Stationary concrete batching plant is fixed on a foundation. They consist of double shaft mixers that are designed to work at high efficiency, capability, and reliability. They are used for large-scale concrete production that requires high-quality concrete. Stationary concrete mixing production equipment is built to offer maximum production capacity and to work long hours. It is highly flexible and can be used for different projects - especially for massive infrastructure and precast concrete projects. The production capacity of stationary Ready mix concrete batching plant is larger than the mobile plant.
Advantages of Stationary Concrete Batching Plant
Efficiency. These plants are designed to mix and produce concrete quickly and efficiently, which means that construction projects can be completed in a shorter amount of time. This can help to save both time and money on a project, as well as help to keep the project on schedule.
Cost-effectiveness. These plants are designed to produce large quantities of concrete at a lower cost than traditional methods, which can help to save money on a construction project. Additionally, since a concrete batching plant can produce concrete on demand, it eliminates the need to purchase pre-made concrete, which can be expensive.
Easy to operate and maintain. These plants are designed to be user-friendly and easy to use, which means that even those with little experience can operate them. Additionally, most concrete batching plants are designed to be low-maintenance, which means that they require minimal upkeep and can be used for a long time without any significant problems.
Versatile. It can be used to mix various types of concrete with different strengths and properties, making it a great option for construction sites that require different types of concrete. This allows for the production of specialized concrete for different projects, such as high-strength concrete for bridge construction, or self-compacting concrete for the construction of high-rise buildings.
Flexibility. These plants can be easily moved from one location to another, which means that they can be used for multiple projects in different locations. This makes them a great option for construction companies that work on a variety of different projects.
Meet specific requirements. For example, some plants can be equipped with special features such as color mixers or high-pressure pumps to produce specialized types of concrete.
Quality. By using precise measurements and computer-controlled systems, these plants can produce concrete that is more consistent in terms of strength, color, and other properties. This can help to ensure that the final product meets all relevant standards and requirements.
Why Choose US
Our History
Our CO-NELE is professional and large manufacturer since 1993, located in Qingdao, a beautiful coastal city. We have obtained more than 100 national technology patents and supplied more than 10,000 mixers and batching plants for customers both home and abroad. We are the most comprehensive professional mixing company in China.
Our Products
Twin shaft mixer, double screw belt mixer, dry mortar mixer, laboratory mixer, asphalt mixer, continuous mixer, concrete batching plant, dry mortar mixing plant, fly ash solidification mixing plant and other series of equipments.
Production Equipment
Austrian IGM welding robot, PENTALASER 12000W laser cutting equipment, Japan FANUC welding robot, CNC vertical lathe, Fully automatic shot blasting and paint baking room, Digital workshop
Our Market
Our mixers and batching plants sales volume is No. 1 in China. We export to more than 80 countries like Germany, America, England, Indonesia, Thailand, Vietnam, Russia, Belarus, Brazil, South Africa, Algeria, Nigeria, Australia, UAE, Saudi Arabia, etc.
Concrete Batching Plant Process Flow
The working of a stationary concrete batching plant is similar to that of a mobile plant. Atlas stationary concrete batch plants process starts from feeding of the aggregates into the feeder bins. It ends when the ready mix concrete is discharged from the mixing unit.
The working principle is dependent on 5 main functions like below:
Aggregate feeding: It means that aggregates and sand have to be fed to the feeding unit.
Binder feeding: Binder refers to cement, fly ash, additives materials that will help to bond the material.
Water feeding: Water is important component. A fixed quantity of water as per the recipe will help bind the ready mix material.
Storage: Storage here refers to the storage of cement, fly ash, etc. These materials are stored in different storage compartments. They are weighed into weighing hoppers and then added into mixing unit.
Controls: Plant control panel is important component and it is responsible for controlling the working of the plant.
First the aggregates are fed into the feeder bins as per their sizes. They are weighed one by one by a weighing conveyor which is suspended on load cells. This weighing conveyor is just below the feeder bins. As soon as the weighing is done the aggregates are transferred to the mixing unit.
On top of the mixing unit we have weighing hoppers for cement, water and additives. These weighing units will weigh respective items prior to discharging the same into the mixing unit. Once inside the mixing units all the items will be mixed uniformly for fixed duration. Water is transferred to the weigh hopper by water pump. Cement is transferred to the weigh hopper by screw conveyor.
A PLC type control panel is used to input recipes, set mixing time and adjust other important parameters.
Components of concrete batch mix plant
A concrete batch mix plant has a number of parts and accessories that combine and work together to produce quality concrete. Some of the major components are as below:
Feeding unit is one of the important component. There are bins located side by side to facilitate feeding of coarse aggregates and sand. The different number of bins are there which will hold different sized aggregates / sand into different compartment. The reason behind putting each material (size wise) into separate bins is that each material will be weighed separately as per designated mix ratio.
Weigh conveyor usually sits below the aggregate feeders. It is suspended and hanging on load cells. It is to weigh aggregates one by one and then transfer the same to charging conveyor of skip. Aggregates are discharged to the weigh conveyor by opening and closing of pneumatic cylinders.
Charging conveyor or a skip is to carry the weighed aggregates to the mixing unit.
