AIR FORCE TACTICS, TECHNIQUES, AND PROCEDURES 3-32.19

AFTTP 3-32.19 24 SEPTEMBER 2018 1

AIR FORCE TACTICS, TECHNIQUES,

AND PROCEDURES 3-32.19

24 SEPTEMBER 2018

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BY ORDER OF THE AIR FORCE TACTICS, TECHNIQUES

SECRETARY OF THE AIR FORCE AND PROCEDURES 3-32.19

24 SEPTEMBER 2018

Tactical Doctrine

RAPID AIRFIELD DAMAGE RECOVERY

ASPHALT BATCH PLANT OPERATIONS

ACCESSIBILITY: Publications and forms are available on the e-Publishing web

site at www.e-Publishing.af.mil

for downloading or ordering.

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AF/A4CXX Certified By: AF/A4CX

(Colonel Michael J. Zuhlsdorf)

Pages: 35

PURPOSE: To provide tactics, techniques, and procedures (TTPs) for asphalt

batch plant operations during Rapid Airfield Damage Repair (RADR). It supports

Air Force Instruction (AFI) 10-210, Prime Base Engineer Emergency Force

(BEEF) Program, AFPAM 10-219, Volume 4, Airfield Damage Repair

Operations, and Air Force Doctrine Annex 3-34, Engineer Operations. Ensure

that all records created as a result of processes prescribed in this publication are

maintained IAW Air Force Manual (AFMAN) 33-363, Management of Records,

and disposed of IAW the Air Force Records Disposition Schedule (RDS) in the

Air Force Records Information Management System (AFRIMS). Refer

recommended changes and questions about this publication to the Office of

Primary Responsibility (OPR) using the AF Form 847, Recommendation for

Change of Publication; route AF Forms 847 from the field through the appropriate

functional chain of command.

APPLICATION: This publication applies to all regular Air Force, Air National

Guard, and Air Force Reserve Command Civil Engineer personnel performing

RADR asphalt batch plant operations. This document is authoritative but not

directive. The asphalt batch plant operations TTPs in this publication take

precedence over those found in other nondirective publications. Applicable AFIs

take precedence when this publication and those AFIs conflict.

2 AFTTP 3-32.19 24 SEPTEMBER 2018

SCOPE: This publication provides TTPs to produce asphalt concrete with a

contingency batch plant after an attack. It provides resource requirement

information for manpower, vehicle, equipment, and repair material; preparatory

actions taken prior to an attack and before commencing repair activities. Finally,

the publication describes batching, stockpiling, and delivery of asphalt to airfield

pavement repair personnel.

The TTPs within this publication are best practices as determined by the Airbase

Acquisition Branch, Air Force Civil Engineer Center (AFCEC/CXAE). Where

applicable, use procedures found in applicable manufacturer’s owners/operators

manuals for specific asphalt recycler make and models.

The use of name, procedures, or mark of any specific manufacturer, commercial

product, commodity, or service in this publication does not imply endorsement by

the Air Force.

Chapter 1—INTRODUCTION 5

1.1. Overview .......................................................................................... 5

1.2. Asphalt Batch Plant Layout .............................................................. 5

Figure 1.1. Typical Asphalt Batch Plant Layout .................................................. 5

1.3. Resources .......................................................................................... 6

Table 1.1. RADR Asphalt Batch Plant UTCs ...................................................... 7

Table 1.2. Asphalt Batch Team Required Resources ........................................... 7

1.4. Asphalt Recycler .............................................................................. 8

Figure 1.2. Asphalt Recycler External Profile View ............................................ 8

Figure 1.3. Asphalt Recycler Internal Profile View ............................................. 9

Figure 1.4. Asphalt Recycler Burner (Rear Hatch) .............................................. 9

1.5. Remote Operation ............................................................................. 9

Figure 1.5. Hydraulic Control Umbilical ........................................................... 10

1.6. Training .......................................................................................... 10

Chapter 2—ASPHALT MIX DESIGN AND STORAGE TECHNIQUES 11

2.1. Overview ........................................................................................ 11

AFTTP 3-32.19 24 SEPTEMBER 2018 3

Table 2.1. Batch/Mix Design Specifications ...................................................... 11

2.2. Creating Asphalt Cookies ............................................................... 11

2.3. Recommended Cookie Storage Technique ..................................... 12

Figure 2.1. Creating Windrows .......................................................................... 12

2.4. Alternate Storage Technique .......................................................... 13

2.5. Reclaimed Asphalt Pavement (RAP) .............................................. 13

2.6. Maximum Raw Material Stockpile Storage Time .......................... 13

Chapter 3—ASPHALT PRODUCTION PROCESS 14

3.1. Batch Start Times ........................................................................... 14

Table 3.1. Asphalt Production and Consumption Rates ..................................... 14

3.2. Tracking Production, Hold Times, and Deliveries ......................... 14

3.3. Overview of Recycler Operation .................................................... 15

3.4. Recycler Operating Tips ................................................................. 15

3.5. Smoke Emission Indicators ............................................................ 17

3.6. Safety .............................................................................................. 17

3.7. Setup Location ................................................................................ 18

3.8. Recycler Setup Procedures ............................................................. 18

Figure 3.1. Four Corner Jacking System ............................................................ 19

3.9. Pre-Operational Checks .................................................................. 19

3.10. Start Up Process ........................................................................... 19

Figure 3.2. Infrared Control Head ...................................................................... 20

3.11. Warmup Process ........................................................................... 21

Figure 3.3. Loading Asphalt Recycler ............................................................... 22

3.12. HMA Production .......................................................................... 23

3.13. Work Interruption ......................................................................... 24

3.14. Shut Down .................................................................................... 25

3.15. Batching Complete ....................................................................... 25

4 AFTTP 3-32.19 24 SEPTEMBER 2018

Chapter 4—RECYCLER CLEANING 26

4.1. During Production Run ................................................................... 26

4.2. End of Production Run ................................................................... 26

Chapter 5—ASPAHLT RECYCLER MAINTENANCE

REQUIREMENTS 28

5.1. Daily ............................................................................................... 28

5.2. Monthly .......................................................................................... 28

5.3. Annually ......................................................................................... 28

5.4. Engine Service and Burner Fuel Filters .......................................... 29

5.5. Hydraulic System Oil and Filter ..................................................... 29

5.6. Burner Malfunction and Troubleshooting ...................................... 29

Chapter 6—RECONSTITUTION AND RETURN TO NORMAL

OPERATIONS 30

6.1. Overview ........................................................................................ 30

6.2. Reconstitution ................................................................................. 30

Attachment 1—GLOASSARY OF REFERENCES AND SUPPORTING

INFORMATION 31

AFTTP 3-32.19 24 SEPTEMBER 2018 5

Chapter 1

INTRODUCTION

1.1. Overview. The Rapid Airfield Damage Repair (RADR) mobile asphalt

recyclers are used to batch hot-mixed asphalt (HMA) from virgin asphalt blocks

(referred to as cookies in this publication), reclaimed asphalt pavement (RAP),

and/or pelletized asphalt for crater repairs with an asphalt cap. Asphalt batching

is accomplished when airfield repairs require asphalt caps, typically when making

repairs to asphalt pavement. One batch plant supports up to two crater repair

teams.

