Chapter 5
Field Manufacture of Asphalt Cutbacks
Various types and grades of asphalt cutbacks can be manufactured in the
field with standard equipment. Thinner cutbacks can be produced from the
more viscous grades. Field manufacture of SC and MC, however, is more
practicable than field manufacture of RC because of the rapid evaporation
of gasoline from RC. Also, a greater danger of fire or explosion from the
gasoline exists.
EQUIPMENT AND PRODUCTION RATE
5-1. Table 5-1 lists the equipment used for the field manufacture of asphalt
cutback. The rate of production is usually controlled by the speed that AC can
be emptied from the drums and heated in the asphalt melters to suitable
temperatures for pumping. The production rate for the asphalt melter is about
750 gallons per hour. Figure 5-1, page 5-2, shows the suggested arrangements
of equipment uses in the manufacture of asphalt cutbacks. For small-scale
production, use a truck- or trailer-mounted distributor or a 5,000-gallon,
trailer-mounted asphalt tank with heating coils, instead of a 4,000-gallon
mixing and storage tank. Arrange piping and pumping to fit each particular
installation. (See Chapter 3 for more information on the equipment used in
the field manufacture of asphalt cutbacks.)
Table 5-1. Equipment Used to Manufacture Asphalt Cutback
Equipment Function
Hot-oil heater Used to heat bitumen.
One asphalt pump is a portable pumping unit that transfers bituminous
material from heating facilities to a storage tank, and another pump
transfers the cutter stock to the mixing tank. A third pump might be
Asphalt pumps
required for circulating cutback in heated storage tanks to obtain even
temperatures when high-viscosity materials are used. A bituminous
distributor can be used as a pumping and mixing unit.
Used to connect 5,000-gallon tanks with the asphalt melter, asphalt
Piping equipment
pumps, and mixing tanks.
Asphalt storage tank Used to store bitumen.
A 15-kW, 3-phase, 60-Hz, 230-V generator used to operate the hot-oil
External electric power
heater.
600-gallon pod fuel tank or 750-
gallon, 2-compartment Used to hold the cutter stock.
proportioning tank, 2 each
A skid-mounted, 750-GPH, dedrumming asphalt melter with a 3,000-
Asphalt melter
gallon storage capacity.
Fire extinguishers Foam-type fire extinguishers used to extinguish fires.
Field Manufacture of Asphalt Cutbacks 5-1
FM 5-436
Tool 4,000-gal asphalt
shed storage tank
Drainage
outlet
33'
Distributor
3'' steam-jacketed outlets
asphalt piping 1'' cutter-stock piping
Fuel supply
for burners 19' 30-GPM portable
gasoline-
dispensing pump
Steam
trap
Steam
blowoff
20
Asphalt kettle, Tank-car heater,
Proportioning tank, 750-
750-gal, 3-car capacity
gal, 2-compartment
skid-mounted
1,000-gal water distributor or Slope the bottom of
750-gal skid tank the tank 2'' toward
3'' steam- the outlet.
jacketed pipe
Elevation 20'
Figure 5-1. Equipment Used to Manufacture Asphalt Cutback
SAFETY
5-2. At least one safety inspector should be assigned to each operation to help
personnel stay focused on their particular job. He ensures that personnel
observe safety precautions within his area of responsibility. Personnel must
strictly observe safety precautions when heating bitumens. They must—
• Keep foam-type fire extinguishers available at all times.
• Maintain oil heaters, storage tanks, asphalt melters, and distributors
in a level position before heating.
• Never heat bitumens near buildings or flammable materials.
• Control ventilation of melters, heaters, and distributors to prevent
escape of flammable vapors near flames or electrical equipment.
5-2 Field Manufacture of Asphalt Cutbacks
FM 5-436
• Stay to the windward side of equipment to avoid excessive exposure to
fumes.
• Reduce heat when foaming might cause overflow.
• Extinguish burners after bitumen has reached the temperature given
in Table 2-1, page 2-2.
• Extinguish burners and evacuate personnel if a dense, yellow vapor
rises from the asphalt melter, distributor, or storage tanks. (This
indicates overheating to the extent that a spark could cause an
explosion.)
• Extinguish burners before spraying bitumen from a distributor.
• Never smoke within 50 feet of any equipment. A designated smoking
area should be at least 100 feet upwind of the equipment during
heating operations.
• Examine all hoisting equipment daily.
• Never fill buckets or containers to the top if they will be hoisted.
