What Are Concrete Batching Systems?
From the overall perspective, concrete batching systems dedicate the whole systems of concrete batching plants.
While, from the partly perspective, concrete batching systems refer to certain specific function systems of concrete batching plant.
Concrete batching systems here equals to the ready mix concrete batching systems, the concrete batching plants, also known as concrete batching machines, concrete mixing stations, concrete mixing plants, ready mix concrete batching plants, precast concrete batching plants , and so on.
Also, concrete batching systems here sometimes mean the function systems of a concrete batching plant, including aggregate conveyor system, aggregate weighing system, concrete mixing system, concrete batching computer system, etc..
What Is Concrete Batching?
To get high quality concrete products, the raw materials of concrete production should be measured and mixed precisely and evenly. The methods of accurate measuring and thorough mixing concrete ingredients are called concrete batching, which are the essential processes of making concrete products.
Related: Concrete Batching Plant Manufacturers
What Is The Purpose Of Concrete Batching System?
The purpose of a concrete batching system is to producing concrete for various construction demands with the approach of batching raw materials evenly, like coarse or fine stones, sand, cement, water, additive, according to different ingredients.
All these concrete products will be used in skyscrapers, buildings , houses, roads, bridges, tunnels, hydraulic engineering, etc.. Every concrete batch plant is a combined system, which assemble controlling, batching, weighing, mixing, conveying, storing, transporting systems in one and aim to every accurate recipe concrete product for every construction application.
Ready Mix Concrete Batching Systems
Ready mix concrete batching system is another name of ready mix concrete batching plant. It is used to product ready mix concrete for all sorts of construction projects, like rural or urban infrastructure, bridges and roads construction, railways and airports construction, energy facility, etc..
Ready mix concrete batching system is widely used in construction field, incessantly providing various ready mix concrete products for modern construction projects.
The same as ready mix concrete batching systems, there are also other types of concrete batching systems playing irreplacable roles in concrete producing for modern construction industry, such as small mobile concrete batching plants, mini concrete batching plants, dry concrete batching plant, central concrete batching plant, precast concrete batching plant and so on.
Just like you see, concrete batching systems are a big family. These members of the family have unique features and play their respective important roles in different construction engineering fields.
Concrete batching systems price ranges from $25,000 to $360,000, which mainly depended on the produce capacity.
The ready mix concrete batching systems with capacity below 60m3/h is called small/mini concrete batching plants.
The ones with capacity above 60m3/h and below 180m3/h are called middle concrete batching systems.
The ones with capacity above 180m3/h are large concrete batching systems.
A Small And Flexible Concrete Batching System-Portable Concrete batching plant
One of the most important features in the field of modern construction engineering is fast and high efficiency. As a part of it, the basic construction raw material supply industry should have such characteristics. Therefore, designers and engineers have introduced a large number of concrete preparation machinery into the market. Among them, a small and flexible concrete mixing system stands out as a shining star, which is the portable concrete mixing plant.
Normally, portable concrete mixing plants are small or medium concrete batching systems, whose production capacity ranges from 25m3/h (HZS25 concrete batch plant) to 60m3/h (HZS60 concrete batch plant). These units are designed compact in one, which ensures an easy installation, convenient dismantle, less labors, simple operation, etc.
In addition, for convenience of movement and transportation, some portable concrete mixing plants are designed rollers under the bottom of the main structure. These rollers are lifted during the processes of concrete producing.
Currently, the price of a portable concrete batching plant ranges from $25,000 to $100,000. The price varies according to the production capacity of the mixing plant, the place of origin, and the brand of the product.
This kind of small and flexible concrete mixing system is favored by more and more consumers because of its low price, less time cost, low financial and manpower consumption, and convenient mobile, disassembly and assembly design.
Luton Group has developed various types of concrete batching systems, to provide you with professional after-sales service. Welcome your consultation.
Build Portable Concrete Batch Plants With Concrete Batching Systems
How to build a concrete batching system? Take a portable batch plant as an example, the following aspects should be take into consideration:
A. Choose a location for portable concrete batching system
Choosing an appropriate location for your portable concrete batching system is a critical factor. This affects not just the construction progress, but also the quality and cost of the construction.
