IRC Code 126-2017: Guidelines on Wet Mix Plant for Highway Construction

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The IRC Code 126-2017, issued by the Indian Roads Congress, is a definitive guide for using wet mix plants in highway construction. Wet Mix Macadam (WMM) is a superior alternative to the traditional Water Bound Macadam (WBM), offering better gradation, faster construction, and enhanced quality. This code provides detailed specifications and best practices for setting up, operating, and maintaining wet mix plants to ensure high efficiency and sustainable construction practices.

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Purpose and Scope of IRC Code 126-2017

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Purpose

The wet mix plant plays a critical role in highway construction, producing a uniform mixture of aggregates and granular materials like sand, lime, or cement. The mix is used as a base or sub-base layer beneath bituminous layers. The code ensures that:

• Aggregates and other ingredients are proportioned accurately.
• Proper mixing is achieved for consistent quality.
• Additives and water are blended in the desired proportions.

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Scope

The guidelines in IRC Code 126-2017 cover:

• Advantages of wet mix plants.
• Key assemblies and components.
• Power requirements and performance.
• Maintenance and safety measures.
• Environmental compliance and pollution control.

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Advantages of Wet Mix Plants

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Wet mix plants offer several benefits over conventional methods:

• Higher production rates.
• Precise blending and proportioning of aggregates.
• Homogeneous mixing with no segregation.
• Reduced water usage.
• Enhanced quality control.
• Lower overall production costs.

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Key Assemblies of a Wet Mix Plant

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1. Aggregate Feeder

This ensures a steady flow of graded aggregates. Each feeder bin is designed to prevent intermixing, and vibrators are used to avoid sticking of fine aggregates.

2. Pug Mill

The heart of the plant, the pug mill, performs forced mixing of aggregates, water, and additives. It ensures a homogeneous and consistent output.

3. Water Tank and Metering Unit

Accurate water addition is facilitated by a spray bar and an electronic flow meter, ensuring optimal moisture content in the mix.

4. Control Panel

A centralized control cabin provides real-time monitoring and adjustments for efficient plant operations. Key parameters such as aggregate proportions, water quantity, and conveyor speed are tracked here.

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Maintenance Guidelines

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Proper maintenance ensures the smooth functioning of wet mix plants:

1. Daily Maintenance:
   • Lubricate all moving parts.
   • Check belt alignment and tension.
   • Inspect valves and gates.
2. Weekly Maintenance:
   • Clean conveyor belts and replace worn-out components.
   • Check scrapers and skirt boards for damage.
3. Monthly Maintenance:
   • Inspect electrical systems and calibration settings.
   • Adjust skirt boards and belt scales as needed.
4. Quarterly Maintenance:
   • Drain and replace gearbox oil.
   • Inspect pug mill liners and paddles for wear and tear.

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Safety Measures

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Ensuring safety is critical for plant operations:

• Equip the plant with emergency stop buttons.
• Train staff on safe operating practices.
• Regularly inspect and maintain fire-fighting equipment.
• Provide workers with personal protective equipment (PPE).

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Environmental Compliance

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IRC Code 126-2017 emphasizes eco-friendly practices:

• Dust suppression systems.
• Green belt development around the plant.
• Adherence to noise and emission limits for diesel gensets.

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Conclusion

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The IRC Code 126-2017 is a comprehensive guide for utilizing wet mix plants in highway construction. By adhering to these guidelines, engineers and contractors can ensure efficient production, consistent quality, and environmentally sustainable practices.

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