• Never allow the asphalt level to fall below the fire tubes while the
burners are in operation.
• Consult appropriate TMs for clean-out operations.
• Wear long-sleeve shirts, cuffless pants, fireproof gloves, heavy-soled
boots, and steel combat helmets or civilian safety hats. This clothing
helps protect workers if hot bitumen accidentally spills on them.
PROCEDURES
5-3. The procedures for the field manufacture of asphalt cutback are outlined
below. Strictly observe the safety precautions associated with the procedures
to avoid the danger of fire or explosion. See Table 5-2 for the composition of
asphalt cutback.
Table 5-2. Composition of Asphalt Cutback
Asphalt Cutback AC Percent of Cutter Stock by Volume
Percent
Penetration Grade Fuel, Diesel
of Total Gasoline Kerosene
Type Grade Oil, or Similar
Limits Preferred Volume or Naphtha or Jet Fuel
Material
RC 70 60-150 85-100 65 35
250 75 25
800 83 17
3,000 87 13
MC 30 54 46
70 85-200 120-150 64 36
250 74 26
800 82 18
3,000 86 14
SC 70 50 50
250 120-300 200-300 60 40
800 70 30
3,000 80 20
Field Manufacture of Asphalt Cutbacks 5-3
FM 5-436
DRUMS
5-4. Use special axes or cutting tools to remove the heads from asphalt drums,
and insp ect the contents of each drum. Eliminate d rums t hat are
contaminated with water or material that could cause foaming or fire. Take
care when opening the drums to avoid serious injury, which can be caused by
improper use of cutting tools.
5-5. Load the drums inside the dedrumming tunnel using an electric winch or
a lifting device to pick up the drums. The Army uses different types of melters.
The main difference between them is the melting capacity, which ranges from
8 to 12 drums inside the dedrumming tunnel. Heat the AC to about 250°F
until it is fluid enough to pump easily. Figure 5-2 shows a typical asphalt
melter.
Discharge door Lift eyes
Tunnel Loading door Hoist
Rub rail
Do
me not W
e
Ch lter nter ARN
ec i s .
k w a c The ING
ith onfi inte
the ned rio
loc sp r of
al a t
sa ce. his
Lift and fety
tow eyes
Gate valves
Rain shield
Thermometer
Storage tank Drum
Hand winch (front door) sling
Asphalt-
Standoff guard jacketed
Toolbox valve Disconnect
-coupling
Loading platform Ladder
Figure 5-2. Model STMD-3000A Asphalt Melter
5-4 Field Manufacture of Asphalt Cutbacks
FM 5-436
ASPHALT CEMENT
5-6. Once the AC (or cutback) is heated to a workable state, pump it to
storage. The 5,000-gallon heated tanks are usually used as storage tanks. Use
the oil-jacketed lines between the units to maintain the asphalt in the
pipelines at a constant temperature that is high enough to keep the asphalt
fluid.
5-7. Blow out all the lines (except oil-jacketed) that become plugged with cold
asphalt. For oil-jacketed lines, heat uneducated elbows and keep oil in the
jacket. If the original asphalt material cannot be delivered hot, pump it
directly to the storage tanks.
5-8. Pump about 2,000 gallons of AC from the heated storage tanks to the
5,000-gallon mixing tanks. If using a distributor or a trailer-mounted tank for
mixing small quantities, pump it about half full to leave space for cutter stock
and the foaming action that may result when adding the cutter stock.
TEMPERATURE
5-9. Adjust the temperature in the mixing chamber between 240° and 250°F.
Pump circulation accompanied by heating or atmospheric cooling will help
regulate this temperature. If the temperature drops below 240°F, the AC will
not be fluid enough to pump easily or mix readily with the cutter stock. At
higher temperatures, much of the cutter stock will be lost in a gaseous form
and a serious fire hazard will exist.
5-10. After the original material in the mixing tank is adjusted to the
specified temperature, stop circulation and estimate the quantity of material
in the tank. Determine the required amount of cutter stock to place in the
mixing tank, and pump the desired quantity into the tank.
5-11. For best mixing results, introduce the cutter stock near the intake pipe
that leads to the circulation pump. Pump the heated original material and the
cutter stock through a closed system in the mixing tank. Cover the openings in
the tank with wet burlap or canvas while blending cutbacks. Ensure that fire-
fighting facilities are readily available.
