Can consistent quality from mobile batch plants be achieved? 5

This may be late for the original question, but in case anyone else needs this info, our firm faces a similar issue for a series of upcoming projects, and I did some fairly extensive research on this topic.

First of all, there are a few key considerations for remote concrete production. First is the target placement rate in cubic yards per hour, assuming a normal workday with time out for breaks and cleaning the equipment. Choice of a system (e.g. how many units you need) is governed by this number. Second is: reliability matters a whole lot more than first cost. Third, ease of cleaning the equipment (if you use typical 8 to 10 yard transit mixers, how do you expect to keep the drums spotlessly clean inside so that buildup doesn't occur?). Fourth, ease of obtaining spare parts (assume you're already planning to hold spares locally for the most likely replacements).

Mobile batch plants, or Volumetric Mobile Mixers (VMMs) have traditionally been regarded with scepticism due to a) volumetric batching and b) relatively low contact time between materials and mixing blades. However, in the past five years, the reputable manufacturers of these machines have formed the Volumetric Mixer Manufacturers' Bureau to produce specifications and assure manufacturer compliance.

I've read the VMMB certification specs. The bottom line is, machines meeting these specs will produce concrete that is as good as anything produced with a conventional batch plant & transit mixers. However, I would personally use VMMs only for "conventional concrete," not for high-spec mixes or heavily modified mixes (lots of admixtures etc.), *unless* I first arranged with the machine manufacturer to run some trial batches on one of their sales-demonstrator machines, and have the trial batches subjected to full lab testing. If you can come up with a really "difficult" mix design, and your preferred brand of VMM can handle it, chances are it can handle other less "difficult" special mixes as well.

Machines produced since or so should carry the VMMB certification plate. If a machine isn't VMMB certified, don't buy it; and if a concrete supplier using VMMs doesn't have certified machines, don't use that supplier.

From what I've been able to find, the most highly recommended VMMs are made by CemenTech and by Reimer. I don't work for either of those, so this isn't an advertisement! If our firm decides to use VMMs on an upcoming project, we'll probably go with CemenTech.

If you use VMMs, you absolutely need skilled and conscientious operators. VMM manufacturers will train, and even if they charge for training, it's worth the price. I would assume the hourly wage questions have been addressed by the relevant unions already, since these machines have been around a good long time.

There are two alternatives, that may turn out to be useful depending on your job situation.

The first is the "self-loading transit mixer," commonplace in Europe (notably Italy) but barely known in North America. This is an offroad chassis with 4-wheel drive & 4-wheel steer, equipped with a mixer drum of from 1 to 4 cubic yards, mounted on a slewing (turntable) frame for 270-to-360-degree placement (front, rear, or side discharge), and equipped with a) a self-loading bucket similar to a front-end-loader shovel and b) a weigh-batching computer (optional accessory, highly worthwihle).

This machine is in effect a self-contained system with proper weigh-batching of all dry ingredients (water is batched by volume via a meter). The weigh-batch computers can handle 30 or so mix designs and up to 20 ingredients per mix design, and print batch tickets on demand. Unlike the VMM, it doesn't require a front-end loader or cement silo (you can use a silo or load cement by bag into the scoop). These machines will also climb steep grades fully loaded, go through deep water, and I suppose some day they might even learn to fly! Personally they are my first choice for remote concrete production.

Some manufacturers' names to put into a search engine: Carmix, Dieci, Merlo, Terex/Mariner, Italmacchine, Utranazz. There are a few more I can't recall offhand, but try putting "mixer" and "dumper" into the search engine, as the manufacturers of these often also make the Euro type of offroad site dumper. Price at the factory gate for a 3 to 4 yard machine should be in the neighborhood of US $75,000, which is amazingly good.

As these machines are virtually unknown in the USA market, the hourly rates for operators haven't been determined yet. What I would do is sit down with the head of the local Operating Engineers' union and discuss the machine in some detail. You want the most skilled operators you can get, and you're already saving money by using this machine (doesn't need ancillary supporting equipment & labour), so it's fair & reasonable to settle on what might otherwise look like a higher than normal hourly wage.

The other option is a large site-mixer with an automatic loading hopper with a scale for weigh-batching. In the USA we used to have a wide choice of manufacturers of machines up to 16-S (16 cubic foot mixed batch) but alas they are no more, so you have to import. Check out for some good examples of these; Winget has been around for about a century. Other manufacturers include Utranazz (UK), Altrad/Lescha (Germany), IMER (Italy; their USA branch doesn't advertise these but the USA reps may be able to handle the importation issues), and most of the European makers of contractors' grade concrete mixers. Aside from Winget and Utranazz in the UK, it would appear that Germany and Italy are the places to look for these.

