Concrete batching plant is an equipment that is widely used in civil as well as road construction. It is used to produce precise and quality concrete mixtures. A concrete batching plant will mix different aggregates, cement, water along with some additive material to create ready mix concrete as per the demand. This material is widely used for making roads, buildings, bridges, dams, airports, etc. In this comprehensive blog post we will try to cover important details about concrete batch mix plants including their benefits, working principle and maintenance tips.
Benefits of Concrete Batching Plant:
A concrete batching plant, also known as a concrete mixing plant, is a crucial machine used in modern construction projects. It combines various ingredients to create ready-mixed concrete for buildings, bridges, roads, and other infrastructure. The advantages that a concrete batch mix plant has are numerous. It can produce quality ready mix concrete material which is as per the project requirement. The versatility offered by the batching plant equipment in producing different types of materials is of high importance. The plant produces quality material with precise mix material ratio. It is very beneficial to avoid wastage and get exact required quantity of RMC. This helps us to extract the maximum out of the batching plant.
Advantages of concrete batching plant
Consistent Quality
Batching plants ensure uniform mixing of concrete ingredients, resulting in consistent quality across all batches. The precision offered by such machine helps in achieving greater targets. This reliability is crucial for construction projects where strength and durability matter.
Efficiency and Productivity:
- Bulk Production: Batching plants can produce large volumes of concrete efficiently. This is especially advantageous for big construction projects.
- Timely Delivery: Ready-mixed concrete (RMC) plants deliver concrete directly to construction sites, saving time and labor.
Customization:
Batching plants allow customization of concrete mixtures based on project requirements. The modern systems come with software which can be customized to achieve the required results. Different grades, strengths, and workability can be achieved by adjusting proportions in the control system.
Reduced Waste:
Precise batching in the modern plants always minimizes material wastage. Ingredients are measured accurately, reducing excess cement or aggregates. This way projects can be executed without any major hazzles.
Cost Savings:
Efficient production and reduced waste translate to cost savings. This also allows to have better structures that will stand the test of time.
RMC plants eliminate the need for on-site mixing equipment and labor.
Environmental Impact:
Batching plants can incorporate recycled materials into concrete mixtures, promoting sustainability.
Centralized production reduces transportation-related emissions. On site batching plants can delivery varied results of mix material as and when required.
Quality Control:
Regular testing and monitoring ensure compliance with standards. Modern systems come with detailed printing options that allow customers to have a higher degree of flexibility.
Batching plants allow adjustments during production to maintain quality.
Flexibility:
Mobile batching plants are portable and adaptable to various job sites. It is astounding to know and understand these mobile machines and the level of accuracy that they can offer.
Semi-automatic and fully automatic plants cater to different operational preferences.
Thus we understand that a concrete batching plant will play a crucial role in modern construction by providing consistent, efficient, and customizable concrete for our infrastructure needs.
Working Principle of Concrete Batch Mix Plant:
A concrete batching equipment follows a systematic pattern to process ready mix concrete. The process of this production starts with the weighing of different materials individually followed by the mixing of all components in a mixer. Below are the steps that a concrete batching plant uses:
Feeding of the aggregates: There are different bins provided that are for accommodation of aggregates of different sizes. Each bin will accommodate a size of aggregate for weighing. This helps in getting accurate results.
Aggregate weighing: The next important step is the weighing of aggregates. They are weighed one by one as they fall into a weighing conveyor. It is important to note that the weighing conveyor is suspended on load cells. This hanging design allows it to weigh the aggregates one by one effectively.
Aggregates transfer: As the aggregates are weighed, the next step is to transfer them to the mixing unit to mix with other substances. The aggregate weighing conveyor is equipped for this dual purpose. Immediately after the weighing is done, it will discharge the contents into the mixing unit.
Cement addition: Cement a binding material is an important part of a ready mix concrete. It is in powder form and stored into separate storage compartment far away from moisture. This compartment is called as a silo. The silo comes equipped with all safety accessories but without the provision for weighing. It has provision for transfer of cement using a screw type conveyor into the weighing unit.
Cement weighing: Cement weighing takes place in a separate chamber. It is called as a cement weigh hopper. This unit is suspended on load cells to get exact and accurate weight reading of cement. The cement weigh hopper is located near the mixing unit. It receives cement in powder form from the cement silo via a screw conveyor unit. The cement hopper will discharge the desired quantity of cement into the mixer after weighing it.
