Standard Operating Procedure of Premix Plant
Standard Operating Procedure of Premix Plant
1.0 Introduction
An asphalt premix plant is a facility where bitumen and aggregates are blended to produce
asphalt mixtures used in road construction and repair. The plant operates by heating, drying, and
mixing aggregates with bitumen to form a uniform and durable pavement material. The quality of
the asphalt premix is crucial in ensuring the longevity and safety of roads, highways, and
infrastructure projects.
Asphalt premix plants come in different types, including batch mix plants and drum mix plants. A
batch mix plant produces asphalt in batches, ensuring precise control over the mix proportions.
In contrast, a drum mix plant operates continuously, providing a steady supply of asphalt mixture.
Regardless of the type, proper operational procedures, maintenance, and quality control
measures are essential for the efficient and safe operation of the plant.
This SOP outlines the step-by-step procedures, safety measures, and quality control
requirements to ensure consistent asphalt production that meets industry standards and
environmental regulations.
LOCATION OF PLANT
IKFF-SOP-032025-REV0
Located in XXX. The premix plant is a temporary setting for the supply the product for the
construction of Kuching Urban Transportation System (KUTS) infrastructure nearby, until the
completion of project.
IKFF-SOP-032025-REV0
a. Aggregates are loaded into different bins according to type and size, which is to be
transferred to the drying drum. Each feed bin is equipped with appropriate sensors
connected to adjustable gates to control the flow of each aggregate.
b. The aggregate is transferred to the weighted feeder to be weighted accordingly before
entering the next phase.
c. After the weight of the aggregate is measured to the desired amount, the material is
conveyed to the vibrating screen to separate the oversized aggregates from entering the
mixing drum.
d. At this section of the process, the aggregates are mixed and dried, and other fillers such as
bitumen are added. The mixture is heated to reduce the moisture and the exhaust gases are
channelled to the pollution control system.
e. Exhaust/Flue gas from the drum mixer is transferred to the air pollution control system for
treatment before discharged into the atmosphere
f. The desired mixture is stored in the hot mix silo via drag conveyor, ready for loading into
IKFF-SOP-032025-REV0
transport lorry.
IKFF-SOP-032025-REV0
2.0 Purpose
The purpose of this Standard Operating Procedure (SOP) is to establish a comprehensive
framework for the safe, efficient, and high-quality operation of an asphalt premix plant. The SOP
provides detailed guidance on production processes, equipment handling, safety protocols,
quality control, maintenance, and compliance with environmental and industry regulations.
By following this SOP, all personnel involved in asphalt premix plant operations can contribute to
a safer, more efficient, and environmentally responsible production process.
IKFF-SOP-032025-REV0
3.0 Scope
This SOP applies to all personnel involved in the operation, maintenance, quality assurance,
safety, and logistics of the asphalt premix plant. It includes detailed guidelines for all critical
aspects of plant operations to ensure a safe and efficient workflow.
This SOP is applicable to all personnel, including plant operators, maintenance staff, quality
control teams, safety officers, and management personnel. Adhering to these guidelines will
ensure that asphalt production is carried out efficiently, safely, and in compliance with regulatory
and environmental standards.
a. Oversees the entire plant operation, ensuring compliance with safety and production
standards.
b. Approves production schedules and ensures efficient resource allocation.
c. Liaises with regulatory bodies and ensures compliance with legal requirements.
d. Conducts periodic performance evaluations of plant staff.
e. Addresses operational issues and implements necessary improvements.
IKFF-SOP-032025-REV0
4.2 Operators:
a. Manage transportation and timely delivery of finished asphalt mix to project sites.
b. Coordinate with production teams to ensure efficient scheduling of dispatch
operations.
c. Ensure proper documentation of dispatch records and compliance with regulatory
transport requirements.
d. Monitor vehicle and fleet conditions to prevent delays and maintain serviceability.
e. Keep updated records of environmental compliance reports and liaise with regulatory
agencies.