These machines are made in two types. One is a large version of the common "portable mixer," with a 200-litre drum (equivalent to a 6-S in the old AGC-USA ratings). The other has a horizontal drum that reverses rotation to discharge (like the old horizontal transit mixers). In both cases you have a hydraulic loading hopper on one side, with a scale; and a calibrated water tank. Optionally you can order a cable-controlled drag-scraper that allows one person to load the aggregates into the hopper without fatigue (highly recommended). These machines range from 200 litres to 500 litres in mixed batch output. Price range is from about $18,000 US to about $45,000 US depending on size and options.

By the way, the cool thing about the British manufacturers of these (e.g. Winget, Utranazz) is that the quoted capacity of the machine (in accord with BSS specs) is the actual mixed batch output, not the dry materials input.

For labour, you need: One person in good physical condition to operate the aggregate drag-scraper (low to medium skill level). One person to batch the cement (from sacks), admixtures if any, and monitor the water system, and operate the mixer controls. This person needs both strength and smarts. Or you could have two people switching off on aggs and cement, and have a mixer operator who is responsible for water & admixes; in which case the mixer operator needs the smarts but not necessarily the strength. The people loading aggs & cement are probably at Labourers' wage rates. The mixer operator might be something to discuss with the local union representatives; again, be willing to go for a higher hourly rate in exchange for a higher standard of training & skill.

One thing these machines don't have is a drum revolution counter or batch timer. However it's a simple matter to add a rev counter, you can build it yourself from parts obtainable at any decent electronics store (e.g. Radio Snack or better). I've asked a couple of the manufacturers of these machines to figure out if a weigh-batching computer could be added (similar to the one on the self-loading transit mixer), and so far, one manufacturer said yes and another is working on it. If you can't get the computer option, you won't have weigh-batch tickets for each batch, and in that case a conscientious operator is a major asset.

For any new concrete production system, it's probably worthwhile to do some rehearsal-runs using only sand or coarse aggs, just to get the pace of the work figured out and all the workers choreographed like a dance performance before an actual project comes up.

Also, regardless of what the manufacturers quote as maximum number of batches per hour, you want to re-calculate the timing yourself based on your own job conditions. Your jobsite conditions will probably be less favourable than the manufacturer's test conditions, so your production rate will be affected accordingly. It's better to know in advance so you can buy an extra machine ahead of time to increase your production capacity (rather than ending up doing "concrete marathons" or getting unplanned cold joints if you have to stop overnight in the middle of a pour).

I could go on about all of this for another two pages but I think I'll stop now (!).

If anyone finds this useful, post to this thread so at least I know I haven't wasted my time writing it!

Investing in a concrete plant requires a lot of pondering and thinking carefully about several aspects, weighing pros and cons, looking into financial matters, and so on.

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So, how can you decide about purchasing a concrete plant?

We have put together the top seven features to be considered before purchasing a concrete mixing plant.

1. Construction Environment, Batching Plant Capacity & Other Related Factors

The construction environment is one of the top factors to be considered when purchasing a concrete plant.
So ask yourself the following questions:

• What is the size of the construction site?
• Accordingly, what should be the size of the equipment?
• Similarly, how much quantity of concrete would be required for the project?
• We primarily make concrete batching plants in three capacities – 15 Cu m3, 20 Cu m3, and 30 Cu m3.
• How busy is the area near the construction site in terms of traffic?
• What is the distance between the construction site and the conveying vehicle?

2. Reliability of the Equipment

The reliability of the equipment and the quality of concrete produced go hand in hand. Thus, it is essential to ensure that the batch plant is reliable enough to get high-quality concrete for your construction work. Take into consideration the following aspects:

• Check the various product features
• Inspect the control system of the equipment
• Look for customization options
• Analyze the product parameters to ensure they meet your
• specifications and requirements

3. Conduct Batching Plant Cost Analysis

Since there are several concrete batching plant options available, it is advisable to set up your budget and make a cost analysis of the equipment you require. It includes:

• Transportation costs
• Installation costs
• Site preparation costs
• Electrical and plumbing costs
• Tax amount, if any

4. Performance/Cost Ratio

When it pertains to the financial aspects, you must conduct a complete analysis. It is not sufficient to merely look into the price of the concrete plant. You must also consider the performance-cost ratio. In other words, check for equipment that offers more benefits at less cost. It will increase the performance-cost ratio.

