What Are Concrete Batching Plants?

Concrete Plants are the facilities where raw materials such as gravel, sand, water, and cement are mixed in certain proportions and ready-mix concrete is produced.

Contractors use Concrete Batching Plants to produce ready-mix concrete. These plants can be very expensive, and most of them do not come cheap. However, they are worth every penny. A concrete batching plant is a type of concrete mixing plant that mixes materials to produce concrete. The mixture produced by these plants is then transported to construction sites where it is used as a building material.

These plants are very useful in modern construction because they save a lot of time. With a concrete batching plant, you can make concrete easily. You can control the consistency of the concrete by basically varying the amount of water, cement, and aggregate added.

We manufacture our concrete batching plants from high-quality components. They are durable and efficient. However, to ensure the longevity of your product, keeping regular maintenance is important.

Manually Mixing Concrete vs.  Concrete Batching Plants

Why you should opt for a concrete batching plant installed on your construction site:

• The demand for concrete is so high that it cannot be met through manual mixing.
• With Concrete Batching Plants, you can produce more concrete with fewer workers.
• Manual Labour takes too much time and effort.
• Concrete Batching Plants are less time-consuming.

What to Know 

• Concrete is made from sand, gravel, crushed stone, coarse aggregate, and water. If it is necessary some additive may be added to the mixture to delay hardening the concrete in a short time.
• Each time you want to produce concrete, you must first calculate the percentage of each material required.
• Then mix all of those materials using our amazing mixers.

Our expert team will install the plant for you. We have been manufacturing and supplying concrete batching plants for years now. Our products are some of the best in the market. They have a long service life and provide quick results too. The quality of concrete plants is very important. If not utilized well, they can become inefficient at times. Therefore, getting a good quality concrete batching plant for your construction site becomes extremely necessary.

If you want to gather more quality information kindly visit our blog to understand the requirements of a high-quality concrete batching plant and the services needed to be provided by the seller (manufacturer).

Main Components Of The Concrete Batching Plant

• Aggregate Hoppers
• Aggregate Weighing Conveyor
• Aggregate Transfer Conveyor
• Cement, Water and Additive Weighing Hoppers
• The Concrete Mixer
• Cement Silo
• Screw Conveyor
• Air Compressor
• Control Room, System Main Software
• Valves, Pistons, and Motors work by air and are controlled by the PLC system.

These are the main components of the concrete batching plant. Now we will briefly explain the specifications of the plant and how these components work.

Aggregate Hoopers

This part of the concrete batching plant feeds the plant with different types of aggregates like fine aggregate (sand) and other bigger-sized aggregates. While feeding the plant weighing precision is one of the most important points. Uncalibrated and undetermined weighing systems lead you to disaster.

There are different designs for different capacities of aggregate hoppers. As you know the capacity is determined by the total concrete production capacity.

Aggregate Weighing Conveyor

What is the best?

For precise weighing systems, the loadcells and their communication with software should be stable and continuous to control the covers where located under these hoppers to adjust the amount of aggregates that are weighed by the loadcells and sent to the mixer by aggregate conveyor.

Quality is NOT ENOUGH for Concrete Batching Plants.

Even the high-quality materials used on your plant without calibration tests mean nothing. So that means you need a good partner to overcome the obstacles together!

Aggregate Transfer Conveyor

Due to the capacity of the concrete plant the carrying capacity changes for the aggregate transfer conveyor.

The conveyor has many important components also. The type of belt, motor (its power), reducers, and most importantly the emergency stop for safety in case of main electricity problems.

It’s not possible to describe all the details because each component includes different materials and each material has its specifications, all these are chosen and applied by our engineers for a better user experience, so if you have questions please contact us. We are here to help and enlighten you.

Cement, Water and Additive Weighing Hoppers

When necessary information is entered into the computer system, software, PLC, sensors, and other pneumatic systems communicate with each other to control valves and motors to transfer the necessary amount of cement, water, and additives into the mixer.

As mentioned before for a better user experience our engineers designed another hopper system to save time and increase the production efficiency for concrete production by putting another feeder above the mixer.

How it works ?

While the mixer batches the concrete mixture, the next portion of the concrete components (aggregate, cement, water, and additive) is prepared for the next cycle and accumulates in the hoppers for the subsequent batch.

This method provides benefits for concrete batching plants like, non-stop production (time-saving), and expressing its real capacity.

The Concrete Mixer

When we start to talk about the concrete mixer,

All mixers have their characteristics, let’s inspect them one by one.

• Pan Mixer
• Planetary Mixer
• Twin Shaft Mixer

Pan Mixer

Pan mixers are one of the most common types used in the construction industry. They consist of a circular pan in which concrete is mixed. The mixing is typically done by blades that rotate inside the pan. Pan mixers are known for their efficiency in mixing and are particularly useful for precast concrete production.

