Concrete Batching Plants are modern production facilities that produce concrete used in almost all construction projects with precise weighing and homogeneous mixing technology.
Concrete in Concrete Plants is produced as follows: High-quality concrete is produced by mixing the aggregate, cement, water and additives forming the concrete precisely in accordance with the predetermined production recipes and mixing them in the fast and high performance concrete mixers placed in concrete plants.
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When the concrete plants were first designed years ago, they were designed as stationary type. But over time and in parallel with the developing technology, stationary concrete plants have also developed greatly.
Stationary Concrete Plant generally consists of the following units:
1. Aggregate Bunker (unit where aggregate is stored)
2. Aggregate Weighing Conveyor (Unit where the aggregate weighed precisely weighed under the aggregate bunker)
3. Aggregate Transfer Conveyor or Aggregate Transfer Bucket (Unit that carries the weighed aggregate to the mixer)
4. Cement Silo (unit where cement is stored)
5. Cement Screw (unit that carries the cement from the cement silo to the cement scale)
6. Cement -Water-Additive Scales (units where cement, water and additive are weighed)
7. Mixer (a mixer in which the weighed materials are mixed homogeneously and quickly)
8. Main Chassis (The unit containing the mixer, cement-water-additive scales, has carrier legs under which a transmixer will enter.)
9. Control Cabinet and Computerized Fully Automatic Control System (Concrete is produced automatically according to the concrete recipes entered the system)
10. Air Compressor and Pneumatic Equipment (Produces compressed air required for the operation of the facility)
What are the Advantages of Stationary Concrete Plant?
Modern Stationary Concrete Batching Plants are designed by considering maximum capacity, high flexibility, efficiency and reliability in order to produce all kinds of high-quality concrete in series.
The advantages of Stationary Concrete Plant are:
1- High Production Capacity and High Performance (Wide concrete production ranges from 30 m³ / h up to 200 m³ / h with single mixer, concrete production capacity up to 400 m³ / h with double mixer)
2- High Configuration Flexibility (Thanks to its flexible structure, configuration options that can meet the needs of the user completely)
3- Special Settlement Opportunity Fully Compatible with the Installation Area (settlement alternatives that can fit different installation areas)
4- Durable and Long-Life Main Chassis and Aggregate Bunker Design (Robust construction, safe transportation, long life working and weighing minimizes vibrations and provides precise weighing)
5- Easy and Fast Maintenance Advantage (Wide maintenance platforms, easy and safe access to the main parts and weighing scales of the mixer, special scale solid upper platform)
6- Special Concrete Production Facility (RCC, concrete parquet, concrete pipe, prefabricated element production) 7- Age Type, Dry Type; Wet & Dry Type Concrete Production Facility
Use areas of stationary concrete plants
Ready-mixed concrete producers who manufacture concrete in their own facilities and sell it to other concrete users and construction companies generally prefer stationary concrete plants due to their advantages in mass production, high performance and high flexibility.
In addition, stationary concrete plants are mostly preferred in construction projects that require high quality concrete production such as roads, dams, airports and high quality concrete. In addition, Stationary Concrete Batching Plants are also used in applications that require special concrete production such as RCC (Cylindrical Compacted Concrete), concrete parquet, concrete pipe, prefabricated element production (prefabricated column and beam etc.) production, and hollow concrete floor production.
Stationary Concrete Plant Features
Thanks to its flexible structure, Stationary Concrete Plants offer configuration options that can meet the needs of the users completely and can be designed in a variety of ways.
In stationary concrete plants, aggregate is transported to the mixer level by means of aggregate transfer conveyor or aggregate bucket. Since the aggregate bucket can operate at a steeper angle, it is suitable in cases where the facility should fit in a less area. But generally, the aggregate is transported to the mixer level via the transfer conveyor. In facilities containing aggregate transfer conveyor, aggregate waiting bunker is placed on top of the mixer.
The aggregate required for 1 cycle continuously in the aggregate waiting bunker is kept ready to be sent to the mixer immediately. In this way, aggregate transfer and mixing processes can be separated and the total cycle time can be shortened and concrete production capacity can be increased.
Stationary Concrete Plants can be equipped with different types of mixers depending on the type of concrete to be produced. Single Shaft (Single Shaft) mixers 0,5 m³; 1, 0 m³; Twin Shaft Mixer (Double Shaft) with 2.0 m³ capacities, 1, 0 m³; 2.25 m³, 3.33 m³; 4.0 m³; With 5.0 m³ capacities;Planetary Mixers 0,5 m³; 1, 0 m³; It can be in 2.0 m³ capacities. Aggregate Bunker can be designed to store aggregates in different capacities per eye (15,20,25,30,40,50 m³) in a range of 3-4-5-6 meshes.
In some fixed concrete plant models, the main chassis (main chassis carrying the mixer) and aggregate bunker can be produced as hot dip galvanized due to its long service life, high durability and precise weighing advantages.
Better weighing accuracy can be achieved when the cement, water and additive weighing scales are placed on the separate weighing frame instead of being transported to the mixer body.
Stationary concrete plants, which are generally designed as wet type, can also be produced as dry type and wet & dry type. Double transmixer discharge possibility, additional weighing scales such as ice, mixrosilica, GGBS and many other options can be added to stationary concrete plants.