Cement weigh scale will hold the cement in small quantity that is transferred from the cement silo / hopper via a screw conveyor. Its task is to weigh the aggregates prior to dispatch into the mixing unit.
Water weigh scale receives water from water pump. It will hold water and weigh the water as per the recipe set in the control panel and then add the same into the mixing unit.
Additive weigh scales are suspended on load cells and they will weigh the additive material prior to dispatch into the mixer.
Cement silo is to hold large volumes of cement that comes in bulk trucks. It is usually provided with safety accessories. A screw conveyor of suitable diameter and length is at the bottom enabling transfer of cement into the cement weigh hopper. Many small capacity of batching plant machines are equipped with a cement hopper. The opening of the hopper is big and it facilitates adding of cement that comes in bags. Bags have to be placed on top of the hopper and once they are torn, cement will fall into the hopper. Cement hoppers are also provided with screw conveyor for transfer of cement into the weigh hopper. Usually a weigh hopper has 2 openings on top for inlet of 2 screw conveyors.
Mixing unit - this is the most critical part and heart of the concrete batch mixing plant. The job of the mixer is to receive all the ingredients and mix them thoroughly for a fixed time. Then it will discharge the contents into a transit mixer or a concrete pump.
Air compressor is one of the important components here. It is used to control all the pneumatic operations of the concrete batch mixer like opening and closing of cylinders that control the feeder gates, opening and closing of butterfly valves fitted with weigh hoppers, opening and closing of the mixing unit gate, etc.
Control panel will control the working of the machine. Latest machines are equipped with plc panel for ease of usage. It is also possible to save and print mix material recipes in the latest equipment. Control panel assist in fast and accurate measurements of the ingredients. With growing demand for high quality and accurate concrete it becomes important to produce quality material without any wastage. This is where control panel helps to control all components of the batching plant.
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.
Service and Maintenance of Concrete Batching Plant
Concrete batching plants entails regular maintenance. Maintenance is critical to extend the operating life of the plant, improve production quality and performance, and prevent failures. Components of a concrete batching plant may wear out or be damaged over time as it operates under heavy workloads. Therefore, regular maintenance will allow the plant to have fewer breakdowns, create fewer maintenance costs and keep it running smoothly for longer. In concrete batching plants, maintenance work may include the following:
Cleaning
Regular cleaning of the concrete plant is important. Soil, sand, and other materials may accumulate on the components and equipment of the batching plant, and these may reduce the performance of the batching plant.
Lubrication
Lubrication of concrete batching plant components reduces friction and prevents failures. Lubrication is especially important for the moving parts and hydraulic systems of the concrete batching plant.
Checks
Regular checking of the control systems of the concrete batching plant and making the necessary adjustments ensures the correct operation of the plant. Checks also ensure that measurements are performed correctly, and that concrete quality is checked.
Replacement of components
Components of a concrete batching plant wear out over time and can be damaged. Therefore, regular replacement of damaged or worn parts is important to improve the efficiency and performance of the batching plant. Regular maintenance extends the useful life of the concrete batching plant and ensures the production of high-quality concrete.
The topography of the land is very important when choosing the site for installing a stationary concrete batching plant. If the location is flat, it can reduce the cost of leveling the site. As far as possible, best available natural conditions should be utilized for reducing the cost.
The availability of good transportation facilities should be considered. The road width, height restriction, and capacity of the road to avoid frequent traffic jams play a critical role in the smooth transportation of the produced concrete to the construction site.
The site location should be as close as possible to local power and water resources.
The location for installation should be selected with sufficient area to meet the needs for current and future development. There should be sufficient area to stack raw materials. Pollution and other issues should also be considered and the location should be situated far away from residential areas.
The site location should be close to the point of sale of the produced concrete. It is preferable that the site be close to the quarry and sand factory. The service radius should ideally be between 50 to 100 kilometers as the cost of transportation directly affects the price and profit of the company.
The Environmental Requirements for Stationary Concrete Batching Plant
The environmental requirements on the working ground.
For the use of non-dusting hard ground in the work site require that the surface of the roads in the stationary concrete batching plant area and the production work area be hardened with concrete or asphalt concrete, and measures should be taken to keep it clean. No dust can be seen when the vehicle is running. Unhardened space should be greened. Some concrete mixing stations had poor site environment in the previous work site, which often brought a lot of dust pollution. Now unified use of non-dusting ground is required. It is necessary to set up a cycle route in the plant area, and set up signs such as guidance, warning and positioning. Car wash stations should also be built in the factory area, which can effectively reduce environmental pollution.
The environmental requirements on the concrete mixing equipment.
During the production process, high efficiency and dustproof devices must be installed on the stationary concrete batching plant. The production, transportation, pumping and test equipment of the ready mix concrete plant should use low-noise, low energy consumption, low emission and other technologically advanced products with superior quality. The process in the agitation production process must be more scientific, such as the dustproof device should be equipped in feeding, mixing and stirring to achieve high-efficiency dust removal, and to achieve the requirements for reducing the noise and dust emission indicators.
The environmental requirements on the other parts.
At present, there is standardized green stationary concrete batching plant in the market. Compared with the traditional mixing plant, the material yard is closed, and the main production building looks more like a factory workshop. Dust collection system is also provided to achieve zero discharge of waste water, waste material and waste pulp.
FAQ
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