With the high-quality development of highway construction, the installation accuracy of asphalt mixing plants directly affects project quality. Asian Construction Equipment Group Co., Ltd. (abbreviated as ACE Group) , combining engineering experience and technological achievements, has formulated this specification to standardize the entire installation process of various models of asphalt mixing plants, ensuring that equipment operates up to standard and contributing to improved quality and efficiency in road construction.
(一) Purpose of the Regulations
These regulations standardize the installation operations of ACE group’s asphalt mixing plants, unifying standards, clarifying requirements, and preventing risks to ensure that the equipment meets design capacity and environmental protection standards after installation. They are applicable to new construction, relocation, and renovation projects.
(二) Scope of Application
This application covers installation preparation, main/auxiliary equipment installation, electrical integration, commissioning, acceptance, and delivery. It is intended for use by ACE group’s technical personnel, partner companies, and on-site personnel, and must prioritize compliance with local regulations.
(三) Core Principles
Following the principles of “safety first, technical compliance, precise positioning, and closed-loop management,” we strictly implement the “Installation and Acceptance Specification for Asphalt Concrete Mixing Equipment” (GB/T 25646-2010) and the ACE group Equipment Manual.
(一) Site and Foundation Engineering
1.Site Selection and Planning: Select a flat area with adequate geological bearing capacity, away from densely populated areas and risk points; plan raw material/finished product storage areas, equipment areas, and maintenance access roads, and install a drainage system to prevent water accumulation.
2.Foundation Design and Construction: Detail the design according to the foundation drawings and geological report from Yajian Technology, ensuring that the concrete strength, impermeability grade, and anchor bolt dimensions meet the standards; after construction, ensure the foundation is level, and avoid placing heavy objects during the curing period.
3.Foundation Acceptance: Complete the bearing capacity test and dimension verification, focusing on checking the anchor bolt positions, foundation elevation, and hole verticality. Installation can only proceed after passing the inspection.
(二) Equipment Unpacking Inspection and Storage
1.Arrival Inspection: Joint acceptance by ACE group, the supervision unit, and the construction unit. Verification of equipment model and quantity, inspection of the integrity of vulnerable parts, and use of professional methods to detect hidden damage to key components.
2.Document Verification: Verification of factory certificates of conformity, schematic diagrams, and other documents; collection of special equipment qualification documents; and archiving.
3.Equipment Storage: Equipment is stored categorized; main units are protected from rain and snow; electrical components are stored in a dry warehouse; metal parts are protected against rust; and precision instruments are protected from moisture and shock.
(三) Tool and Material Preparation
1.Specialized Tool Configuration: Equip with suitable lifting equipment, precision measuring tools, welding equipment, and electrical testing instruments. Tools must be calibrated and certified.
2.Auxiliary Material Requirements: Anchor bolts should be high-strength type; sealant should be temperature- and oil-resistant; lubricant should be the type specified by ACE group; insulation materials should meet thermal conductivity requirements.
(一)Mixing Tower Installation
1.Base Installation: Lift the base to the foundation using a crane, level it, and initially fix it. Fill the gaps with secondary grouting. Tighten the anchor bolts after the strength meets the requirements.
2.Tower Assembly: Assemble the tower body from bottom to top. Clean and seal the flange surfaces, then tighten the bolts. Measure the verticality of each section and correct any deviations.
3.Mixing System Installation: Lift the mixer to the designated location and fix it. Connect the inlet/outlet and pipes, ensuring a seal. Install the motor and reducer, and adjust the tension of the transmission components.
(二) Drying Cylinder Installation
1.Support Installation: Pour the support foundation, level it, and then grout it. Hoist the drying cylinder onto the support, adjusting the roller spacing to ensure smooth rotation.
2.Burner Installation: Install the burner along the center line, connect the fuel pipeline and perform a seal test. Install safety devices such as flame detectors.
3.Transmission System Commissioning: Install the motor, reducer, and transmission components. Adjust the tension and apply lubricant. Perform a no-load test run to check for smooth operation.
(三) Vibrating Screen Installation
Frame Fixing: Hoist the frame to the foundation and fix it in place. Adjust the level and install vibration damping pads to ensure stability.
Screen Installation: Install the screen according to the aggregate gradation and tension it. Install the vibrating motor and adjust the eccentric block angle to achieve the designed vibration frequency and amplitude.
(一) Installation of the Batching System
1.Storage Installation: Install stone silos, powder silos, and asphalt tanks, ensuring they are stable and spaced correctly; install dust collectors in the powder silos and heating and temperature control devices in the asphalt tanks.
2.Feeding Equipment Installation: Install feeders at the bottom of the silos, adjusting the outlet position to ensure smooth material flow, and connect to the electrical system for precise material control.
