2013-3 Batch Plant Checklist [PDF]

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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?



6



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



11



● 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.



14



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:



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(Name: …………………………………) (Organisation: …………………………) Head of Audit Team



(Name: …………………………………) (Organisation: …………………………)



The Members of Audit Team 1.



Name: ……………………………



4



Organisation: …………………… 2



Name: ……………………………



Organisation: …………………… 5



Organisation: …………………… 3.



Name: …………………………… Organisation: ……………………



Name: ……………………………



Name: …………………………… Organisation: ……………………



6



Name: …………………………… Organisation: ……………………