It is possible to produce concrete even at -30 ° C by adding special equipment required for working in winter conditions (complete closure of the facility with insulated sandwich panels, aggregate in-bunker steam system, steam generator, electric bunker overhead caps etc.) to fixed concrete plants.
In order to be shipped to overseas, stationary concrete plants are also designed for container transportation. While high capacity mixers are shipped with 40 'FR (Flat Rack), all other units can be shipped easily and economically with 40' OT (Open Top) Containers.
High-quality concrete construction equipment enables efficient completion of construction projects in a shorter timeframe. By reducing labor requirements and delivering superior construction services more quickly, companies can enhance profitability. Advancements in technology have led to the development of a variety of concrete construction equipment options, offering construction firms improved processes and productivity.
A concrete batching plant is a piece of equipment used to blend various ingredients to create concrete. Ingredients commonly used in concrete plants include water, air, admixtures, sand, aggregates (such as rocks and gravel), fly ash, silica fume, slag, and cement. A concrete batching plant can have a variety of parts and accessories, including: mixers (either tilt drum or horizontal or in some cases both), cement batchers, aggregate batchers, conveyors, radial stackers, aggregate bins, cement bins, heaters, chillers, cement silos, batch plant controls, and dust collectors.
A concrete batching plant, also known as a concrete mixing plant, is a machine designed to blend various materials such as sand, cement, water, etc., to produce concrete.
These ingredients are mixed in different proportions depending on the desired characteristics of the final concrete product required by the company.
The batching plant is a crucial piece of equipment in the construction industry, comprising several essential components including cement and aggregate batchers, aggregate bins, conveyors, mixers, heaters, cement silos, control panels, and dust collectors. The efficiency of the batching plant is paramount for producing high-quality and durable concrete.
Batching equipment employed in conjunction with paving operations often entail additional requirements beyond those specified for other types of concreting operations. Below are several types of concrete batching plants commonly utilized.
A commercial concrete batch plant primarily consists of five main systems: the mixing host, material weighing system, conveying system, storage system, and control system. Designed for commercial purposes, these plants should be efficient, economical, and compliant with environmental protection standards.
Contact us to discuss your requirements of mini concrete batching plant. Our experienced sales team can help you identify the options that best suit your needs.
A dry mix concrete plant, also known as a transit mix plant, utilizes weigh batchers to measure sand, gravel, and cement via digital or manual scales. The ingredients are then discharged into a chute, which leads into a truck. Simultaneously, water is either weighed or volumetrically metered and discharged through the same charging chute into the mixer truck. These components are mixed for a minimum of 70 to 100 revolutions during transportation to the jobsite.
A wet mix concrete plant combines some or all of the aforementioned ingredients, including water, at a centralized location into a concrete mixer. This means that the concrete is mixed at a single point and then simply agitated en route to the jobsite to prevent setting, either using agitators or ready-mix trucks, or hauled to the jobsite in an open-bodied dump truck.
Wet mix plants differ from dry mix plants in that wet mix plants contain a central mixer, which can offer a more consistent mixture in a shorter time frame (generally 5 minutes or less). Dry mix plants typically exhibit more break strength standard deviation and variation from load to load due to inconsistencies in mix times, truck blade and drum conditions, traffic conditions, etc.
With a central mix plant, all loads undergo the same mixing action, and there is an initial quality control point when discharging from the central mixer. Some plants combine both dry and wet characteristics for increased production or for seasonal variation.
A mobile concrete batch plant, also referred to as a portable concrete plant, is a highly productive, reliable, and cost-effective piece of equipment for producing concrete batches. It enables users to batch concrete at virtually any location and then move to another site for further batching. Portable plants are particularly suitable for temporary projects or even stationary locations where equipment height is a concern or the required production rate is lower.
The stationary concrete batching plant is engineered to deliver high-quality concrete consistently. It boasts large output, high efficiency, stability, and adherence to strict specifications. With reliable and flexible components, maintenance is straightforward, and the plant exhibits a low failure rate. Widely used in various projects such as roads, bridges, ports, tunnels, dams, and buildings, stationary concrete batching plants are a dependable choice for construction endeavors.
Compared to traditional concrete plants, the aggregates metering system in tower batching plants reduces four intermediate links by transitioning to vertical unloading metering. This method significantly saves measurement time and enhances production efficiency. Tower batching plants are designed based on floor modules or containers, depending on the model. These floor modules and containers are factory-made, including electric installations, enabling rapid installation and commissioning. The aggregate silo volume and quantity can be adjusted according to customer requirements.
The containerized concrete batch plant represents a new type of batching plant, comprising mixing systems, control systems, material storage systems, weighing systems, conveying systems, and others. With features such as a small footprint, quick installation, and convenient transportation, the container mixing plant offers several advantages.
Unlike traditional concrete plants, the container mixing plant eliminates the need for setting legs and mounting brackets, simplifying basic design and construction requirements. It boasts excellent environmental performance, convenient transportation, and straightforward installation. Suitable for various construction projects including hydropower, highways, ports, airports, bridges, and commercial concrete batching plants, the container concrete batching plant is versatile and efficient.
A concrete batching plant can reduce labor costs and boost profits by delivering quality construction services to customers more efficiently. The key lies in selecting the one that best suits your specific requirements.