5. Choice of Main Engine

The main engine of a concrete batching plant must be chosen after due care and inspection. You must look for the following attributes:

• Reliable concrete mixer
• Ability to produce good quality concrete
• Must have strong overload capacity
• Should have high production efficiency
• Must have the adaptability to the mixing of various commodities

6. Look Out for Aggregate Options

It is a very crucial aspect to be considered while purchasing a concrete batching plant. So get to know the type of cement available in your region. It will be the deciding factor as far as the number of bins for the plant is concerned.

7. Worth of the Manufacturer’s Brand Name

It is vital to opt for a manufacturer who is well-known and reliable. You should ask for the following:

• The technology used
• Quality of materials used to assemble the equipment
• After-sales services provided by the manufacturer
• Whether or not the manufacturer provides training on the safe and efficient use as well as regular maintenance and upkeep of the concrete plant.

The vital aspect while choosing a concrete plant is to search for the best combination of quality and price, i.e., the equipment should be of superior quality at an affordable price.

Contact us to discuss your requirements of mobile asphalt drum mix plant. Our experienced sales team can help you identify the options that best suit your needs.

Do not hesitate to contact us in case of any queries regarding concrete plants. For assistance of any kind, reach out to our experts.

FAQs

What is a concrete plant and how does it work?

A concrete plant is a facility that combines various ingredients like cement, water, aggregates, and admixtures to produce concrete in large volumes. It consists of components like mixers, silos, conveyors, and batching systems. Modern plants use automation to ensure accurate mixing and high-quality concrete output.

How to choose a suitable concrete batching plant for your project?

When exploring how to choose a suitable concrete batching plant, consider key factors like required output capacity, site constraints, mobility needs (stationary vs mobile), automation level, and budget. It’s also crucial to evaluate the reputation of the concrete plant manufacturer and after-sales support to ensure long-term reliability.

What are the different types of concreting plants available in the market?

Common types of concreting plants include dry mix plants, wet mix plants, mobile concrete batching plants, stationary plants, and compact plants. Each serves different project requirements—mobile plants are ideal for temporary sites, while stationary plants are preferred for large-scale operations with consistent concrete demands.

What components are essential in a modern concrete plant?

Key concrete plant components include aggregate batching systems, cement silos, conveyors, mixers, water dosing systems, and control panels. High-quality components ensure accuracy, efficiency, and minimal downtime. Advanced plants also feature real-time data tracking and automated controls for precision mixing.

How much does a concrete batching plant cost in India?

Wondering how much does a concrete batching plant cost? The price can range from ₹15 lakh to ₹1 crore or more, depending on the plant’s capacity, level of automation, and features. Customization, transport costs, and installation charges can also impact the final pricing.

What should I look for in a reliable concrete plant manufacturer?

Choosing the right concrete plant manufacturer involves assessing their industry experience, product range, customization ability, warranty policies, and customer support. A trusted manufacturer should offer certified quality, reliable performance, and easy availability of spare parts and service.

Can I upgrade existing equipment instead of buying a new concrete plant?

Yes, if your current system meets most needs, upgrading individual concrete plant components—such as mixers, control systems, or cement silos—can enhance performance and extend the plant’s lifespan. This approach is cost-effective and helps meet evolving project requirements without a complete overhaul.

How to buy a suitable concrete batching plant online or from a local vendor?

If you’re wondering how to buy a suitable concrete batching plant, start by defining your project requirements, then request quotes from reputed manufacturers. Compare product specifications, warranties, and service offerings. Whether purchasing online or locally, always verify certifications and seek references or case studies.

Are mobile concrete plants as efficient as stationary ones?

Mobile concrete plants offer high flexibility and quick setup, making them ideal for short-term or remote projects. While they may have a lower output than stationary units, modern mobile plants are equipped with efficient mixing systems and automation, ensuring consistent performance for mid-scale production needs.

What maintenance is required to keep a concrete batching plant running efficiently?

Regular maintenance of a concrete batching plant includes checking mixer blades, cleaning the batching system, inspecting the control unit, lubricating moving parts, and ensuring all concrete plant components function smoothly. Preventive maintenance minimizes breakdowns, ensures consistent output, and extends equipment lifespan.