1.2. Asphalt Batch Plant Layout. Batch plants should be located within a seven

minute commute to the airfield. The asphalt batch plant requires space with a

stabilized surface for storing asphalt products (i.e. asphalt cookie stockpiles, RAP,

HMA stockpiles), operational space for two recyclers, and space to load RADR

warehouse dump trucks. Figure 1.1 provides an example batch plant layout.

Figure 1.1. Typical Asphalt Batch Plant Layout.

6 AFTTP 3-32.19 24 SEPTEMBER 2018

1.2.1. Batching may be setup indoors (e.g., inside a hangar) during inclement

weather conditions, but proper ventilation and sufficient clearance to overhead

structures must be provided when batching indoors. Batch plants may also be

collocated with a RADR warehouse (see AFTTP 3-32.18, RADR Warehouse

Operations).

1.2.2. Position recyclers on stable ground and that is as level as possible. Use a

mat under jack feet when setup on soft ground.

1.2.3. Clear area of flammable materials and ensure area is clear of overhead

structures and utilities. In addition, position recyclers clear of air handling systems

of nearby structures.

1.2.4. Locate recyclers in close proximity to one another so that one operator may

operate both recyclers simultaneously, and to provide one general area for

collecting the HMA for loading dump trucks or stockpiling (Figure 1.1). One

front end loader (FEL) and operator is dedicated to load the hopper (also known

as the charging box/tray, but will be referred to as the hopper from this point on)

on both recyclers and to load the produced HMA in dump trucks, or create HMA

stockpiles when dump trucks are full or delivering asphalt to the airfield.

1.2.5. In many instances, the 4-yard buckets delivered with the RADR FELs are

too large to fit under the recycler discharge chute, even when the jacks are fully

raised (this issue is being addressed in future purchases). It is recommended an

inventory be conducted on FEL buckets on the installation to determine if there is

smaller 4-yard bucket that fits under the recycler discharge chute, or if there is a

2-yard bucket, and designate that bucket for Asphalt Batch Plant operations. If a

smaller bucket is not found, choose from one of the following options as a

solution:

• Dig a pit beneath the discharge chute; however, this option is not suitable

for batching indoors during inclement weather)

• Park recyclers on an elevated platform, such as 2” x 8” lumber

• Use a back-hoe to drag the HMA from underneath the discharge chute

1.3. Resources. Table 1.1 lists Asphalt Batch Plant Unit Type Codes (UTCs).

Table 1.2 identifies manning requirements and their duties and responsibilities.

AFTTP 3-32.19 24 SEPTEMBER 2018 7

Table 1.1. RADR Asphalt Batch Plant UTCs.

Capabilities

Small

Medium

Large

Very Lg

4FWAE – RADR Asphalt Batch Plant Operations

Asphalt Recycler Set (2 per set) 1 2 3 4

Front End Loader

4FWAB – WRM RADR Asphalt Crater Repair Material

Flowable-Fill (Super Sacks)

252

420

588

*Asphalt (Tons)

120

200

280

*At the time of publishing it was not determined if asphalt will be included in

4FWAB or if the user will have to source material locally.

Note: Flowable fill will be postured at the applicable warehouse. Asphalt will be

stockpiled at the asphalt batch plant.

Table 1.2. Asphalt Batch Team Required Resources.

Position

Suitable AFSCs

Veh/Equip/Tools

Lead/Operator

Primary: 3E2X1

Subs: 3E3X1, 3E4X3, 3E5X1,

3E6X1

Loader

Operator

Primary: 3E0X2,

Subs: 3E0X1, 3E1X1, 3E2X1

Asphalt Recyclers

Helper

Any

Shovel, Rake, etc.

Note: Hand tools, infrared thermometers, and release agent and sprayers can be

found in the RADR Tool Trailers (UTC 4FWCR).

Note: A light cart from the 4FWCR UTC is earmarked for the asphalt batch plant

for nighttime operations.

1.3.1. Logistics Chief. A primary responsibility of the Logistics Chief is to ensure

batch teams are completing their assigned tasks as efficiently as possible and to

help remove obstacles that negatively impact their operations. The Logistics Chief

also stays informed on batch plant operations to include RAP stockpiles, batch

start times, total HMA produced, HMA maximum hold times, and delivery

schedules.

1.3.2. Batch Plant Team Lead. The Batch Plant Lead operates the recyclers and

manages the production of asphalt for applicable repairs. He/she ensures produced

asphalt is loaded in warehouse dump trucks to be delivered to the airfield at

8 AFTTP 3-32.19 24 SEPTEMBER 2018

appropriate times as directed by the Warehouse 1 Lead. Each plant supports up to

two repair teams and receives directions from the Warehouse 1 Lead on when to

begin and stop production. Raw asphalt material (e.g., cookies or rap) inventory,

production, hold times, and deliveries are reported to the Logistics Chief so

actions may be initiated to share material with other batch plants as needed, and

acquire, or produce additional materiel if shortages are expected.

1.3.3. Warehouse 1 Team Lead. When supporting asphalt repairs, the

Warehouse 1 Lead manages all aspects of asphalt production and delivery. He/she

determines the number of plants required to meet the required tonnage, when to

start production to ensure asphalt is ready for placement, but not stockpiled long

enough to cool below 270°F before placement, and when to begin plant shutdown.

He/she also manages the delivery schedules from the batch plants to appropriate

repair zones.