IKFF-SOP-032025-REV0
a. All personnel must wear safety boots, gloves, helmets, high-visibility vests, and heat-
resistant clothing.
b. Respiratory protection must be used in areas with high dust or fume concentrations.
c. Hearing protection is required when working near loud machinery.
a. Bitumen and fuel storage areas must be kept away from ignition sources.
b. Fire extinguishers and fire suppression systems must be easily accessible and regularly
inspected.
c. Emergency fire drills should be conducted periodically.
d. Smoking and open flames are strictly prohibited in fuel and bitumen storage areas.
a. Bitumen storage tanks must be equipped with temperature control systems to prevent
overheating.
b. Workers handling hot bitumen must wear heat-resistant gloves, face shields, and
protective clothing.
c. Bitumen spillage must be cleaned up immediately to prevent fire hazards and
workplace injuries.
d. Mixing chambers and heating elements should be routinely checked for leaks or
blockages.
IKFF-SOP-032025-REV0
a. Ventilation and exhaust systems must be in place to control the release of airborne
contaminants.
b. Workers should be provided with dust masks and respirators in areas prone to high
dust levels.
c. Water sprays and dust suppression systems should be used to minimize airborne
particles.
d. Air quality monitoring should be conducted regularly to ensure compliance with health
and safety standards.
a. Clear signage and designated pathways should be established for trucks and heavy
machinery.
b. Speed limits must be enforced within the plant to prevent accidents.
c. Drivers and equipment operators should undergo periodic safety training.
d. Pedestrian access should be restricted in high-risk areas to prevent collisions.
a. Hearing protection devices should be provided to workers exposed to high noise levels.
b. Noise barriers and insulation materials should be installed around loud machinery.
c. Operations should be scheduled to minimize prolonged exposure to excessive noise
levels.
a. Waste disposal systems must be in place for hazardous and non-hazardous materials.
b. Oil and chemical spills must be contained immediately using absorbent materials.
c. Runoff water should be treated before being discharged into surrounding areas.
d. Compliance with local and international environmental regulations must be maintained
at all times.
IKFF-SOP-032025-REV0
By implementing these operational safety measures, the asphalt premix plant can minimize risks,
enhance worker safety, and maintain compliance with industry standards.
IKFF-SOP-032025-REV0
a. Inspect all plant equipment, including mixers, dryers, conveyors, and burners, for any
signs of damage or wear.
b. Ensure all safety devices, such as emergency stop buttons, alarms, and fire suppression
systems, are functional.
c. Verify that the storage tanks for bitumen and aggregates are adequately stocked.
d. Conduct a test run of the conveyor belts and mixing components to detect any
irregularities.
e. Check fuel and electrical connections to ensure proper functioning.
a. Load aggregates into the feeder bins according to the required mix design.
b. Transport aggregates through the conveyor system to the drying drum, where they are
heated to the specified temperature.
c. Store bitumen in a temperature-controlled tank and heat it to the required viscosity
before mixing.
d. Add mineral fillers and additives, if required, to enhance the properties of the asphalt
mix.
a. In batch mix plants, aggregate materials are weighed and mixed with bitumen in the
pug mill according to the specified mix design.
b. In drum mix plants, aggregates and bitumen are continuously fed and mixed in the
drum to maintain a steady asphalt production rate.
c. Maintain strict temperature control during the mixing process to ensure optimal
bonding between aggregates and bitumen.
d. Monitor moisture levels in the aggregates to prevent variations in mix quality.
a. Conduct sample testing at regular intervals to ensure the asphalt mix meets required
specifications.
b. Verify the mix temperature before loading it into delivery trucks to ensure proper
workability and compaction.
c. Adjust mix proportions and burner temperatures if deviations from the required
specifications are detected.
IKFF-SOP-032025-REV0
a. Load the hot asphalt mixture into insulated delivery trucks using controlled discharge
systems.
b. Ensure uniform distribution of the mix in the truck to prevent segregation during
transportation.
c. Cover the loaded asphalt to maintain temperature and prevent contamination.
d. Dispatch the trucks to the construction site while adhering to transportation safety
regulations.
a. Gradually lower production rates before completely shutting down the plant to prevent
abrupt system failures.
b. Clean out residue from the mixing chamber and other components to prevent material
buildup.
c. Perform routine maintenance checks and document any issues requiring repairs.
d. Store unused raw materials properly to maintain their quality for the next production
cycle.
e. Shut down fuel sources and secure electrical systems before leaving the plant.