Advantages:

Uniform mixing of concrete. Suitable for small to medium-sized batches. Easy to clean and maintain.

Disadvantages:

Limited capacity compared to other types of mixers. It may require manual loading and unloading of materials.

Planetary Mixer

Planetary mixers, also known as countercurrent mixers, have a complex mixing action that ensures a thorough mix of the concrete components. The mixer consists of one or two mixing stars that rotate around their axes while they orbit around the mixer’s central axis.

Advantages:

Produces highly homogeneous mixtures. Ideal for high-performance concrete. Efficient in mixing a wide range of concrete types, including colored and fiber-reinforced concretes.

Disadvantages:

Higher initial cost. More complex maintenance compared to simpler mixers.

Twin Shaft Mixer

Twin shaft mixers are known for their high efficiency and ability to produce large volumes of concrete in a short period. They consist of two horizontal shafts with mixing paddles that rotate in opposite directions.

As you know, over time, the interior surface of the mixer gets worn. To prevent undesired situations, all the interior surfaces of the mixer are covered by hardened abrasion plates. Even though the interior surface is covered by steel plates, the abrasion plates wear out over time. Depending on the production frequency, this process may accelerate, and you may need to change these plates once every 6-7 months.

WARRANTY IS NOT AN OPTION FOR MIXERS.

Advantages:

Rapid and thorough mixing. Capable of handling large batches, making them ideal for high-volume projects. Excellent for producing consistent and high-quality concrete.

Disadvantages:

Higher power consumption. More complex design, which may lead to higher maintenance requirements.

Cement Silo

A cement silo is a storage container used for holding and dispensing cement in concrete batching plants. It is typically a cylindrical structure made of steel or concrete, designed to store large quantities of cement in a dry and controlled environment. The main functions of a cement silo include:

Storage: Keeps cement dry and protected from the elements, preventing moisture absorption which can lead to clumping and reduced quality.

Dispensing: Equipped with a discharge system, such as a screw conveyor or pneumatic system, to accurately dispense the cement into the batching process.

Capacity: Varies in size, ranging from small silos holding a few tons to large industrial silos capable of storing hundreds of tons of cement.

Regular maintenance and monitoring are essential to ensure the silo operates efficiently and safely, avoiding blockages and ensuring a consistent supply of cement for concrete production.

Screw Conveyor

A screw conveyor is a mechanical device used in concrete batching plants to transport cement, fly ash, and other bulk materials from storage silos to the mixing equipment. It consists of a rotating helical screw blade, known as a flighting, housed inside a tube or trough.

Function: Moves materials along the conveyor by rotating the screw, pushing the material forward.

Design: Typically made of steel for durability and designed to handle various types of materials.

Efficiency: Provides a consistent and controlled flow of materials, ensuring accurate batching and mixing processes.

Applications: Commonly used in construction, agriculture, and industrial settings for efficient material handling.

Regular maintenance of the screw conveyor is important to prevent wear and ensure reliable operation.

Air Compressor

An air compressor in a concrete batching plant is a crucial component that supplies compressed air for various pneumatic systems and equipment within the plant.

Function: Provides the necessary air pressure to operate pneumatic valves, actuators, and other control systems.

Importance: Ensures efficient and precise operation of the batching and mixing processes by powering air-operated equipment.

Maintenance: Regular checks and servicing are needed to maintain optimal air pressure and prevent system failures.

Using a reliable air compressor helps maintain the overall efficiency and productivity of the concrete batching plant.

Control Room and System Main Software

The control room and system main software are integral to the operation of a concrete batching plant, providing centralized control and automation.

Control Room: A dedicated space where operators monitor and manage the batching process. Equipped with control panels, computer systems, and monitoring equipment to oversee plant operations in real-time.

System Main Software: Software that automates and controls the batching process, ensuring accurate measurement and mixing of materials. Includes recipe management, production tracking, and data logging for quality assurance and operational efficiency.

Together, they ensure precise and efficient production of concrete, enhancing the plant’s performance and reliability.

 

Valves, Pistons, and Motors in a Concrete Batching Plant

Valves: Devices that control the flow of materials or air in the system. Pneumatically operated to open and close as needed. Regulate the release of cement, water, and aggregates during the batching process.

Pistons: Cylindrical components that move back and forth within a cylinder. Powered by compressed air to create linear motion. Operate gates, hoppers, and other moving parts within the plant to facilitate material handling.

Motors: Machines that convert electrical energy into mechanical motion. Often air-driven in pneumatic systems for smooth operation. Drive various mechanical processes, such as conveyors and mixers, ensuring efficient operation.

These components are controlled by a PLC (Programmable Logic Controller) system, which automates and coordinates their actions to ensure precise and efficient batching and mixing of concrete.

You may check out our wonderful Concrete Batching Plants!