What Is Concrete Batching Plant

Concrete Batching plant is equipment that is elaborately designed to combine coarse aggregates, sand with water, cement, and other admixture as per a preset proportion to produce homogenous and uniform concrete. The final mixture can be widely used to construct skyscrapers, sidewalks, bridges, houses, highways, airports. etc.

Batching plant capacity ranges from 25m³/h to 240m³/h, largely depending on the types of concrete batch plants and concrete batching plant design. For instance, The size of stationary batching plants is commonly larger than that of mobile ones.

How many types of concrete batching plants are there? To learn about or to purchase concrete batch plants, figuring out the classification of them is undoubtedly the most primary and critical step. The classification methods of concrete plants nowadays are so diverse and complex that some confusion may arise in your mind from time to time. The following summary will help you tackle this problem.

Types of Concrete Batching Plant

Classification Basis Type A Type B
Structure Stationary Mobile
Mixing Mode Batch Continuous
Process Layout Single-stair Double-stair
Water-adding Mode Ready-mix Central-mix
Mixer Twin-shaft Horizontal Planetary Vertical

1. Based on the structure, batching plants can be divided into mobile type and stationary type.

2. In terms of the mixing mode, they can be divided into batch type and continuous type.
The currently popular concrete batching plants carry out production one batch by another, while the other type carries out continuously.

3. Based on process layout, they can be categorized into single-stair type and double-stair type.
Storage silo, weighing device, mixer of the single-stair batching plants are arranged from top to bottom. Sand, fly ash, cement, and other materials are elevated to the storage silo at one time, and then weighed, batched, and mixed until the concrete is made. This type is characterized by reasonable process flow, high productivity, but a large investment.

The storage silo and mixer of the double-stair concrete plants are roughly at the same elevation. The aggregate is firstly lifted to the storage bins, where it is cumulatively stored and separately weighed, and then sent to the mixer by an elevating bucket or belt conveyor. The materials need to be lifted twice, so the efficiency is comparably lower, but since the height of the whole complete plant is reduced, the disassembly and assembly are convenient, and the investment is smaller.

4. Based on how the final mixture is made, they can be assorted into ready-mix type and central-mix type.
Ready-mix batching plant is also called a precast concrete production plant. All elements are consolidated except for water. On the way to the job site, water is added into the transit mixer and the dry mixture gets mixed therein.

All ingredients, including water, are blended by a concrete mixer before the resultant mixture streams into the transit mixer. The central mix batch plant is hance also known as wet mix batching plant.

5. The mixer, the critical component of a concrete plant, mainly falls into the twin-shaft mixer and planetary vertical shaft mixer

Vibration mixing, the newest and simultaneously the most advanced technology, has been invented by us last year. The key point of this patented technology is that a vibrator mounted on the shafts of the conventional twin-shaft mixer, generates a vibrating force intermittently, keeping the materials vibrating during the mixing process. In this course, the solid cement mass is broken up and fully bonded with the water and aggregate. Using the vibrating mixer, the strength of concrete increases by 8%, and mixing time is shortened by 20%, actual data suggests.

How Does A Concrete Batching Plant Work

Concrete batching plant is a kind of combined device, mainly composed of main building structure, mixer, powder silo, screw conveyor, belt conveyor, weighing system, liquid supply system, gas supply system, electric control system, dust removal device, batching station, control room, used for centralized production of concrete.

Despite the difference in the size of the stationary concrete batching plants and the mobile ones, both have the same working principle.

the components of concrete batch plant
Components of Concrete Batch Plant
the flow chart of concrete batch plant
Batching Plant Process Flow Chart

Concrete Batching Plant Process Flow

How is concrete batching done in a batching plant

Batching Plant Operation Procedure

1. Load the aggregates like gravel and sand into individual storage bins, and after being weighed individually, they will be dispatched to the feeding belt conveyor, which then convey them to the weighing hopper on the top of the concrete mixer.
2. Under the control of the control system, the cement is transported to the weighing hopper by the screw conveyor; the water and additives are also transferred to their respective weighing hoppers.
3. Open the pneumatic door of the weighing hoppers; open the pneumatic butterfly valve of the cement weighing hopper, fly ash weighing hopper, and the water weighing hopper; Open the pneumatic ball valve of the additive weighing hopper.
4. Turn on all the weighing hopper vibrators and water inlet pressure pumps to make all materials enter the concrete mixer to blend evenly.
5. Once the setting time is over, the mixer will discharge the mix into a transit mixer or a concrete pump.

Please keep in mind that commonly the concrete must be prepared, transported, and then applied between 30-45 minutes, which is also known as preparatory setting time, concrete must not segregate in the whole course.

Advantages of Mobile Concrete Batching Plants

Along with the increase of the number of construction projects and the amount of concrete required, especially, more and more projects need to complete in a short time, mobile batch plants is increasingly preferred by the contractors.

the components of concrete batching plant
the flow chart of concrete batching plant

The mobile concrete batching plant is concrete production equipment that integrates the storage hopper, mixer, conveyor, weighing device, and control system into a trailer unit, having mobility performance greatly improved. Therefore, it enjoys some unique advantages.

1. With the towing design, it can be towed away easily. It is convenient to disassemble and move.
2. Manual, semi-automatic, and full-automatic options are available. Free production control, high measurement accuracy, automatic drop height adjustment.
3. Save the cost of transit mixers, reduce transportation time, and reduce concrete quality degradation caused by long-term transportation.
4. The quality and slump of the concrete can be controlled on-site, saving waste caused by substandard quality.

Batching Plant Inspection Checklist

How to check the quality of the concrete batch plant, what should be paid attention to before the first use of your concrete plant, the answers to these critical questions are summed up by us as follows.

1. Inspect the quality of the steel bars, the size of the mesh, and the accuracy of the screening when it comes to vibrating screen.
2. To see whether the work of the transmission system is active and whether there is any abnormal noise.
3. The transmission of belt conveyors, bucket elevators, and cantilever drag shovel should be stable, with no abnormal noise, no jamming.
4. Examine the flexibility and accuracy of the measurement system.
5. Observe whether the rate of temperature rise of the reducer is aligned with the qualification certificate or not.
6. Material's In and out through the measuring hopper should be smooth, with no signs of accumulation, overflow, etc.
7. The safety valve cannot show air leakage.
8. Check whether the quality of the cement tank is qualified.
9. The circuit equipment should be reasonable and accurate.

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