A batching plant is a machine where parts of concrete are homogeneously mixed to acquire desired strength and high-quality concrete.
Concrete batching plants measure the quantity of cement, sand, coarse aggregate, water, penetration required for concrete mix design.
Batching of concrete could be achieved by either weight batching or volume batching.
Weight batching is completed based on the weight of the components, whereas volume batching is completed based on the amount of the material.
The measurement of materials for making concrete is called batching.
- Types of concrete batching plants based on mixers:
- Transit Mix Plant / Dry Concrete Batching Plant:
- Central Mix Plant / Wet Concrete Batching Plant:
- Types of Concrete Batching Plants based on plant location:
- Stationary Concrete Batching Plant:
- Mobile Concrete Batching Plant:
- Advantages of batching plants:
- Disadvantages of batching plants:
- Batching Plant Process Flow Chart:
- Application of Batching Plants:
Types of Concrete Batching Plant:
Types of concrete batching plants based on mixers:
Concrete batching plants could be divided on the basis of mixers as transit mix plants and central mix plants.
Transit Mix Plant / Dry Concrete Batching Plant:
The Transit Mix Plant / Dry Concrete Batching Plant makes use of manual or digital scales to aggregate and weight the cement.
Water can also be weighed or measured separately.
After weighing, the fabric is poured into a transit mixer, which is transported to the location.
All supplies are blended during transportation to the construction site.
Water is added either to the location or throughout transportation, relying on the situation of the plant or site.
Central Mix Plant / Wet Concrete Batching Plant:
Central mix plant / wet concrete batching plant weighs all the required ingredients together with water.
The materials are mixed in a mixer situated at a central location within the plant.
After the mixing process, the concrete is poured into the shifting truck, which delivers it to the location.
It needs to be kept in mind that the truck should transfer so that the concrete does not freeze.
Types of Concrete Batching Plants based on plant location:
Concrete batching plants can be classified as stationary and mobile concrete batching plants based on the location of the plant.
Stationary Concrete Batching Plant:
Stable concrete batching plants as indicated are steady and situated in a long way from the construction site.
Concrete is transported to the construction site using a truck; steady concrete batching plants are simple to set up.
They are bigger in dimension than cellular concrete batching plants.
They have excessive effectivity and produce good high-quality concrete & care must be taken that the truck reaches the location on the desired time.
Otherwise, the concrete will start to freeze and due to this fact, the inferior concrete can be distributed.
They have a wider vary of batching than cellular concrete batching plants.
Stationary concrete batching plants are generally used for industrial projects with large span and enormous demand for concrete.
Mobile Concrete Batching Plant:
Sometimes the stationary concrete batching plant is situated at such a distance that the price of transporting the concrete will increase and therefore the higher cost of the building.
In such circumstances, mobile concrete batching plants are extra popular.
They are compact batching plants with physical storage, weighing, mixing and discharging models.
It has versatile motion, due to this fact could be transported to the development web site; thus, batching of concrete is completed on-site.
After setting up the plant, the contractor can modify concrete manufacturing according to the job requirement.
After the construction is over, the batching plant is moved to a different site for further use.
By using mobile concrete batching plants, within the case of stationary plants, delay in transport of vans could be avoided.
However, this sort of concrete batching plant has low effectivity and capability, then stationary plants.
Batching of concrete is a vital aspect of concrete construction.
If the material is not weighed correctly, the concrete won’t obtain the specified strength and due to this fact, the general durability of the structure decreases.
For small scale projects, manual batching could be achieved, however for large and significant projects, it’s better to have a concrete batching plant for concrete of high efficiency, excessive speed and accuracy and high quality.
Advantages of batching plants:
1. A centralized concrete batching plant can serve a large space.
2. The plants are situated in areas for industrial use, and still, supply trucks can serve residential districts or inside cities.
3. Better quality concrete is produced.
4. Elimination of storage space for basic materials on site.
5. Elimination of hiring of plant and machinery.
6. The wastage of basic materials is avoided.
7. Workers associated with the production of concrete are eliminated.
8. The time required is greatly reduced.
9. Noise and dust pollution on the site is reduced.
Disadvantages of batching plants:
1. Materials are tied into a central plant, and mixing begins at that plant, so the travel time, plant to the site is crucial over long distances.
2. The access road and site access must be able to carry a greater load of ready-mix trucks plus load.
This problem can be overcome by using so-called ‘mini mix’ companies, which use smaller 4 m3 capacity mixers that are able to reach more restricted sites.
3. The limited-time between mixing and curing of the concrete means that the ready-mix must be kept in the plant within 210 minutes of batching; modern mixtures can modify that time period precisely.
Batching Plant Process Flow Chart:
Application of Batching Plants:
For Ready Mix:
A concrete plant, also known as ready mix concrete plant, is usually located inside the city and concrete is transported to the site by a concrete truck mixer.
Ready-mixed concrete plants are required for the durability, reliability, safety, and environmental protection of concrete plant systems.
For Precast Applications:
Precast concrete is a concrete product that is processed in a homogeneous process in the manufacturing unit.
With cast-in-place concrete, precast concrete can be produced, cast in batches and cured.
Precast concrete batching plants have a safe construction environment, low prices, and high-quality materials; the construction speed can be improved.
It is also used in transportation, construction, water conservation and various fields.
Frequently Asked Questions:
What is batching and mixing of concrete?
Batching is the process of measuring concrete mix ingredients either by volume or by mass and introducing them into the mixture.
How much is a concrete plant cost?
The estimated cost for installation of a concrete batching plant will be around Rs 57 lakh to Rs 2 crore.
Is Ready Mix Concrete cheaper?
RMC is 5% expensive, but if you add value saved by time, effort and hassle, then RMC is definitely cheaper.
Is code for ready mix concrete?
As per Indian Standard Code of Practice (IS 4926)
The batching plant will produce a very limited amount of waste and materials.
A concrete recycling machine will be installed on-site to recycle concrete waste to reduce material consumption and waste generation.