Water weighing: Similar to the principle of cement addition and weighing, a separate water weighing and discharge hopper is present near the cement weighing hopper. It receives water from the water tank. This hopper is also suspended and hanging on load cells, this enables it to weigh the accurate quantity of water prior to sending the water to the mixing unit.
Additive addition: Different additives can be added into the mix material as per the requirement. The plant is equipped with an additive bowl hanging on load cell. It follows the same principle of the cement and water weighing for additive addition into the mixing unit.
Mixing Unit: The twin shaft mixer is the heart of the concrete batching mixing plant. It may not participate in the weighing process of the materials, but it certainly does a very important job. It will accommodate all the materials for homogeneous mixing. This is an important process and the job of mixing unit cannot be considered inferior. It does a very important task of blending all the materials to form a perfect ready mix material. The paddle arms and tips equipped with the mixer play an important role in lifting the materials up so that a very superior quality of mixing and binding is achieved at the end of the mixing cycle.
A concrete batch plant will use a 60 second weigh-mix cycle. It is calculated from the time of weighing till the time of discharge of materials. The batching plant capacity is calculated on the size of the mixer. The mixer size of 0.5 m3 will yield 30 m3/hr. of wet concrete in a time of 60 seconds.
Maintenance Tips for Concrete Batch Mix Plant:
Proper maintenance and clean-up is essential for ensuring the smooth operation, production and performance of an concrete batch mix plant. Here are some maintenance tips to keep in mind:
Purchase from a Quality Manufacturer
The quality of equipment is of prime importance to a quality manufacturer. He will understand the value of delivering a quality product and back it up by top notch service. It is very important that you will discuss your in-depth requirement with the manufacturer and check if they understand your requirement. It is very important to go with a manufacturer who understands your listed requirements and is able to solve your needs. Once you invest in a quality equipment, the first important step is done correctly. A quality machine manufacturer will charge more but they will also deliver the correct specified goods.
Role of Operator
The operator’s role cannot be considered less in the maintenance and performance of a concrete batch mix plant. An experienced person will ensure that minimum downtime is observed and the plant is kept running to its maximum potential. A well trained and motivated operator will add value. He should follow manufacturer’s guidelines and best practices. It is also important that the operator will be well versed with all the components and their regular maintenance process.
Buy Quality Parts Only from the Manufacturer
If genuine parts are used from the manufacturer, it will be the best for performance of the plant. High quality and genuine parts will give best results and it is no rocket science that it will be beneficial for the overall performance of the plant.
Regular Maintenance Day
A maintenance day should be scheduled for maintenance of the batch plant. It will keep the plant in top conditions as it will allow cleaning and maintenance in one go. Any parts that are causing problem or may cause problem can be identified and an immediate solution can be brought. Timely cleaning and lubrication will do wonders for all the equipment. Any parts that are causing trouble or can cause trouble can be rectified at a very early stage. Such a regular maintenance schedule will prevent major breakdown and allow longer life span of the components.
Watch for Abnormal Movements
Abnormal movements in the plant can be indicative of potential issues. It is highly dangerous to continue the operation of the plant when abnormality is observed. The plant should be stopped and rectified. It is crucial to routinely check the plant for any unusual movements, sounds, or vibrations and to take immediate action in order to prevent this. These may indicate worn-out parts, loose bolts, or misaligned components. Prompt identification and resolution of these problems can avert more harm and guarantee seamless functioning.
Daily Inspection
Daily inspections are crucial for identifying and addressing any issues or potential problems in your batching plant. Inspect all the components, including the conveyor belts, mixer, electrical system, and other parts, for signs of wear, damage, or malfunction. Address any issues immediately to prevent further damage and downtime. Daily maintenance can also incorporate proper cleaning of the batch plant when it is shut down. This will allow the plant to be free and clean before the start of the operation on next day.
Plan in Advance
Effective maintenance planning involves proactive measures. Follow the manufacturer’s recommended plan for maintenance. Arrange maintenance activities ahead of time, plan them for times when output isn’t as high, and assign the required personnel and resources. Get the equipment checked with the manufacturer’s technician. This enables to address maintenance and repairs in a timely manner.
Stock of Spares
Having a stock of spare parts readily available is crucial for the smooth operation. It is highly recommended to purchase genuine spare parts from the manufacturer or authorized dealers and keep them in stock to quickly replace any damaged spare immediately.
It is crucial to comprehend every facet of the device prior to making a purchase. It is crucial to have a skilled operator who can properly maintain the equipment.
Contact us to know more how we can help you.
