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A concrete 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. Sakrete is an industry leader in ready mixed construction products and has been the pro's choice for concrete and mortar mix since 1936. Watch Associate Bob and Quikrete's Randy Williams demonstrate the different types of Quikrete Concrete mix, including ready-to-use, high early strength. The heart of the concrete batching plant is the mixer, and there are many types of mixers such as Tilt Drum, Pan, Planetary, Single Shaft and Twin shaft mixer. The twin shaft mixer can ensure an even mixture of concrete through the use of high horsepower motors , while the tilt mixer offers a consistent mix with much less maintenance labor and cost. A Pan or Planetary mixer is more common at a precast plant. Aggregate bins have 2 to 6 compartments for storage of various sand and aggregate (rocks, gravel, etc.) sizes, while cement silos are typically one or two compartments, but at times up to 4 compartments in a single silo. Conveyors are typically between 2. Typical plants are used for ready mix, civil infrastructure, and precast applications. A Dry mix Concrete Plants, also known as Transit Mix Plants, weighs sand, gravel and cement in weigh batchers via digital or manual scales . All the ingredients then are discharged into a chute which discharges into a truck. Meanwhile, water is either being weighed or volumetrically metered and discharged through the same charging chute into the mixer truck. These ingredients are then mixed for a minimum of 7. A Wet mix Concrete Plants, combines some or all of the above ingredients (including water) at a central location into a Concrete Mixer - that is, the concrete is mixed at a single point, and then simply agitated on the way to the jobsite to prevent setting (using agitors or ready mix trucks) or hauled to the jobsite in an open- bodied dump truck. Dry mix differ from Wet mix plants in that Wet Mix contain a central mixer whereas dry , which can offer a more consistent mixture in a shorter time (generally 5 minutes or less). Dry mix plants typically see more break strength standard deviation and variation from load to load because of inconsistencies in mix times, truck blade and drum conditions, traffic conditions, etc. With a Central Mix plant, all loads see the same mixing action and there is an initial quality control point when discharging from the central mixer. Certain plants combine both Dry and Wet characteristics for increased production or for seasonality. Different types of concrete batch plants types are available for a variety of applications. Mobile Concrete Batching Plant. Certain batch plant designs may be considered mobile, but not necessarily easy to setup and teardown. These categories typically differ in the ease of startup and teardown and the presence of portable features such as axles, brakes, and lights. Mobile batching plants are typically a single unit, made up of a cement silo, an aggregate bin, an aggregate conveyor and the cement and aggregate batchers, but at higher hourly production capacities may require numerous loads for a single plant. Typically, a mobile batching plant can be dismantled and reassembled in a few days time. As a result, they can be used at multiple construction sites to reduce transportation costs. Automation and control. With concrete performance so dependent on accurate water measurement, systems often use digital scales for cementitious materials and aggregates, and moisture probes to measure aggregate water content as it enters the aggregate batcher to automatically compensate for the mix design water/cement ratio target. Many producers find moisture probes work well only in sand, and with marginal results on larger sized aggregate. Concrete usage in superstructures like Burj Khalifa in Dubai have tested the limits to which a Control System can manufacture precision concrete. Dosing of Cement, Sand, Crushed Stone, Chemicals and Water in exactly the same proportion as the concrete recipe stipulates is the ultimate test of any control system. It is important that the Control System achieves the closest value to target weight. The fastest controls limit the number of jogs to maximize plant production rates. Variations in materials, weather and humidity, numerous mechanical points, and human input cause even the most accurate automation control to overweigh or underweigh material. Concrete Plant Manufacturers Bureau. According to the CPMB's website, . The absence of suitable dust collection and filter systems in cement silos or at the truck loading point is the major source of particulate matter emission in the air. The loading point is a large emission point for dust pollution, so many concrete producers utilize central dust collectors to contain this dust. Notably, many transit mix (dry loading) plants create significantly more dust pollution than central mix plants due to the nature of the batching process. A final source of concern for many municipalities is the presence of extensive water runoff and reuse for water spilled on a producer's sites.
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