1.4. Asphalt Recycler. The asphalt recycler in the 4FWAB UTC is a tandem axle

trailer weighing 11,000 pounds and can be towed by any 1.5-ton vehicle. When

transporting, adjust the drawbar so the recycler is in a horizontal positon and the

permitted supporting load will not be exceeded. The recycler’s intended use is

recycling cold asphalt mix (fines, milling asphalt) and broken slabs up to 11.8

inches by 15.75 inches by 4 inches.

1.4.1. The hopper on top of the recycler is loaded with a FEL; the hopper tilts and

dumps material into the tumbler chute as needed. Do not fill more than 4,400 lbs

into the recycler tumbler, which corresponds to 1,015 psi (70 bar) on the hydraulic

oil pressure gauge. The unit uses a rotating drum with internal baffles to tumble

the asphalt through a bath of hot air. Figure 1.2 shows an external profile view of

the asphalt recycler and Figure 1.3 portrays the internal profile view.

Figure 1.2. Asphalt Recycler External Profile View.

AFTTP 3-32.19 24 SEPTEMBER 2018 9

Figure 1.3. Asphalt Recycler Internal Profile View.

1.4.2. The hot air is produced by a diesel fired, twin stage burner at the rear of the

drum (Figure 1.4). The burner introduces hot air into the drum through a coned

opening in the end of the drum; this prevents direct contact of the flame with the

material being heated. The burner is equipped with four settings: off, fan only,

low heat, and high heat.

Figure 1.4. Asphalt Recycler Burner (Rear Hatch).

1.5. Remote Operation. A 25-foot hydraulic control umbilical (Figure 1.5),

which can be connected to either side of the recycler, provides an efficient means

to operate both recyclers simultaneously. Umbilical functions include:

• Drum forward and reverse with detent in forward position

• Hopper up and down with detent in lower position

10 AFTTP 3-32.19 24 SEPTEMBER 2018

• Drum high speed; engage and disengage

Note. Never reverse drum or open door while in high speed

• Open Door—Operate drum reverse direction - hold door switch in open

position. When drum stalls, release door switch. Engage drum in forward

position (detented).

• Close Door—Operate drum in normal forward direction (detented).

Move door switch to closed position. When drum stalls, release door

switch. Reverse Drum one (1) rotation and then back to forward or

detented position.

Figure 1.5. Hydraulic Control Umbilical.

1.6. Training. Pavements and Construction Equipment (3E2X1) and Electrical

Power Production (3E0X2) personnel receive asphalt recycler training at home

station via computer based training on the Civil Engineer Virtual Learning Center,

and hands-on training during Silver Flag training.

AFTTP 3-32.19 24 SEPTEMBER 2018 11

Chapter 2

ASPHALT MIX DESIGN AND STORAGE TECHNIQUES

2.1. Overview. The recommended mix design in UFC 3-250-03, Standard

Practice Manual for Flexible Pavements, is for a gradation 2 (12.5 mm or 0.5

inch) nominal HMA Pavement (see AFH 32-1034, Materials Testing, for

gradation testing instructions). If the recommended mix design is not available,

experiments have shown that a locally procured HMA SP-12.5 provides adequate

performance. Table 2.1 shows the UFC 3-250-03 specified gradation range and

the gradation range provided by a commercial asphalt provider.

Table 2.1. Batch/Mix Design Specifications.

Specifications

Actual Mix Design from

Local Procured HMA

Sieve Size

UFC Control

Points

(% Passing)

HMA Fine SP-12.5

(% Passing)

Inch

3/4

19.0

100

1/2

12.5

76 – 96

3/8

9.5

69 – 89

No. 4

4.75

53 – 73

No. 8

2.36

38 – 60

No. 16

1.18

26 – 48

No. 30

0.60

18 – 38

No. 50

0.30

11 – 27

No. 100

0.15

6 – 18

No. 200

0.075

3 – 6

4.8

Note: Italicized number represent values outside UFC criteria.

2.2. Creating Asphalt Cookies. Asphalt cookies are non-compacted chunks of

HMA and virgin asphalt mix components. Cookies should be created before

hostilities are imminent. The following vehicles and equipment are recommended

for constructing HMA cookies:

• FEL with bucket

• Hand tools: shovel (x2), scale/measuring tape

• Compact track loader (CTL) with sweeper attachment (optional)

12 AFTTP 3-32.19 24 SEPTEMBER 2018

2.2.1. Step 1. Designate and prepare a paved surface area by clearing any debris

or objects. Use the CTL sweeper attachment to sweep the surface (optional).

2.2.2. Step 2. Stockpile HMA material near the designated windrow area.

2.2.3. Step 3. Use the FEL to pick up approximately 0.5 ton of stockpiled material

and dump material at one end of the designated area for windrows.

2.2.4. Step 4. Place the bucket just over the dumped HMA with the bucket tilted

down so the underside is almost vertical. Using a tape or scale, set the cutting edge

of the bucket approximately 2.5 inches from the paved surface.

Note: Available footprint may determine the windrow height. The thinner the

windrow, the better the material breaks into manageable size chunks when

scraping up the windrow with the loader bucket.

2.2.5. Step 5. Move FEL backwards to drag, strike off, and spread the HMA and

create the windrow. Use shovels to keep HMA behind the bucket as necessary.

2.2.6. Step 6. Repeat steps 3 thru 5 until all stockpiled material is spread into

windrows.

2.2.7. Step 7. Let windrow material cool to ambient temperature.

2.3. Recommended Cookie Storage Technique. The preferred method of

storage is to keep the HMA material placed in windrows until it is needed for use

(Figure 2.1). When ready to begin producing HMA scrape/push windrow

material to the center of the windrow. As the material is being pushed, the material

breaks into cookies. Use the FEL bucket edge to break up any HMA cookie with

a length or width dimension larger than 15 inches. The HMA cookies can then be

stockpiled at the HMA batch plant. This storage method requires a significantly

larger area for storage than stockpiling the same amount of material.

Figure 2.1. Creating Windrows.

AFTTP 3-32.19 24 SEPTEMBER 2018 13

Note: There is an inversely proportional relationship between the cookie size and

production rate of the asphalt recycler. The optimum cookie size for the recycler

is 2.5 inches thick and no larger than 15 inches wide by 15 inches long.

2.4. Alternate Storage Technique. If space is an issue, store cooled cookies in

20-ton stockpiles. The two major problems associated with stockpiling are

consolidation and moisture retention.

