Craft Skills Training Module

LEVEL 2

CP 101: Asphalt & CTB Plant Process

PRESENTED BY: Yavuz Yuksel / Recep Duran

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 Section 1: General Asphalt & CTB
Plant
MODULE CONTENT
Section 1: General Asphalt & CTB Plant
Section 2: Materials & Equipment
Section 3: Team Members
Section 4: Asphalt & CTB Production Key Skills
(Classroom)
Section 5: Quality Considerations
Section 6: ES&H Considerations
Section 7: Asphalt & CTB Production Key Skills (Practical)
Section 8: Summary
Section 9: Questions and Answers Session
Section 10: Test

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 Section 1: Introduction to Asphalt &
CTB Prod.
Asphalt
Highly viscous liquid or semi-solid paving
material
composed of bitumen and aggregate mixed
with specified ratios.
Asphalt Plant
A production plant designed for Asphalt
Production.

Cement Treated Base (CTB)

A mixture of aggregate material with Portland
cement and water
CTB Plant
A production plant designed for
Mechanical Sub-base and/or CTB Production.

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 Section 1: Introduction to Asphalt &
CTB Prod.
The Process (CTB Plant)
Feeding plant with Raw
Materials
Mixing materials
Loading trucks
Weighing and delivering to
job site
The Process (Asphalt Plant)
Feeding plant with Raw
Materials
Hot mix asphalt production
Loading trucks
Weighed and delivered to job
site

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 Section 2: The Asphalt and/or CTB
Plants Team
Quarries and Plants Manager (QPM) / BLIO
Overall responsibility for Asphalt & CTB Production
Equipment Manager (EM)
responsible for inspecting all equipment prior to use and if
approved, apply KMP approval sticker to the piece of equipment.
Site Superintendent (SS)
responsible for establishing and maintaining the procedures and
guidelines for inspection to assure that the technical requirements
and specifications are met and ensuring work is performed in
accordance to prepared risk assessment.
Plants Foreman (PS)
coordination with QC supervisor in order to meet specification
coordination with Safety supervisor for safe work
control of equipment in a daily basis for continuous production of
plant material.
Asphalt or CTB Plants Operator (PO)
Responsible for continuous operation of the plant
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 Section 3: Raw Materials (Asphalt)
Aggregate Bitumen

LPG or Fuel Oil Filler (Stone dust)

(for heating aggregate)

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 Section 3: Raw Materials (CTB)
Aggregate (0-32mm) Cement

Water

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 Section 3: Produced Materials
(Asphalt)

Aggregate Bitumen Filler Asphalt Layer

0-4, 4-8, 8-16, YES NO Asphalt

16-22mm Treated Base
0-4, 4-8, 8- YES NO Asphalt Binder
16mm Course
0-2, 2-4, 4-8, YES YES Asphalt Wear.
8-11mm Course

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 Section 3: Produced Materials (CTB)

Aggregate Cement Water Paving Layer

0-32mm YES YES CTB

0-32mm No YES Mechanical

Subbase

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 Section 3: Equipment (Asphalt)
Asphalt Plant with Wheel Loader
accessories

Scale Bridge Generator

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 Section 3: Equipment (CTB)
CTB Plant with accessories Wheel Loader

Scale Bridge Generator

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 Section 4: Key Skills Feeding plant
with Raw Materials
Both Asphalt & CTB plants
shall be fed with the
appropriate raw material.
Previously produced
aggregate by crusher shall
be transported and
stockpiled in close proximity
to each plants feeding
bunkers.
During Asphalt & CTB
production the aggregate Bitumen, cement or fuel oil
will be fed via a wheel will be provided from local
loader. market.
Manufacturer will transport
these materials to the
plants.
After scaling these
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 Section 4: Key Skills Feeding plant
with Raw Materials
Bitumen and fuel oil is transported by manufacturers tankers.

Cement and filler is transported with Silobuses.

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 Section 4: Key Skills Production 1/2

Asphalt plant is fed with bitumen

and aggregate, hot mix asphalt is
produced by heating the
aggregate and mixing it with
bitumen as per mix design.

Asphalt plant operator controls

the production inside Control
Room according to the mix
design.

Asphalt plant operator also

controls the loading of trucks
inside Control Room.
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 Section 4: Key Skills Production 2/2
When CTB plant is fed with
cement, aggregate and
water, CTB is produced by
mixing them as per mix
design. If the cement is
included in mixture, then CTB
will be produced. If cement is
not included in the mix design
then Mechanical Subbase is
produced.

CTB plant operator controls

the production inside Control
Room according to mix
design.

CTB plant operator also

controls the loading of trucks
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 Section 4: Key Skills Loading trucks
Both in Asphalt and CTB plants, trucks will be loaded by
automatic loading silos.
Plant operators manage the loading of each truck.
QC department takes samples from the trucks so that the
appropriate tests can be conducted in QC Labs.
Each truck must enter the scale to be weighed.

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 Section 4: Key Skills Scaling and
Delivery Tickets
Each produced material and raw material batch will be weighed
by a Scale bridge.
The weight of the materials will be calculated as the difference
of the loaded and unloaded truck. The scale shall be able to
give 3 copies of delivery tickets and will include the following
information:
Plant name
Date of loading
Time of loading
Type of material
From (departure of material)
To (destination of material)
Weight of loaded truck
Weight of unloaded truck
Weight of material
Truck Plate

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 Section 5: Quality Considerations
Good Practice Bad Practice

Correct size should be loaded to correct

bunkers.
4-8mm 8-16mm

4-8mm 4-8mm

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 Section 5: Quality Considerations
Good Practice Bad Practice

Only aggregate should be loaded to bunkers.

4-8mm Coca-Cola bottle.

4-8mm 4-8mm

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 Section 6: ES&H Considerations - JHA

Emre Isil is preparing and is to be inserted when complete

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 Section 6: ES&H Considerations

Before working at site all personnel should receive BEGP

ES&H Induction.
Personnel should be aware of their surroundings heavy
machinery in close proximity
Persons and equipment should be kept apart where possible
using barricades and signage.
Trained and competent Flag man should assist, guide and
direct equipment.
Equipment should be in good condition and have appropriate
inspection tag visible.
Ensure work areas and access/egress to/from work areas are
illuminated sufficiently during night shift.

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 Section 6: ES&H Considerations
PPE Personal Protective Equipment

PPE to be worn on site

Hard Hat Glasses Gloves Steel Capped Boots High Visibility

Vest

Dust mask to be worn

when appropriate

Dust Mask Ear Protection

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 Section 6: ES&H Considerations
PPE Personal Protective Equipment
Good Practice Bad Practice:

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 Section 7: Key Skills - Practical
Go to site / training yard to receive practical
demonstration of the process of Asphalt and CTB
production process.
After receiving demonstration workers will perform the
task them selves under the supervision of foreman.
Foreman will assess the workers competence and decide
if pass or fail.

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 Section 8: Summary Process Chart 1

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 Section 8: Summary Process Chart 2

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 Section 9: Questions

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 Section 10: Test (10 Questions)

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 Section 10: Test (10 Questions)

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 Answers
1. C
2. C
3. B
4. A
5. B
6. A
7. D
8. C
9. B
10. A

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