Batching Plant - Concrete Batching

What is a batching plant or concrete batching?

Batching means classification, but in the concrete industry it works like a large balance and it is weighing concrete materials such as sand. A concrete production factory was known as Batching Plant, Batch Plant or Concrete Batching Plant consists of several machines for producing concrete with different materials. These include water, air, sand, gravel, cement, and additives.

 

The production method for ready mixed concrete is carried out in two general types:

- Dry batching plant

- Wet batching plant

A system can also be dry and wet, which is done by a double-sided hopper.

The most important part of a batching plant is its mixer which is somehow the heart of the batching plant and the best of its kind has a gearbox and high power combination. drum mixer Mostly is used in North America, Twin Shaft mixer in Europe, as well as a pan mixer or planter mixer, is used in the precast structure.

Material feeders in batching plants are constructed from 2 to 6 bunkers, which depends on the capacity and volume of concrete needed in a day. Conveyors or band conveyors are usually used in widths of 60 to 100 cm, which has 2 directions for materials transfer from under the main feeder (below the feeder) and another conveyor (mother conveyor) that is located in front of the conveyor below the feeder to the mixer (wet batching) or cement scale (dry batching).

 

Dry batching plant

In dry batching plant of materials (sand, gravel, cement and water) after weighting is poured into the truck mixer without mixing, and they mixed within the truck mixer, the aggregate in truck mixer should be rotated and mixed 70 to 100 rounds to reach the destination, with a minimum of 30 minutes and a maximum of 90 minutes.

Dry batching plant is used in the most ready-mixed concrete production factories because of the time it takes to obtain concrete.

 

Wet batching plant

Concrete mixer is used in the wet batching plant where the materials (sand, gravel, cement, and water) are transferred to the mixer by conveyor after being weighed, and mixed thoroughly in the mixer, which usually takes about 2 minutes, After the mixer, they enter the dump truck that is quickly transported to the place of use.

Usually, the wet batching plant is used near project sites where the quality of concrete production in this type is better than the dry design.

 

Wet and dry batching plant

This system has been in use for many years and uses a double hopper on top of the mixer, where the dry materials enter the mixer on one side and leave the mixer on the other.

 

Automation and Control

Batch plant automation and control system can be designed automatically and manually, which in automatic mode does not require operator skill to do batch operations. In this case, the operator just pressing the start button and when the truck mixer is ready to load, the PLC system of batching plant will do everything such as the weighting and the instructions for the jacks and the water meter automatically.

In Tarahan batching plants, automation System can be controlled remotely with an internet connection. When batching plant automation system fails, company specialists will fix the problem by connecting to the machine automation system and do not need to send technical force.

 

Types of batching

Batching are mostly made in two models:

1.feeder or liner batching

2.dragline batching

dragline batching: It is one of the oldest production lines in the concrete manufacturing industry, with the use of a material rake to transfer and weigh into the system. Features of this system can be no need of a loader but one of its disadvantages is maintenance and repair of the system due to the Being old.

Feeder or Liner Batching: This batching plant system consists of tanks next to each other usually consisting of 3 or 4 bunkers depending on the production capacity. These bunkers are attached to load cells for weighing materials, which make this system compact and easy to use and maintain.

 

Feeder Batching Plant is designed and manufactured in three types:

- Stationary batching plant

- Mobile batching plant

- Portable batching plant

 

Batching Plant Production Line:

1. Cement silos: they are used for storage of consumed cement; the size of silos is 30 to 100 tons

2. Feeder: The required sands separately are stored here, which is made up of three to six bunkers

3. Water Source: The required water of the concrete enters the mixer after automatic measurement by the water meter.

4. Concrete mixer: for mixing cement with sand, gravel, and water (Twin Shaft Mixer, Pan Mixer, etc.)

5. Control Room: Control of all valves and weight and amount of materials by one operator

6. Scale: It weighs the cement from the silos by a load cell and inserts it into the mixer.

7. Water meter: To measure the volume of entered water to the concrete mixer

8. Screw: For conveying cement from silo to scales

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