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Concrete is a fundamental material in the construction industry, serving as the backbone for various structures and infrastructure projects. In the process of global modernization, the demand for concrete is incalculable. To meet the growing demand for high-quality concrete, the use of concrete batching plant has revolutionised concrete production.

The wide market prospect and lucrative profits have attracted a large number of investors to enter the construction industry. But there are so many customers who may not quite understand how to buy the right concrete batching plant for themselves. Investing in the right concrete batching plant is critical for the success of construction projects.

Choosing a concrete batching plant is not easy. It is a decision that involves several aspects and multiple dimensions. With a multitude of options available in the market, it can be overwhelming to select the perfect concrete plant for the construction needs. The right batching plant ensures that the concrete mix is consistent, of high quality, and meets the project requirements.

Different businesses, different solutions

The type of business directly affects the choice of concrete batching plant. In fact, several businesses will require the installation of one to several concrete batching plants. It can be a plant to sell ready mixed concrete, or also a company to produce precast concrete elements, such as beams or tiles. In many other cases it can be a public work or a construction business that will require a plant to regularly supply the needed concrete. Each business has its own peculiarities and demand.

Production capacity

One of the most important factors to consider when selecting a concrete batching plant is the production capacity needed to meet the project requirements. Multiple types of concrete batching plants are available with variations based on their concrete manufacturing capacities measured in cubic meters per hour. The plant’s capacity should align with the project’s size and the estimated concrete output.

While high capacity concrete batching plants will be required to cater to the mass concreting demands in bigger projects, lesser capacity plants are suitable for small and medium scale construction projects. In the real estate and precast industry sectors, the smaller capacity batching plants like 18 m³/h to 30 m³/h are mainly used, whereas, for the infrastructure projects like bridges, dams, airports etc., the bigger capacity plants like 90 m³/h to 200 m³/h and higher are used. Mid-sized 30 m³/h to 60 m³/h plants are popular in ready mix concrete segment.

Types of Concrete Batching Plants

Different types of concrete batching plants are available, each designed to meet specific production needs and requirements. The main three types for considerations are:

Stationary concrete batching plants:

Stationary concrete batching plants are suitable for large-scale construction projects with a consistent demand for concrete. They are designed to produce a high volume of concrete and can be customized to meet specific project requirements. These plants have a higher production capacity than mobile plants and are installed to remain in one location for an extended period.

Mobile concrete batching plants:

Mobile concrete batching plants are ideal for small to medium-sized construction projects and for projects with intermittent concrete needs at temporary or remote locations. They are a great solution for remote locations where transporting concrete becomes extremely difficult or impossible. These plants on wheels can be easily transported to the site and produce high-quality concrete on-site, eliminating transportation costs.

Compact concrete batching plants:

Compact batching plants are designed to occupy less space while maintaining a certain production capacity. They are suitable for small to medium-sized projects with limited space availability. Compact plants often integrate storage bins, a cement silo, a mixer, and control equipment into a single unit or a compact configuration.

Batch Mixer

Concrete mixers are responsible for producing homogenous mix in shortest time. In modern concrete batching plants mainly three types of concrete mixers are used for producing homogenous mix in short time.

Pan type mixer:

Pan type mixers are widely used in small and medium capacity concrete batching plants. Since pan mixer is particularly efficient with stiff and cohesive mixes, they are most common type of mixers used in the precast industry for both wet-cast and dry-cast concrete mixes.

Planetary mixer:

Planetary concrete mixer is widely used to produce precast concrete, commercial concrete and high performance concrete. It is suitable for mixing dry hard concrete and suitable in the production of building blocks and prefabricated parts, and also can be used to produce steel fiber reinforced concrete, color concrete and dry mortar, etc.

Twin-shaft mixers:

Twin-shaft mixers are capable of handling most mix designs, from zero slump to high-slump slurries. Some can also handle heavy clays and soils containing rock and other entrained objects. They are used in high capacity concrete batching plants for producing large volume of quality concrete in shortest possible time.

Type of concrete needed

The type of concrete needed for the project should also be considered when choosing a batching plant. For example, precast concrete requires a different batching and mixing process than ready-mix concrete. Similarly, specialty concrete mixes may require specific equipment components or capabilities that not all standard concrete batching plants possess.

Concrete mixes requiring chilled water should have a chilling unit together matching with the capacity of the batching plant.

Components and accessories

Depending on the project and application requirement, configuration of concrete batching plant can vary to include various controls and accessories. Some projects may require different types of ingredients like fly ash, additives etc. in such case there may be need of silos and tanks with conveying system. Depending on the concrete mix, additives, silica, chilled water, ice flakes, etc. are used today; concrete batching plant needs to be set according to these requirements. Environmental sustainability is becoming increasingly important in the construction industry. If the plant is to be installed in town then dust collectors and wastewater treatment systems needs to be integrated in the plant to reduce the environmental impact.

Control and automation system

The control and automation system is responsible for controlling and monitoring the various components of the batching plant. A well-designed system is able to control the flow of materials, monitor the mixing process, and alert operators to any issues that may arise. It can store and retrieve data about the production process, making it easier to optimize the plant’s performance over time.

Investing in the right concrete batching plant is critical for the success of construction projects. By looking for the essential features discussed above, construction companies can ensure a high-quality and efficient concrete batching plant that meets their project or business needs.