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PINDAAN 3/2013 1
ASPHALT PLANT CHECKLIST (BATCH) Asphalt Plant
:.………………………………………..........................................
Date
:………………………………………………………………………
No.
ACTIVITIES
BITUMEN, AGGREGATES, MIX DESIGN & LAB EQUIPMENT 1
PAST RECORDS ● Aggregate approval/test results. ● Bitumen approval/test results. ● Mix design approval (including trial lay). ● Binder content, aggregate gradation & Marshall test results. Satu (1) ujian setiap 200 tan asphalt.
● Gradation analysis of aggregates in hot bins. Satu (1) ujian setiap hot bin setiap hari.
2
BITUMEN ● Source of bitumen approved.
M
3
Bitumen diuji sepenuhnya di ‘independent lab’ berdasarkan MS 124 dan semua keputusan ujian ‘lulus’.
AGGREGATES ● Source of coarse aggregate approved.
M
Agregat kasar diuji sepenuhnya di ‘independent lab’ berdasarkan JKR/SPJ/1988 atau JKR/SPJ/2008 dan semua keputusan ujian ‘lulus’.
● Source of fine aggregate approved. M
Agregat halus diuji sepenuhnya di ‘independent lab’ berdasarkan JKR/SPJ/1988 atau JKR/SPJ/2008 dan semua keputusan ujian ‘lulus’.
M
● Each aggregate is stored in a separate stockpile.
M
● Stockpile of fine aggregate is kept under a waterproof roof structure.
4
MIX DESIGN ● Mix design prepared and approved by KPPS/JD.
M
Laporan rekabentuk campuran hendaklah disertakan dengan kelulusan bitumen dan agregat di atas.
5
LABORATORY TEST EQUIPMENT
M
● Is a laboratory available?
M
● Is the laboratory capable to carry out the following tests? Bitumen content.
M
Aggregate gradation.
M
Thickness.
M
Density.
M
● Equipped with the following laboratory test equipment; Penetration.
M
Ring & Ball Softening Point.
M
Flash Point.
YES
NO
PINDAAN 3/2013 2
No.
ACTIVITIES ● Equipped with laboratory test equipment to determine binder content of bituminous tack coat (i.e. grade of tack coat).
M
Kuari mestilah menyediakan tiga (3) beaker berisipadu 1 liter (low form) dan tiga (3) glass rod selain oven dan balance, walaupun tidak membekalkan tack coat dan menjalankan kerja paving.
M
● Have laboratory test equipment been checked and certified / calibrated (annually)? Date checked …………. Certified by ……………. Is copy of certification/calibration available?
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QC SYSTEM ● QC system is available. ● Competent quality officer is available.
PLANT OPERATIONS 7
COLD BINS
M
● Each aggregate is stored in a separate cold bin.
M
● No spill over of aggregates into adjacent bins.
8
SCREENS ● Equipped with four (or more) screens. ● Shall be readily accessible for inspection.
M
● Condition of each screen is satisfactory (no tear).
9
HOT BINS ● Equipped with four (or more) hot bins. ● Each bin is equipped with an overflow pipe to prevent backing up of aggregates into other bins.
M
● Samples can be readily obtained from each bin. ● Have means for observing the aggregate level. ● Thermometers are fitted in each bin.
M
● Have thermometers been checked and certified/calibrated (annually)? Date checked …………. Certified by ……………. Is copy of certification/calibration available? ● Separate dry storage is provided for mineral filler.
M
M
● Equipped with a weigh box or hopper for accurately weighing out aggregate from each bin. ● Has weight box/hopper been checked and certified/calibrated (annually)? Date checked …………. Certified by ……………. Is copy of certification/calibration available? ● Discharge gate does not leak when closed. ● Scale dial is visible to operator without significant parallax errors.
YES
NO
PINDAAN 3/2013 3
No.
M
M
10
ACTIVITIES ● Have scales dial been checked and certified/calibrated (annually)? Date checked …………. Certified by ……………. Is copy of certification/calibration available? ● Test weights (not less than ten 25 kg test weights) are present for checking, adjusting and calibrating scales. ● There is at least one recent record (< 12 months) on the usage of the test weights in checking the scales.
BITUMEN STORAGE TANK ● Have means of indicating the volume of biumen at all times. ● Have means of drawing off samples.
M
M
M
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● Provides for continuous circulation of hot bitumen through the bitumen feeding system and back into the bitumen storage tank. ● The end of the return line discharging into the bitumen storage tank shall be kept submerged in the bitumen to prevent oxidation of the returning hot bitumen. ● A thermometer is fitted to the bitumen storage tank or bitumen feed line. ● Have thermometers been checked and certified/calibrated (annually)? Date checked …………. Certified by ……………. Is copy of certification/calibration available? ● Bitumen storage tank and bitumen feeding system are equipped with heating system and insulating jackets.
BITUMEN PROPORTIONING ● Equipped with weigh bucket for accurately weighing the quantity bitumen entering the mixer. ● Discharge mechanism does not leak or drip when closed.
M
● Have scales been checked and certified/calibrated (annually)? Date checked …………. Certified by ……………. Is copy of certification/calibration available?
12
BATCH MIXER ● The clearance of the paddle blades from all fixed & moving parts of the mixer shall be not more than 20mm. ● Pugmill is closed or equipped with dust hood to prevent loss of fines from mixture. ● Discharge gate does not leak when closed.
13
M
PLANT SETTING ● Computer is able to display details of mixing proportion according to approved mix design, and mix temperatures. ● Print out of recent mix production (< 1 month) which shows the aggregates, filler and bitumen tonnages is available.
YES
NO
PINDAAN 3/2013 4
No.
ACTIVITIES
YES
M
●The accuracy of the plant setting as displayed on the computer screen have been checked and verified.
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LORRY TRANPORTER SCALES
M
● Has weigh bridge been checked and certified/calibrated (annually)? Date checked …………. Certified by ……………. Is copy of certification/calibration available?
NO
Note: M – Mandatory Remarks:……………………………………………………………………………………………… ……………………………………………………………………………………..……..…………… ……………………………………………………………………………………………………………
Is the plant qualified to produce asphalt for use in JKR paving works? YES
NO
Nota: i) YES – semua item mandatori DIPATUHI dan minimum 50% daripada item bukan mandatori LULUS. ii) NO – mana-mana item mandatori TIDAK DIPATUHI atau minimum 50% daripada item bukan mandatori GAGAL.
Auditor:
Auditee:
……………………………………………
……………………………………………
(Name: …………………………………) (Organisation: …………………………) Head of Audit Team
(Name: …………………………………) (Organisation: …………………………)
The Members of Audit Team 1.
Name: ……………………………
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Organisation: …………………… 2
Name: ……………………………
Organisation: …………………… 5
Organisation: …………………… 3.
Name: …………………………… Organisation: ……………………
Name: ……………………………
Name: …………………………… Organisation: ……………………
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Name: …………………………… Organisation: ……………………