Concrete Batching Plant Design
Concrete Batching Plant Design takes the concrete production requirements and creates a concrete batching plant to deliver the production requirements.
To understand the design principles of a concrete batching plant we need to understand how a concrete batching plant works.
A Concrete Batching Plant is a piece of machinery that manufactures concrete. Concrete consists of sand, aggregate, cement, water and add-mixtures.
The concrete batching plant stores the sand and aggregate in large hopper bins and the cement in horizontal or vertical cement silos.
The plant is controlled by software, sensors, water flow valve, admixture pumps and belt conveyors.
There are a number of mixer types including, drum, pan, screw and twin shaft.
Adding the ingredients to make concrete is called dosing.
The software is programmed with the concrete design mix and then doses the materials into the mixer.
The measurement of the ingredients is by volume or weight.
Weight Metric Batching Plant
Weight metric batching plant has weight cells at the bottom of the pan mixer. Each ingredient is transported into the mixer and weighed before the next one is added. The software is programmed with the sequence.
The computer then stores the data for quality control. If the actual weights do not conform to the design weights, an alarm is set off for manual adjustment before the mixer begins to mix.
The pan mixer uses batch cycles and the output quantity is measured by the volume of concrete produced per batch times the number of batches produced per hour. The out is determined by the mix design and the sequence of the dosing.
Weight metric batching is very accurate and +- 1% dosing accuracy can be achieved. This accuracy allows for an optimised concrete process reducing waste.
Volumetric Batching Plant
The volumetric batching plant used gates to measure the quantities. The material is passed through a gate at a given speed. The gate area x the speed determines the quantity of material being mixed.
The mixer is normally a screw and the concrete is manufactured in a continuous process.
Volumetric batching is accurate to +- 3%. Due to the measuring method, it is normal to add a little more cement to ensure the concrete matches the design strength.
Dosing Concrete Batching Plant
Concrete can also be produced by dosing drum trucks. The material quantities are dosed by weight and then transported dry to the truck via a belt conveyor.
The mix includes the sand, aggregate, cement, admixtures but not the water.
Water is added by the truck as it travels to the construction site. This is advantageous for long trips as the concrete arrives at the site fresh. As soon as water is added to the mix, the cement begins the process of hydration and will begin to set within a time limit. The time limit will depend on the quantity of cement in the mix and the admixtures.
Hot Weather Batching
Producing concrete in hot weather causes the concrete to set faster. Admixtures can be added to slow the initial set, but in some cases, this is not enough.
Hot weather chiller batching plant can be used. Ice is produced and added to the aggregate to cool them down. The ice then melts during mixing and becomes the design water component of the mix.
The concrete is then transported to where it is being placed.
it is normal for the hot weather batching plant be set up on site to reduce the transport time keeping the concrete cool as long as possible.
Cold Weather Batching
In arctic climates, the cold weather stops the hydration process by freezing the water.
The sand, aggregate and water are heated up to allow hydration to take place.
The concrete is poured into insulated formwork and covered with insulation to ensure it keeps its heat for hydration and to set to the design mix.
Wet and Dry Batching
There are two design for concrete batching plant wet and dry batching plant. The principles are much the same. One produces we concrete for general construction, the other a semi-dry mix for the manufacture of pre-cast products such as building blocks.
Types of Concrete Batching Plant
Mobile Batching Plant
Mobile batching plant is either put on a vehicle or the main chassis has wheels for the plant to be towed.
Two types of vehicular mobile batching plants are available. Volumetric and Weight Metric. The United Kingdon has a large number of vehicular batching plants, most are volumetric but weight metric vehicles are becoming more popular due to the dosing accuracy.
The towed batching plant has an output range from 5m3/hr to 60m3/hr. The advantage of this type of plant is it can be set up and ready to make concrete with hours of arriving at the site. The plant can be towed from project to project giving the plant a high utilisation and return on investment.
Semi-Mobile Batching Plant
Semi-Mobile batching plant falls within the same output range as the mobile plant, 5m3/hr to 60m3/hr but the plant sits on a chassis that has adjustable legs instead of wheels.
The plant is transported on low loaders from site to site.
Static Batching Plant
The static batching plant has an output range from 60m3/hr to 300m3/hr. They are normally purpose-built but there a number of standard designs.
The main difference of a static batching plant is size. Everything is scaled up to produced mass concrete. The design principles are the same for all types.
Concrete Batching Plant Design Layouts
The links below will send you to a concrete batching plant design page showing you a range of designs from 5m3/hr 90m3/hr
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About The Author of Concrete Batching Plant Design
Bob Evans is the Marketing Director for Fibo Intercon.
Bob has been in the construction and civil engineering industry for over forty years.
You can ask Bob a question on Concrete Disposal or any other question on concrete or concrete batching plant by texting him on 07896 246 224 or Book a CALL.
Thanks Bob Evans