2.4.1. Experience has shown that large, conical stockpiles have a tendency to form

an 8 to 10 inch crust over the stockpile. This crust can be easily broken by a front

end loader. Also, the crust tends to shed water and prevent the rest of the pile from

consolidating.

2.4.2. The stockpile should be built on a solid surface to prevent contamination or

compaction of the underlying surface. The finer particles in the processed cookies

tend to absorb and retain moisture, which increases the moisture content of the

material. Cookies or the production rate has to be sacrificed if there is an increase

in moisture content. An increase in moisture content by even 0.5 percent will

seriously hinder HMA production capabilities. Hence, proper drainage of the

stockpile should be provided. Tall conical stockpiles provide better drainage

compared to low, flat stockpiles. Depending on the annual moisture level in the

region, use of protective coverings such as tarps or structures should be

considered.

2.4.3. Check stockpiles for consolidation weekly and when consolidation

becomes obvious, turn and re-pile (consolidation time varies depending on

stockpile size and environmental factors).

2.5. Reclaimed Asphalt Pavement (RAP). The quality of RAP cannot be

guaranteed without material testing as described in AFH 32-1034. Possible use of

a rejuvenator or additional asphalt may be required when using RAP. If a need

arises to use existing paved asphalt surfaces to make RAP supplies, use

conventional practices and equipment for removing and breaking the asphalt

paved surfaces.

2.6. Maximum Raw Material Stockpile Storage Time. Research to determine

the effects of weathering and oxidation on asphalt stockpiles is currently being

conducted. Findings will be included in this publication as they become available.

14 AFTTP 3-32.19 24 SEPTEMBER 2018

Chapter 3

ASPHALT PRODUCTION PROCESS

3.1. Batch Start Times. Begin the recycler warmup process when released from

the shelter area after the attack (see paragraph 3.11) so the recyclers are ready to

produce quality asphalt when needed. Warehouse 1 Lead manages the asphalt

production and delivery processes. For asphalt capped repairs, the Crater Repair

Team Lead informs the Warehouse 1 Lead when pavement breaking is about to

commence. At this time, Warehouse 1 Lead requests the Batch Plant to begin

batching operations in order to have HMA delivered to the airfield when the

capping crew is ready to begin capping repairs. Table 3.1 provides data used to

help manage the asphalt production process.

Table 3.1. Asphalt Production and Consumption Rates.

Batch Plant

Hourly Prod

Rate*

(tons)

Team

Hourly

Consump

tion

ates**

(tons)

Surplus / Deficit

(tons/hr.)

Recommended

Prod

uction Start

Time

Min. Prod

uction

Time

(hrs.)

1 14 1 9 + 5

2.5 hrs. after release

(1 hr. before need)

2.57

1 14 2 18 - 4

1.5 hrs. after release

(2 hr. before need)

5.15

2 28 3 27 + 1

2 hrs. after release

(1.5 hrs. before need)

3.85

3 42 5 45 - 3

1.5 hrs. after release

(2 hr. before need)

4.28

4 56 7 63 - 7

0.5 hr. after release

(3 hr. before need)

4.5

*One batch plant using two asphalt recyclers, each one capable of

producing 7 tons per hour of asphalt.

**Assumes 8.5’ x 8.5’ x 4” cap @ 150 lbs/ft

mat density.

3.2. Tracking Production, Hold Times, and Deliveries. The Batch Team Lead

keeps Warehouse 1 Lead informed of asphalt production, stockpile size and hold

times. Dump truck operators inform the Warehouse 1 Lead of dump truck load

and hold times, and start and finish of asphalt deliveries.

AFTTP 3-32.19 24 SEPTEMBER 2018 15

3.2.1. Maximum stockpile hold times vary, depending on environmental

conditions and whether the batch plant is located indoors or outdoors. A rule of

thumb is maximum stockpile hold times consistently being added to in temperate

and dry weather conditions is three hours. There is no rule of thumb for cold

weather conditions; stockpiles must be constantly monitored in cold weather to

ensure the stockpiles are used before cooling below useable temperatures. Projects

are scheduled to determine more definitive stockpile hold times and will be added

to this publication when projects are complete.

3.2.2. Cover the HMA stockpile with tarps, from the inclement weather kit in the

4FWCR UTC, when temperatures are below 70°F or when crater repair delays

occur to help prevent the HMA from cooling too quickly.

3.3. Overview of Recycler Operation. The described operating procedures

herein maximize HMA production rate and meet specific discharge temperatures

(340° F is the typical target) while operating the recycler in continuous mode

using HMA cookies. The operator attempts to maintain a constant 1,015 PSI (70

bar) drum pressure during warm-up (paragraph 3.11) and continuous operation

by monitoring the drum pressure read-out and adding material in the charging box

as necessary. The unit should be operated on high heat for the majority of the

warm-up period (approximately 10 minute warm-up). After the warm-up period,

the operator adjusts the heat as necessary to meet the target discharge temperature.

When the discharge temperature becomes relatively constant, the operator

typically switches to low heat for the majority of the continuous production run.

3.3.1. If material discharge temperatures drop below specified temperature ranges,

the operator switches to high heat for a short period (approximately 1-2 minutes)

to increase the drum temperature and then switches back to low heat to continue

production. The operator may need to cycle in and out of high heat more

frequently if the RAP material has high moisture content or if the operator

overloads the drum (more than 1,015 PSI [70 bar]) inadvertently or in an effort to

increase the production rate.

3.3.2. Circumstances may dictate a higher target discharge temperature (i.e. 350-

370°F). Two operating adjustments can be made to increase the discharge

temperature. First, the operator can cycle in and out of high heat more often.

Second, the operator can under-fill the drum (below 1,015 PSI [70 bar]) to

increase heat transfer from the drum to the material inside the drum. A

combination of these two options may be required.

3.4. Recycler Operating Tips.

16 AFTTP 3-32.19 24 SEPTEMBER 2018

3.4.1. Do:

• Make sure machine is properly leveled and weight is on all jacks.

• Maintain consistent load in machine to reduce smoke and overheating.

• Make sure door on drum is at the bottom position and opened when

machine is idle to drain water.

• Keep rollers and chain well lubricated they are exposed to high

temperatures.

• Keep drum drive chain in proper adjustment, chain and teeth will last

longer.

• Keep roller path clean, rollers will last longer.

