type typically uses advanced heating and control systems, improving energy utilization efficiency. Therefore, both types of bitumen decanting machinery have their own unique.

Model: RLB60 ~ RLB160

RAP Process Capacity: 60 t/h ~ 160 t/h

RAP Proportion: 30% ~ 50%