5-12. When manufacturing cutbacks from AC, start pumping as soon as the
AC is fluid enough to pump without damaging or placing a strain on the
trailer-mounted asphalt pump. Ensure that the temperature is as low as
possible, not to exceed 250°F because of the fire hazard. After mixing, usually
about 30 minutes, pump the newly manufactured asphalt cutback to final
storage.
MATERIAL REQUIREMENTS
5-13. Table 5-2, page 5-3, lists the composition of asphalt cutbacks. The
following example shows how to calculate the combined quantities of AC and
cutter stock needed for a specific type and grade of asphalt cutback:
Example: Calculate the quantity, in gallons, of AC and diesel oil that must be
combined to produce 750 gallons of SC-800.
Field Manufacture of Asphalt Cutbacks 5-5
FM 5-436
Solution: SC-800 is composed of 70 percent soft AC, with a preferred
penetration of 200 to 300 and 30 percent diesel oil by volume (Table 5-2, page
5-3).
(0.7) (750) = 525 gallons of AC
(0.3) (750) = 225 gallons of diesel oil
5-14. The procedure for determining the proportion of cutter stock added to
asphalt cutback to produce a lower (thinner) grade is outlined below. Use the
data in Table 5-2 and the following formula:
100 ( a – b )
x = --------------------------
100 – b
where—
x = percent of cutter stock to be added to the cutback to be thinned
a = percent of cutter stock in desired cutback of lower grade
b = percent of cutter stock in cutback to be thinned
Example: Calculate the amount of kerosene and MC-800 cutback used to
produce 1,000 gallons of MC-70 cutback.
Solution:
100 ( 35 – 18 )
x = --------------------------------
100 – 18
x = 20.7 percent kerosene
x = 79.3 percent MC-800
To produce 1,000 gallons of MC-70, combine 207 gallons (1,000 x 0.207) of
kerosene with 793 gallons (1,000 x 0.793) of MC-800.
5-15. Use the following example to calculate yield:
Example: The materials available in the field for bituminous construction
include 1,000 gallons of 120 to 150 penetration AC, 750 gallons of MC-3,000,
and 1,750 gallons of kerosene. Determine the following:
• How many gallons of MC-30 can be produced by combining the AC
with the kerosene.
• How many gallons of MC-30 can be produced by combining the MC-
3,000 with the kerosene.
• How many total gallons of MC-30 can be produced.
Solution: Determine the percentage of AC and kerosene in MC-30 by
referring to Table 5-2. MC-30 contains 54 percent AC and 46 percent kerosene.
If 1,000 gallons of 120 to 150 penetration AC represents 54 percent of the MC-
30 to be produced, use the following formula to determine how many gallons of
kerosene should be added to the AC:
percent of asphalt percent of kerosene
------------------------------------------- = -----------------------------------------------
1, 000 gallons x
54 46
--------------- = ------
1, 000 x
5-6 Field Manufacture of Asphalt Cutbacks
FM 5-436
46(1,000)
x = ----------------------- = 851 gallons
54
where—
x = gallons
Combining 1,000 gallons of AC and 851 gallons of kerosene produces 1,851
gallons of MC-30.
Use the following formula to determine the percent of kerosene added to MC-
3,000 to produce MC-30:
100 ( a – b )
x = --------------------------
100 – b
where—
x = percent of kerosene to add to MC-3,000
a = percent of kerosene in MC-30 (see Table 5-2, page 5-3)
b = percent of kerosene in MC-3,000 (see Table 5-2)
100 ( 46 – 14 ) 3, 200
x = -------------------------------- = --------------- = 37.2 percent
100 – 14 86
Use the following formula to determine the amount of MC-30 that can be
produced by combining the MC-3,000 with the kerosene. The previous
equation determined that 37.2 percent of the MC-30 is kerosene, so the
remaining 62.8 percent is MC-3,000.
628 37.2
--------- = ----------
750 x
where—
x = amount of kerosene, in gallons, to add to 750 gallons of MC-3,000
( 750 ) ( 37.2 )
x = ----------------------------- = 444 gallons
62.8
The amount of kerosene is as follows:
• Available = 1,750 gallons.
• Previously used = 851 gallons.
• Remaining = 899 gallons.
Since 899 gallons of kerosene are available and only 444 gallons are needed,
there is enough kerosene to thin all of the MC-3,000. Add 750 gallons of MC-
3,000 to 444 gallons of kerosene to make MC-30 (makes 1,194 gallons). The
total amount of MC-30 that can be produced is 3,045 gallons (1,851 + 1,194).
Field Manufacture of Asphalt Cutbacks 5-7