(二) Conveying System Installation
1.Belt Conveyor Installation: Ensure the frame is level, adjust idlers, rollers, and belt tension to prevent deviation, and install safety guards.
2.Powder Pipeline Installation: Use wear-resistant pipes, connect flanges and seal, install valves and elbows to ensure smooth conveying.
3.Asphalt Pipeline Installation: Insulate the pipeline, connect with special sealing materials, and install asphalt pumps and heating equipment to prevent solidification.
(三) Dust Collection System Installation
1.Dust Collector Installation: Select a pulse-jet bag filter based on production capacity, install it in an easily accessible location for maintenance, and ensure unobstructed ductwork.
2.Ventilation Duct Installation: Connect the dust collector to the dust-generating point, ensuring duct strength and sealing to guarantee effective dust collection.
3.Exhaust Fan Installation: Install the exhaust fan and adjust its rotation speed to ensure stable negative pressure in the system. Add shock absorbers to reduce noise.
(一) Electrical Control Cabinet Installation
1.Cabinet Fixing: Installed in a dry, well-ventilated control room, ensuring verticality, levelness, reliable grounding, and sufficient spacing for operation and maintenance.
2.Wiring Standards: Wiring according to the schematic diagram, laid out according to voltage levels, with neatly fixed wire harnesses, clear labeling, and secure, insulated terminals.
(二) Motor and Sensor Wiring
1.Motor Wiring: Measure the insulation resistance before wiring. Connect the wires according to the nameplate and install cable protection. Ground the motor casing. Install overload protection for large motors.
2.Sensor Installation: Install temperature, pressure, and other sensors in designated locations. Ground the wiring shielding layer, keep them away from power cables to prevent interference, and ensure accuracy after calibration.
(三) Grounding and Lighting Systems
1.Grounding System Installation: A combined grounding system shall be adopted, with grounding electrodes and grounding wires installed to ensure reliable grounding of equipment casings, control cabinets, etc., and that the resistance meets standards.
2.Lighting System Installation: Explosion-proof lighting fixtures shall be installed in the work area to ensure sufficient illumination. Emergency lighting shall be provided, with independent circuits.
(一) No-load Commissioning
1.Single-machine commissioning: Start the equipment according to the principle of “electrical first, then mechanical; auxiliary equipment first, then main equipment,” and check the motor rotation direction, vibration noise, and lubrication.
2.Interlocking commissioning: Start the entire set of equipment to simulate production and check the interlocking control, material conveying, and emergency stop functions.
(二) Load Trial Run
1.Trial Production Preparation: Prepare materials according to the mix proportions and adjust equipment parameters to ensure readiness.
2.Trial Production Operation: Gradually increase material input for trial production, monitor equipment operating parameters and mix quality, and check equipment seals and wear.
3.Problem Rectification: Develop rectification plans promptly for any problems found; production can only continue after standards are met.
(一) Acceptance Contents
1.Installation Quality Acceptance: Check the equipment’s levelness, verticality, connection firmness, and sealing; verify the compliance of electrical wiring and grounding.
2.Performance Index Acceptance: Measure equipment capacity, mixture qualification rate, energy consumption, and environmental protection indicators to ensure compliance with design requirements.
3.Document Acceptance: Verify the completeness of documents such as unpacking records, foundation reports, installation records, and commissioning reports.
(二) Acceptance Report
After acceptance, ACE group, the construction and supervision units jointly signed the “Asphalt Mixing Plant Installation Acceptance Report” and attached supporting materials for filing.
1.Equipment Delivery: Complete handover procedures and deliver technical documentation (installation/operation/maintenance manuals, spare parts list) and acceptance report.
2.Personnel Training: Conduct training on equipment structure, operation, troubleshooting, and maintenance for user operators and maintenance personnel. Only those who pass the assessment are allowed to work.
This regulation is interpreted and revised by the Engineering and Technology Department of Asian Construction Equipment Group Co., Ltd. . For matters not covered herein, please refer to national standards and equipment manuals.
Installation must comply with safety regulations, be equipped with protective facilities, and personnel must be certified to work.
After installation, the equipment shall be maintained regularly according to the “Maintenance and Upkeep Regulations for Asphalt Mixing Plants”.
This specification embodies the technology and experience of Asia Construction Technology, providing a standardized framework for asphalt mixing plant installation. In practical application, adjustments must be made based on project specifics, while strictly adhering to national standards and regulations. Asia Construction Technology will continue to optimize this specification to provide better support to its clients and contribute to the high-quality development of road construction.
Important Note: All operational requirements and technical specifications in this procedure are for reference only. Actual implementation should be based on the specific circumstances of the project and the guidance of professional technicians. Asia Construction Technology Co., Ltd. shall not be liable for any losses caused by directly applying this procedure.
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