By strictly adhering to this operational procedure, the asphalt premix plant can maintain high
efficiency, minimize downtime, and ensure a safe and quality-controlled production process.
a. Conduct routine testing of aggregates for gradation, moisture content, and cleanliness.
b. Ensure bitumen quality by checking viscosity, penetration grade, and temperature
stability.
c. Verify that mineral fillers and additives conform to required specifications before use.
d. Maintain proper stockpile management to prevent contamination and segregation of
raw materials.
b. Conduct trial mixes before full-scale production to validate the performance of the
asphalt mix.
c. Adjust the proportion of aggregates, bitumen, and fillers if variations are detected.
a. Monitor and regulate the temperature of aggregates, bitumen, and the final mix to
ensure uniformity.
b. Regularly check the mixing time in batch plants and the drum speed in continuous
plants to optimize the blending process.
c. Inspect burner performance to ensure efficient heating and prevent excessive fuel
consumption.
d. Ensure proper calibration of weighing systems for accurate material proportioning.
IKFF-SOP-032025-REV0
a. Conduct Marshall Stability tests, asphalt content analysis, and density tests on sample
batches.
b. Check for air voids, workability, and moisture susceptibility in the produced asphalt
mix.
c. Ensure the mix has adequate adhesion properties to prevent premature stripping.
d. Perform in-house and third-party lab testing to validate compliance with industry
standards.
a. Inspect delivery trucks before loading to ensure they are clean and free from residual
materials.
b. Ensure uniform loading procedures to minimize segregation of the mix during
transportation.
c. Monitor temperature consistency at the time of loading to prevent excessive cooling
before application.
a. Maintain detailed records of quality test results and production data for future
reference and audits.
b. Implement corrective actions if test results indicate non-conformance with mix design
requirements.
c. Conduct periodic reviews of quality control processes to improve overall plant
efficiency and product consistency.
By enforcing these quality control measures, the asphalt premix plant can ensure high-
performance asphalt production that meets project requirements, enhances pavement durability,
and minimizes the risk of defects during road construction.
IKFF-SOP-032025-REV0
a. Implement a regular cleaning schedule to remove dust, spilled aggregates, and bitumen
residues from work areas.
b. Ensure workspaces, control rooms, and storage areas remain organized and clutter-
free.
c. Maintain clear pathways for equipment and personnel to enhance workplace safety.
d. Ensure waste materials, including used filters, oil, and asphalt residues, are disposed of
in compliance with environmental regulations.
e. Keep fire extinguishers and emergency equipment in designated locations, ensuring
they are accessible and functional at all times.
f. Conduct routine inspections of ventilation and exhaust systems to prevent dust
accumulation and maintain air quality.
By implementing these maintenance and housekeeping measures, the asphalt premix plant can
operate more efficiently, reduce equipment failures, and maintain a safe and organized work
environment, ultimately improving overall productivity and longevity of plant operations.
a. Maintain daily logs of asphalt production, including mix proportions, batch numbers,
and production output.
b. Record the temperature of bitumen and aggregates during mixing to ensure
compliance with design specifications.
c. Document any deviations in production and corrective actions taken to address
inconsistencies.
a. Maintain records of aggregate and bitumen testing, including sieve analysis, moisture
content, and bitumen penetration tests.
b. Log asphalt mix testing results, including Marshall stability, flow, and void content
analysis.
c. Document rejected batches and corrective measures taken to improve quality.
b. Log training sessions conducted for plant personnel on safety protocols and operational
procedures.
c. Record fire safety drills, emergency response exercises, and inspections of safety
equipment such as fire extinguishers and first-aid kits.
a. Store records securely, either in physical logs or digital databases, ensuring they are
easily accessible when needed.
b. Implement version control and approval processes for documents to prevent
unauthorized modifications.
c. Train personnel on proper record-keeping practices to maintain consistency and
accuracy in documentation.
d. Periodically review records for completeness, accuracy, and compliance with industry
requirements.
By maintaining thorough documentation and record-keeping practices, the asphalt premix plant
can ensure regulatory compliance, improve operational efficiency, and facilitate continuous
process improvement.
IKFF-SOP-032025-REV0
a. Ensure all employees understand and adhere to local, state, and federal regulations
regarding plant operations.
b. Maintain up-to-date licenses and permits required for plant operations.
c. Conduct periodic audits and inspections to assess compliance with safety,
environmental, and quality standards.
By implementing a structured training and compliance program, the plant can enhance
operational efficiency, minimize risks, and ensure adherence to industry best practices.
These references serve as a guide for ensuring compliance and best practices in asphalt premix
IKFF-SOP-032025-REV0
plant operations.