• Minimize loading of oversize chunks and rocks—the drum paddles and

shell will last longer.

• Keep drum rotating and blower on during cool down at end of

production.

• Keep door actuator paddles clean to avoid excessive drum door ramp

wear and paddle damage.

• Keep engine RPM and generator belt tension properly adjusted to

maintain correct voltage for burner system.

• Keep burner properly adjusted.

• Bleed fuel system after changing filters.

• Keep machine clean, material buildup will cause rapid wear to

components.

• Turn drum while burner is firing.

3.4.2. Do Not:

• Run machine on extremely soft surfaces without pads under jacks as the

machine can settle unevenly and cause misalignment and uneven loads

on drum.

• Surge load machine.

• Run burner without drum rotating.

• Run burner without material in the drum except for initial warm-up.

AFTTP 3-32.19 24 SEPTEMBER 2018 17

• Leave material in drum at end of production, it will all fall to bottom of

drum and cause excessive unbalance in drum on startup causing possible

drive damage.

• Attempt to run burner without engine at full RPM, electrical component

damage may result due to low voltage.

• Weld on machine without unplugging generator and disconnecting

battery.

• Hit override button repeatedly (more than 3 consecutive times as it could

damage fire control relay) locate the problem and correct.

• Drop material from excessive height into charging box.

3.5. Smoke Emission Indicators. Smoke from the recycler indicates some

operating conditions.

3.5.1. White smoke coming out of the inlet, but dissipates within 50 feet: caused

by water and is not an issue.

3.5.2. White/blue smoke out of inlet, but does not dissipate within 50 feet:

Finishing area of drum is well above 350°F and is flashing A/C off material. This

will be more defined if in Low Fire or Burner Off/Blower On. Adjust feed/

discharge rate of machine to control. Use shutdown steps to control. White smoke

off material at discharge indicates material is overheated, should only see slight

blue haze coming off material at discharge. Target 300-325°F. Also, can be result

of overfilling machine and pushing material up into burner funnel bringing

material in contact with flame.

3.5.3. Black smoke at burner start and during operation indicates low air volume

on burner. Material buildup in fan segments cutting air volume resulting in wrong

air/fuel mixture. Clean blower fan.

3.5.4. Brown/black smoke. There is a fire in the drum. Cut burner, add material

to cool drum. Leave door closed five minutes then start discharging and resume

operation.

3.5.5. Slight blue haze out inlet and off of material. Optimal!

3.6. Safety. Before putting the recycler into operation, familiarize yourself fully

with all parts and functions of the machine and the manufacturer’s operating

instructions/safety precautions (provided with the recyclers).

18 AFTTP 3-32.19 24 SEPTEMBER 2018

3.7. Setup Location. The asphalt batch plant area should be setup in an area that

meets the following criteria.

3.7.1. Set recyclers up on stable ground as level as possible.

3.7.2. Leave ample space around recyclers for loading and unloading.

3.7.3. Clear the area of flammable materials.

3.7.4. Locate recyclers in an area free of overhead obstructions such as structures,

overhangs, power lines, and trees.

3.7.5. Avoid operating recyclers in areas where exhaust gases could enter air

handling systems for adjacent facilities.

3.7.6. Do not operate recyclers in enclosed structures without adequate overhead

clearance, proper exhaust handling system and sufficient make up air to handle

exhaust and requirements of engine and burner.

3.7.7. Stockpile HMA cookies (feed stockpile) near the asphalt recyclers so that

the FEL operator can easily access the feed stockpile but not be hindered when

retrieving HMA from both recycler discharge areas. Spacing/dimensions in

Figure 1.1 are examples and may not be the same for all locations. It is the FEL

operator’s discretion how much space is necessary between the stockpiles and the

asphalt recycler equipment.

3.8. Recycler Setup Procedures.

3.8.1. After positioning recycler, set parking brake and chock wheels before

disconnecting from tow vehicle.

Note. If setting up on very soft (i.e. loose dirt) surface, place mats under supports

to help keep the recyclers from sinking and becoming out of level on soft ground.

Setting recyclers on asphalt surfaces works the best.

3.8.2. Unlock manual locks and lower drop legs and pins (Figure 3.1).

3.8.3. Operate jack control (Figure 3.1) to raise the recycler to operating height.

Do NOT operate jack actuators with manual locks engaged. Adjust all four

corners to level the unit.

3.8.4. Tighten manual locks.

3.8.5. Spray down the throat, backstop, and discharge gate mechanism with

release agent.

AFTTP 3-32.19 24 SEPTEMBER 2018 19

Figure 3.1. Four Corner Jacking System.

3.9. Pre-Operational Checks.

3.9.1. Inspect all engine fluid levels.

3.9.2. Check hydraulic oil level (bottom quarter of sight glass when cold).

3.9.3. Inspect engine and generator belts for condition and correct tension.

3.9.4. Inspect burner filters.

3.9.5. Lubricate rollers and drive chain.

3.10. Start Up Process.

Note. If below 32°F, use extension cord in toolbox and connect to receptacle on

front panel of machine and 120VAC power source and allow minimum of 5

minutes to warm fluids and battery.

3.10.1. Step 1. Remove hydraulic control umbilical (Figure 1.5) from toolbox to

connect to right side (R/S) or left side (L/S) of recycler as required. Set control

switch in engine compartment to correspond with side chosen for operation (right

or left). Make sure all umbilical switches are in off position.

20 AFTTP 3-32.19 24 SEPTEMBER 2018

3.10.2. Step 2. Remove infrared control head (Figure 3.2) from toolbox and

position on desired side of machine and connect wiring accordingly.

Figure 3.2. Infrared Control Head.

3.10.3. Step 3. Start engine and allow to warm and stabilize at idle (if below 60°F,

turn on 12VDC fuel heater).

3.10.4. Step 4. Turn on master switches to enable hydraulics and infrared

thermometers to monitor discharge temperature.

3.10.5. Step 5. Engage drum to aid in warming up hydraulic system.

3.10.6. Step 6. Remove ratchet and socket from toolbox for jack manual locks

and loosen all jack locks.

3.10.7. Step 7. Lower dropdown sections of elevation jacks to last pin hole. Install

support pins and safety pins.

Note. It may be required that you lower the front of machine by lowering propping

jacks to get pins in for rear drop legs. Then raise the front of machine to set front

drop legs.

