A good maintenance routine is the cheapest way to keep an asphalt plant producing in the season. This checklist groups the work by interval. It is a general guide based on common industry practice — always follow the intervals and torques in your plant’s own manual first.

Safety first. Before anyone works inside a drum, mixer, elevator, silo or baghouse: stop the plant, lock out and tag out the power and fuel, let hot parts cool, and check the atmosphere where required. See our safety checklist.

Daily — before start-up

Area Check
General Walk-around: loose bolts, leaks, unusual noise from the previous day noted in the log
Cold feed Bin gates free; feeder belts tracking; no oversize or contamination in bins
Conveyors Belts centered; no damaged idlers; scrapers in contact
Burner Fuel level and filters; no leaks; air damper moves freely
Drum Tyres and rollers clean; no material build-up at seals
Elevator Chain/belt tension; no buckets loose
Mixer Gates close fully; no hardened mix build-up
Baghouse Compressed air at pressure; drain water from air tanks
Bitumen Tank temperatures and levels; pump and lines heated
Control Alarms clear; scale zero readings normal

Daily — during and after production

  • Watch baghouse pressure drop and exhaust temperature — sudden changes mean trouble
  • Note burner flame, mix temperature and drum discharge temperature trends
  • After shutdown: run the mixer empty and clean gates; clear spillage under conveyors; record hours, tons and faults in the plant log

Weekly

Area Task
Lubrication Grease bearings and points listed in the lubrication chart
Drum Check tyre-roller contact and alignment; drive chain or gear
Burner Clean nozzle and electrodes if needed; check flame shape
Elevator Inspect buckets, chain wear, sprockets
Screen Check meshes for holes or blinding; springs; bearings temperature
Mixer Inspect paddle tips and liners; check paddle-to-liner clearance
Baghouse Check pulse valves fire in sequence; inspect a few bags
Scales Check zero and span with test weights if output looks wrong
Electrical Check cabinet cooling, filters and dust; tighten loose terminals

Monthly

Area Task
Drum Measure flight wear; check shell for hot spots or cracks
Mixer Measure liner and paddle wear; check shaft seals and gearbox oil
Elevator and screen Measure chain elongation; replace worn meshes
Baghouse Inspect more bags and cages; check for corrosion and air leaks in ducts
Burner Combustion check — see burner tuning
Calibration Calibrate cold feeders and scales — see calibration
Bitumen system Check pump wear, valve packings, heating elements or thermal-oil system
Safety Test emergency stops, guards and interlocks

Off-season (annual)

  • Replace worn mixer liners, paddles and arms
  • Replace worn drum flights; check tyres and trunnions; realign the drum
  • Inspect and replace filter bags as needed; service pulse valves
  • Overhaul the burner; clean fuel tanks and lines
  • Replace elevator chain and buckets if elongated or worn
  • Service gearboxes — oil change and inspection
  • Inspect structure and welds; repaint corroded areas
  • Check and clean electrical cabinets; test insulation of motors
  • Recalibrate all scales before restart

See the full off-season shutdown and restart checklist.

Detailed guides by system

System Guide
Drying drum Drying drum maintenance
Mixer Twin-shaft mixer maintenance
Elevator and screen Hot elevator and vibrating screen maintenance
Baghouse Baghouse care
Burner Burner tuning
Faults Common problems and fixes
Parts Spare parts list

Keep a plant log

Record every day: hours run, tons produced, fuel used, faults, parts replaced and who did the work. Over a season it shows which parts wear fastest at your site — the basis for your spare parts stock and your next off-season plan.

Need a maintenance plan for your plant? Ask our engineers.