Discover if a 120 TPH asphalt mixing plant can meet the demands of a 30 km toll road project with tight deadlines. Explore efficiency and performance insights.
When facing tight project deadlines, contractors often wonder if a 120 TPH (tons per hour) asphalt mixing plant is sufficient for large-scale highway construction. A 30 km toll road may seem like a long stretch, and meeting time constraints depends on more than just raw production capacity. Let’s dive into this question from both the contractor’s and project manager’s perspective to help you make an informed decision.
Before evaluating whether a 120 TPH plant is fast enough, we need to estimate the asphalt volume required. On average, a 30 km dual carriageway toll road with two 3.5-meter-wide lanes per direction, paved with 10–15 cm thick asphalt layers, requires between 100,000 to 150,000 tons of asphalt, depending on the design standard and the number of layers.
Assuming three layers (base, binder, and wearing course) and an average thickness of 12 cm, the asphalt demand can exceed 130,000 tons. That means asphalt hot mix plant productivity and daily output play a crucial role in meeting project milestones.
With a 120 TPH asphalt plant operating efficiently for 8–10 hours a day, you can expect daily output between 960 and 1,200 tons. Over a 3-month (90-day) period, excluding rain delays or breakdowns, the plant could theoretically produce over 100,000 tons.
However, this assumes optimal conditions. If the plant only operates 6 days a week or faces weather-related stoppages, total output may drop. This is why planning buffer time is essential.
Now, if your construction schedule allows for 100 days of paving, your team would need to pave about 1.3 km per day. This would require around 1,300–1,500 tons of asphalt daily. In that case, a 120 TPH plant might be cutting it close unless supplemented by:
Even if the plant's capacity seems enough on paper, real-world challenges impact productivity. These include:
If the plant is too far from the paving site, transport delays reduce efficiency. A distance over 20 km may require additional trucks or even a mobile plant setup to stay on schedule.
Downtime due to fuel shortages or poor maintenance can cause major delays. A well-maintained plant with a reliable fuel supply ensures consistent output.
Temperature control is critical. If asphalt cools during transport, it may not meet compaction requirements, forcing rework and wasting time. Choosing a plant with precise temperature control and automatic fault detection reduces risks.
If you're managing a single paving team, and the project allows moderate daily output, then a 120 TPH asphalt mixing plant can meet your needs with tight but realistic scheduling. However, for high-speed toll road construction involving multiple paving crews and long daily paving targets, a higher capacity plant (160 TPH or 200 TPH) may offer better peace of mind and on-time delivery.
That said, a 120 TPH plant offers several benefits:
If you're considering this capacity, make sure the plant offers:
Also, consider mobile or semi-mobile models if your project moves across multiple segments of the road.
A 120 TPH stationary or portable asphalt mixing plant can work for a 30 km toll road project with tight deadlines—but only if paired with smart planning, efficient logistics, and disciplined operation. It’s not just about the machine; it’s about how you use it.
At AIMIX, we provide more than just asphalt mixing plants. We offer complete support—from layout design to on-site installation and local service in Indonesia. Our 120 TPH plants are proven in toll road and urban expressway projects, with high fuel efficiency, advanced control systems, and strong technical support.
If you’re unsure whether 120 TPH is right for you, our engineers can help you evaluate your paving schedule and propose a customized solution that fits your needs and budget. 👉 Contact us today to get a tailored asphalt mixing plant solution for your toll road construction!