3.10.8. Step 8. Bring engine to full throttle with drum drive engaged.

3.10.9. Step 9. Open jack control box and use the ALL JACKS LOWER switch

to extend all jacks at the same time. Raise machine to end of jack stroke. The amp

gauge will jump up when the first jack reaches the end. The breaker for that jack

will pop if switch is maintained...if breaker pops, reset.

3.10.10. Step 10. Use individual switches (Figure 3.1) to level machine by

referencing the dual axis level to the lower right of jack control box.

3.10.11. Step 11. When machine level has been achieved, tighten all elevation

jack manual locks with ratchet and socket provided.

AFTTP 3-32.19 24 SEPTEMBER 2018 21

3.10.12. Step 12. Lower manual backstops for backboard down to 4th hole and

secure.

3.10.13. Step 13. With aid of the mini-chain fall in the toolbox, first raise the

backboard to remove transport chains. Connect hooks to loop on back of board to

stow them. Using chain fall, lower the backboard to ground and unfold extensions.

3.10.14. Step 14. Lower and pin ladder assembly.

3.10.15. Step 15. Open burner control panel and move step switch to Position #1.

Confirm fuel suction and pressure values are correct.

3.10.16. Step 16. Confirm display is correct. Clean drum temperature sensor

window if required.

Note. Drum temperature display will start to read low as the window gets dirty.

Clean with a soft rag, wetted with some fuel oil.

3.10.17. Step 17. Operate umbilical to verify all functions:

• Drum forward and reverse with detent in forward position

• Hopper up and down with detent in lower position

• Drum high speed; engage and disengage

Note. Never reverse drum or open door while in high speed

• Open door and operate drum reverse direction - hold door switch in open

position. When drum stalls, release door switch. Engage drum in forward

position (detented).

• Close Door and operate drum in normal forward direction (detented).

Move door switch to closed position. When drum stalls, release door

switch. Reverse Drum one (1) rotation and then back to forward or

detented position.

3.10.18. You are now ready for operation. Ensure a sufficient quantity of material

is on-hand for desired production before lighting burner.

3.11. Warmup Process. The warmup process is a multi-step process to run

asphalt cookies or RAP through the asphalt recycler to produce HMA at the

correct temperature.

3.11.1. Step 1. Move burner control switch to Position #2. Burner should light at

8-second mark. Run burner in Position 2 (low fire) approximately two (2) minutes

depending on ambient temperature (up to five (5) minutes in extreme cold).

22 AFTTP 3-32.19 24 SEPTEMBER 2018

3.11.2. Step 2. Fill hopper (Figure 3.3) and load drum with light load

(approximately 725 psi [50 bar]). Leave in “Low Fire” for five (5) minutes.

Figure 3.3. Loading Asphalt Recycler.

3.11.3. Step 3. Move burner control to Position #3. Continue with door closed

(approximately three minutes).

3.11.4. Step 4. Open door. The first couple of drops may not be turned yet.

Monitor temperature. If not above 250°F by fifth (5th) drop, close door and move

burner switch back to Position #2. Wait approximately three (3) minutes. Then

open door and check temperature of the discharge material. It should be

approaching 300°F at this time. Leave the door open and return step switch to

Position #3 (High Fire). Maintain drum load at about 725 psi (50 bar) by using

small dumps out of the hopper. As the drum gains temperature, you will need to

increase drum load to a maximum of 1015 psi (70 bar) to control discharge

temperature. Do not exceed 1015 psi (70 bar) at any time. If unable to control

discharge temperature at 1015 psi (70 bar), switch back to low fire.

3.11.5. If the HMA discharge temperature is within or above the specified

temperature range, continue discharging HMA. Lowering the burner setting

and/or loading more material into the drum will reduce the temperature of the

material in the drum which in turn lowers the discharged HMA temperature.

3.11.6. If the HMA discharge temperature is below the specified temperature

range, close the discharge gate and continue to heat and mix the material.

3.11.7. It is common for material discharge temperatures to rise or fall a few

degrees before normalizing and leveling out. If the initial discharged material

AFTTP 3-32.19 24 SEPTEMBER 2018 23

temperature is slightly below the specified range, discharge HMA for 30 seconds

to allow the temperature to rise into the acceptable range. If temperature does not

rise into the acceptable range, close the discharge gate.

3.11.10. Step 5. Repeat Steps 3 and 4 until the HMA discharge temperature is

within the desired range. The burner switch may have to be switched between

setting 2 (burner stage 1) and 3 (burner stage 2) to maintain a discharge

temperature within the specified temperature range.

3.11.11. Step 6. Once the warm-up period is complete (material temperature has

stabilized), place asphalt produced during the warmup period back in the feed

stockpile to be rerun and used for repairs if it has not been overheated (above

380°F). Dispose the asphalt produced during the warmup period if it was

overheated.

Note: If the plant is on semi-improved surfaces, use the asphalt produced during

warmup as a bed for the stockpiled material.

3.12. HMA Production. Remove HMA material under the discharge gate as

needed and load in dump trucks or transport to storage using a front end loader

with a bucket.

Note: Early in the production process, maintain temperatures in the higher part of

the desired range (350 - 380°F) to help ensure proper stockpile temperatures. As

asphalt production nears 50 percent of the required production, gradually bring

the temperature down to the lower part of the range (290 - 310°F) to decrease time

required to cool repairs.

3.12.1. During asphalt production, the operator should ensure the pressure ratings

are maintained between 900-1,000 pounds per square inch (60-70 bar). If the drum

pressure drops, the temperature will begin to rise in the drum affecting quality of

the asphalt. If the drum pressure is too high, temperature will begin to drop

lowering its effect on the consistency of the asphalt.

3.12.2. Maintain a consistent drum pressure by monitoring the intake and

production of material. Making the drum lighter or heavier as needed to maintain

a consistent temperature.

3.12.3. During batching operation the asphalt recycler can become jammed or

clogged with debris. The recycler operator removes any debris or asphalt clumps

within the recycler to ensure the proper operation. Perform the following actions

to help prevent buildups, clogs, and jams:

24 AFTTP 3-32.19 24 SEPTEMBER 2018

• Check throat area periodically for obstructions. Blockage in this area

causes rapid overheating of material in the drum due to reduced airflow.

• In extreme cases, a pry bar may be used to remove buildup of asphalt

lumps at the charging box/tumbler chute entrance.

