3-2. Initial Start-Up
Do not operate asphalt melter without protective, insulated clothing, particularly
gloves. High operating temperature of heat transfer oil piping and asphalt melter
may cause severe burns by grabbing or leaning on equipment.
Do not operate the asphalt melter in the rain. Operation of melter during rain
may cause the asphalt to boil and catch fire. After a rain or during humid
conditions, open the tunnel doors and dry the unit before operating. Keep the
a. Inspect installation of melter unit and all piping for proper connections.
b. Refer to operating instructions of heat source plant, and start heater. Adjust heater as required to insure
delivery of heat requirements of melter.
c. Close the asphalt jacketed valve.
d. Open all three gate valves on heat transfer oil piping. Tunnel inlet and outlet gate valves should be
opened fully, with the storage tank inlet valve opened only half way.
e. Open the tunnel front doors and load six asphalt drums, open end down, on each side of the tunnel.
Loading of drums must be done quickly. Asphalt may start to come out of drums
and adhere to heat coils, preventing their being moved farther into the tunnel. If
this happens, close the doors and allow asphalt to melt completely before
proceeding to load melter.
f. When all drums are loaded, close the front doors of tunnel and allow the asphalt to melt and drain into the
3-3. Operating Instructions
b. When initial charge of drums is empty, open doors at both the front and rear of the tunnel. Load new
asphalt drums, open end down, in same manner as loading of initial load. Empty drums will be pushed out the
rear door as full drums are loaded into the front.
It is recommended that six drums be loaded into one side of tunnel at a time,
then loading the other side of the tunnel.
Do not overload the storage tank. The storage tank is designed to hold 3000
U.S. gallons. Maintain records of amount of asphalt cement de-drummed and
amount pumped from storage tank to insure that this capacity is not exceeded.
c. Continue loading the de-drumming tunnel as required to provide amount of asphalt required for job
d. Periodically monitor the thermometer (Figure 3-1) for proper operating temperature range, 235° ± 150° F.
for asphalt cement rated at 85-100 penetration. Temperature of asphalt cement in storage tank may be
lowered by adjustment of heat transfer oil gate valves to restrict flow of hot oil to coils of storage tank. Do not
restrict oil flow to tunnel during de-drumming operations, maximum heat is desired to shorten melt-down of
e. To transfer melted asphalt cement from storage tank, start supplied material pump and open asphalt
jacketed valve (Figure 3-1). Meter the flow of asphalt pumped from storage tank, so a record can be
maintained of the amount of material in the tank at all times.
f. When required amount of asphalt cement has been melted, heat in the tunnel coils is no longer required.
Push empty drums from tunnel and close the tunnel inlet gate valve (Figure 3-1). Adjust storage tank inlet gate
valve and outlet gate valve (Figure 3-1) as necessary to maintain proper temperature of asphalt cement in
3-4. Shutdown Instructions
a. All melted asphalt cement must be pumped from the storage tank. Visually check storage tank by
removing front rain shield.
b. When satisfied that all material has been pumped from storage tank, close the asphalt jacketed valve
Not all material can be removed by pumping, approximately 1-1/2 to 2 inches of
material will remain in the storage tank.
c. Disconnect all sections of asphalt flexible hose piping and drain all material.
d. Shutdown hot oil heater (Refer to heater instructions).