• For large chunks, reverse drum direction for approximately one minute

and pull chunk materials back into production area of the drum to reheat.

• Between production runs, check for any buildup of materials at the

charging box/tumbler chute entrance.

Note: Stockpiles should be covered with tarps and a berm constructed around the

stockpiles during inclement weather. Tarps and berm material are included in the

Inclement Weather Kit from UTC 4F9CR.

Note: Tests in temperate and dry weather suggests 10 tons of asphalt can be held

in a 10-ton dump truck no longer than 3 hours. Asphalt may cool below minimum

placement temperature of 270°F if held beyond 3 hours.

3.12.4. When enough HMA has been produced, cease loading the hopper, but

continue dumping hopper contents into the drum until empty. Do not over load

the drum (exceed 1,015 PSI [70 bar]). Raise the loading tray fully and continue

producing asphalt.

3.12.5. Monitor the drum temperature and reduce the burner stage accordingly as

material moves through the drum and out the discharge gate.

3.13. Work Interruption. Perform the following actions if there is an interruption

in the HMA production process.

3.13.1. If the work is to be interrupted for up to thirty minutes, discharge the

tumbler to one third or half of its contents, close the discharge gate, keep the

tumbler turning and switch burner to position "0".

3.13.2. If the work is to be interrupted for more than 30 minutes, discharge the

tumbler completely and switch off burner and engine.

3.13.3. At continuous operation keep the contents of the tumbler at a level

corresponding to 1,015 PSI (70 bar) on the hydraulic oil pressure gauge, keep

burner operation at maximum rate and discharge the reprocessed asphalt

continuously.

AFTTP 3-32.19 24 SEPTEMBER 2018 25

3.13.4. Fill asphalt lumps into the recycler until the reading of the hydraulic oil

pressure gauge is 1,015 PSI (70 bar) and 870 PSI (60 bar) when using asphalt

fines (material passing through a #4 sieve [4.75-mm]).

3.14. Shut Down.

3.14.1. Step 1. Perform an end-of-production run to clean the recycler and to

ensure it is ready for its next mission (see paragraph 4.2).

3.14.2. Step 2. Unlock all manual locks on elevation jacks. Lower front of unit to

free up backboard. Clean and raise backboard and secure. Raise all elevation jacks

completely and secure all manual locks.

3.14.3. Step 3. Idle engine down and shut off all control switches. Allow engine

to cool two (2) minutes and shut down.

3.14.4. Step 4. Stow all gear.

3.15. Batching Complete. Batch Plant Team Lead informs the Logistics Chief

when personnel have finished their tasks and are idle so they may be loaned to

other teams as necessary.

26 AFTTP 3-32.19 24 SEPTEMBER 2018

Chapter 4

RECYCLER CLEANING

4.1. During Production Run. Check for material buildup between production

runs at the charging box/ tumbler chute entrance. If major build-up occurs, use

crowbar and hand tools (chisel, hammer-drill, hammer, etc.) to remove material

buildup. Machine must be totally cooled and not in operation (OFF) before

removing any buildup inside these areas.

4.2. End of Production Run.

4.2.1. Step 1. Close the discharge gate and keep the contents tumbling for five

minutes at the first burner firing stage to ensure all the asphalt lumps are

thoroughly heated.

4.2.2. Step 2. Fully open discharge gate to discharge material in the tumbler.

4.2.3. Step 3. Switch the burner to stage 1 (burner fan still blowing, no heat).

4.2.4. Step 4. With the aid of the leveling jacks, lower the discharge end of the

recycler to ensure complete discharge of the contents.

4.2.5. Step 5. Fully open the discharge gate (manually) to remove any bigger

chunks of material trapped in the tumbler.

4.2.6. Step 6. While the engine is still running and the burner fan blowing, spray

the gate, gate tracks, and drum channel with asphalt release agent to ensure all

asphalt has been removed.

4.2.7. Step 7. Leave the engine running and the burner fan blowing (burner switch

in stage 1) until the tumbler has cooled below 120°F (50°C).

4.2.8. Step 8. Close the discharge gate.

4.2.9. Step 9. Stop the tumbler drive with the discharge gate at the bottom of the

drum open.

4.2.10. Step 10. Turn the burner switch to stage 0 (everything off) and turn off the

recycler engine.

4.2.11. Step 11. Clean caked or stray asphalt off the recycler.

4.2.12. Step 12. Clean up the area surrounding the recycler.

AFTTP 3-32.19 24 SEPTEMBER 2018 27

4.2.13. Step 13. Wash down the throat area, discharge gate, and backstop with

release agent.

28 AFTTP 3-32.19 24 SEPTEMBER 2018

Chapter 5

Asphalt Recycler Maintenance Requirements

5.1. Daily:

• Check engine oil, water, and air filter restriction.

• Check engine and generator drive belt tension.

• Check hydraulic oil level.

• Check fuel filters.

• Check and lubricate all rollers and drive chain. (10 shots rollers, keep

chain wet).

• Check that all burner components are secure.

• Check burner for fuel leaks.

5.2. Monthly:

• All items on Daily list.

• Clean roller paths and roller pockets.

• Check drum drive chain tension and adjust if necessary.

Note. Adjusting chain tension should be accomplished by an experienced

operator. Improper tension will cause damage to drum chain, drum drive

components, and/or drum teeth.

• Clean burner primary fuel screen and inspect secondary filters.

• Check drum end clearance and adjust if required.

• Lubricate charging box cylinder pins.

• Clean all tank breathers.

• If stationary, rotate wheels to keep from damaging bearings.

5.3. Annually:

• All items on Daily and Monthly list.

• Change hydraulic oil and filter.

• Inspect drive chain, drum teeth, drive sprocket and idler.

• Inspect all carry, side and thrust rollers.

• Inspect drum inlet area and drum for wear.

• Inspect drum door and actuators for wear and buildup as required.

AFTTP 3-32.19 24 SEPTEMBER 2018 29

• Clean and inspect burner, replace nozzles, reset electrode gap.

• Clean valley of blower vanes, air box and damper door. As they fill with

debris air volume drops and burner falls out of adjustment. More

frequently if operated in very dusty environment.

5.4. Engine Service and Burner Fuel Filters. 250 hours normal service, 200

hours severe conditions.

5.5. Hydraulic System Oil and Filter. 1000 hours/1 Year.

5.6. Burner Malfunction and Troubleshooting. In case of a burner malfunction

do not try to re-start the burner by pushing the reset button more than three times.

Too many re-starts which fail again may cause the burner relay to become

overloaded and fail completely. It is advisable to solve the problem by systematic

study and following the trouble shooting diagram in the Operators’ Manual.

30 AFTTP 3-32.19 24 SEPTEMBER 2018

Chapter 6

RECONSTITUTION AND RETURN TO NORMAL OPERATIONS

6.1. Overview. This phase begins when directed to return to normal operations.

During this phase, begin implementing plans to reconstitute the RADR

equipment, materials, and vehicles and then resume normal operations. Supervise

an orderly return to the normal operating facilities, or movement to a temporary

or permanent facility. Maintain communication with command and control (C2)

agencies during transition and report mission manpower and capability.

6.2. Reconstitution. When directed, begin the following reconstitution actions:

• Replenish virgin asphalt/rap stockpiles.

• Perform vehicle post operational inspections and take appropriate action

for any discrepancies found.

• Clean recyclers.

• Refuel recyclers and vehicles.

• Return vehicles to their duty locations or staging areas.

JOHN B. COOPER, Lieutenant General, USAF

DCS/Logistics, Engineering & Force Protection

AFTTP 3-32.19 24 SEPTEMBER 2018 31

Attachment 1

GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION

References

AFDA 3-34, Engineer Operations, 30 Dec 2014

AFI 10-210, Prime Base Engineer Emergency Force (BEEF) Program, 21 Jan

2015

AFMAN 33-363, Management of Records, 1 Mar 2008

AFH 32-1034, Materials Testing, 3 Apr 2015

AFPAM 10-219V4, Airfield Damage Repair Operations, 28 May 2008

AFTTP 3-32.18, Rapid Airfield Damage Recovery Warehouse Operations, Apr

UFC 3-250-03, Standard Practice Manual for Flexible Pavements15 May 2001

UFC 3-270-07, O&M: Airfield Damage Repair, 12 Aug 2002

Bagela BA 10000 Asphalt Recycler Operators’ Manual, no date

AFCEC/CXA Publication, Asphalt Production Using Hot Mix Asphalt (HMA)

Cookies and an Asphalt Recycler, no date

Abbreviations and Acronyms

AFI—Air Force Instruction

AFMAN—Air Force Manual

AFRIMS—Air Force Records Information Management System

BEEF—Base Engineer Emergency Force

C2—command and control

CTL—compact track loader

FOD—foreign object debris

OIC—Officer in Charge

OPR—Office of Primary Responsibility

RADR—Rapid Airfield Damage Repair

RAP—reclaimed asphalt pavement

RDS—Records Disposition Schedule

TTP—tactics, techniques, and procedures

32 AFTTP 3-32.19 24 SEPTEMBER 2018

UFC—Unified Facilities Criteria

UTC—Unit Type Code

Terms

Airfield—An area prepared for the accommodation (including any buildings,

installations, and equipment), landing, and takeoff of aircraft.

Crater—Craters represent damage that penetrates through the pavement surface

into the underlying base and sub grade soil, which uplifts the surrounding

pavement and ejects base, sub base soils, rock, and pavement debris around the

impact area. Large craters have an apparent diameter equal to or greater than 6 m

(20 ft). Small craters have an apparent diameter less than 6 m (20 ft).

Debris—Material ejected from the crater including broken pavement and soil.

Debris is some-times usable as backfill material particularly for large crater repair,

but for small crater or spall repair it is generally not advisable.

Facility—A real property entity consisting of one or more of the following: a

building, a structure, a utility system, pavement, and underlying land.

Minimum Airfield Operating Surface (MAOS)—The combined requirement

for airfield surfaces for both runway and access routes. The MOS is part of the

MAOS.

Minimum Operating Strip (MOS)—1. A runway which meets the minimum

requirements for operating assigned and/or allocated aircraft types on a particular

airfield at maximum or combat gross weight. 2. The MOS is the smallest area to

be repaired to launch and/or recover aircraft after an attack. Selection depends

upon mission requirements, taxi access, resources available, and estimated time

to repair. For fighter aircraft, the typically accepted dimensions are 5,000 feet long

by 50 feet wide.

Mission—1. The task, together with the purpose, that clearly indicates the action

to be taken and the reason therefore. 2. In common usage, especially when applied

to lower military units, a duty assigned to an individual or unit; a task. 3. The

dispatching of one or more aircraft to accomplish one particular task. (JP 1-02)

Personnel—Those individuals required in either a military or civilian capacity to

accomplish the assigned mission.

Procedures—Standard, detailed steps that prescribe how to perform specific

tasks.

AFTTP 3-32.19 24 SEPTEMBER 2018 33

Recovery—The development, coordination, and execution of service- and site-

restoration plans for impacted communities and the reconstitution of government

operations and services through individual, private-sector, nongovernmental, and

public assistance programs that: identify needs and define resources; provide

housing and promote restoration; address long-term care and treatment of affected

persons; implement additional measures for community restoration; incorporate

mitigation measures and techniques, as feasible; evaluate the incident to identify

lessons learned; and develop initiatives to mitigate the effects of future incidents.

Runway—A defined rectangular area of an airfield, prepared for the landing and

takeoff of aircraft along its length. A runway is measured from the outer edge of

the thresholds from one end of the runway to the others. The width of the runway

is typically measured from the outer edge of the load-bearing pavement on one

side to the outer edge of the load-bearing pavement on the other side. In some

cases the runway may be measured from the outside edge of the runway marking

line on one side to the outside edge of the marking line on the other side and any

remaining load bearing pavement is considered shoulder.

Spall—Pavement damage that does not penetrate through the pavement surface

to the underlying soil layers. A spall damage area could be up to 1.5 meters (5

feet) in diameter.

Support—1. The action of a force that aids, protects, complements, or sustains

another force in accordance with a directive requiring such action. 2. A unit that

helps another unit in battle. 3. An element of a command that assists, protects, or

supplies other forces in combat. (JP 1-02)

Tactics—1. The employment of units in combat. 2. The ordered arrangement and

maneuver of units in relation to each other and/or to the enemy in order to use

their full potentialities. (JP 1-02)

Techniques—Non-prescriptive ways or methods use to perform missions,

functions, or tasks.

Threat—An indication of possible violence, harm, or danger.