To reduce the construction cost and facilitate the project, the portable concrete batching plant should be situated in a location with reasonable traffic and with convenient entrance and exit passages.
The terrain is also important, as a high terrain is required under the premises of the construction area of a concrete plant.
Also consider the water content of the aggregate – whether it will affect the quality and productivity of the concrete. If the terrain is low, proper drainage facilities should be designed as it is easy to accumulate water.
Finally, make a proper analysis of the drainage capacity. This is required to avoid water accumulation, which may affect the output during heavy rains.
B. The configuration of portable concrete batching plant
It is important to consider the theoretical production of the concrete plant when purchasing a concrete mixer batching plant. Theoretical production should be higher than the anticipated production need.
For example, if projects’ required amount of concrete is 35 m3/h, then we should choose hzs50 concrete plant with a theoretical production of 50m³/hour instead of hzs35 concrete plant with 35m³/hour. Cause the theoretical yield is generally smaller than the actual production.
If you are not sure of which model of concrete plant to purchase, seek Luton’s professional guidance for your requirements. Our sales team will help you choose the right configuration and provide solutions to meet your demands.
C. The arrangement of staffs
Though the concrete mixing system uses a fully automated computer-controlling process, operators’ supervision is indispensable in this process. Therefore, we only need to recruit some experienced concrete plant operators.
LUTON concrete batching system is classified into standard concrete plant and small portable concrete plant. The former includes 6 models: hzs60, hzs75, hzs90, hzs120, hzs180, hzs240; the latter has 3 models: hzs25, hzs35 and hzs50. LUTON provides installation services in order to help customers’ batching plant yield products as soon as possible.
In addition, LUTON Machinery specializes in manufacturing construction machines and concrete mixing equipment over 20 years. In the past 20 years, LUTON has been committed to maximizing the benefits of its customers by producing quality products and designing suitable concrete and aggregate production solutions.
Main Components Of Concrete Batching Systems
Aggregate belt conveyor system
Aggregate feeders are the components that aggregates are loaded in the first step of the whole process. There are hoppers installed side by side for storing and feeding coarse aggregates and sand. The different number of hoppers will hold different size aggregates or sand. Then every size material will be weighed separately as every designed mix ratio.
Aggregate weighing system
Weighing conveyor is usually located below the aggregate feeders. It is suspended and hanging on load cells. It is to weigh aggregates one by one and then transfer them into the mixing unit. At the crucial point in mixer design, weighing systems are necessary. These devices are calibrated periodically to ensure the grade or quality of the output.
Batching plant conveyor belt
Batching plant conveyor belt is to carry the weighed aggregates to the mixing unit.
Cement weight scale
Cement weigh scale will hold the cement in small quantity that is transferred from the cement silo via a screw conveyor. Its task is to weigh the aggregates before dispatching into the mixing unit.
Water and additive weight scale
Water weigh scale gets water from water pump. It holds and weighs the water according every recipe set in the control panel and then add it into the mixing unit. Additive weigh scales are suspended on load cells and they will weigh the additive material then dispatch it and water together into the mixer.
Cement silo with batching plant screw conveyor
Cement silo is to store large volumes of cement that comes from bulk trucks. It is usually provided with safety accessories. A batching plant screw conveyor of suitable diameter and length is at the bottom enabling transferring cement into the cement weigh hopper. Some small capacity plants are installed with a cement hopper, whose opening is big for facilitating adding cement from bags. Cement hoppers are also provided with screw conveyor for transfer of cement into the weigh hopper.
Concrete mixing system
The most crucial central and heart of a ready mix concrete batching system, where all the weighed ingredients are batched thoroughly in a set time, then discharged into the transit mixer or a concrete pump.
Related: Twin Shaft Mixer Batching Plant
Air compressor is another important component. It is used to control all the pneumatic operations of the ready mix concrete batching plant such as 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 mixer gate, etc.
Concrete batching computer systems
High quality concrete production requires precise control. A full range of control systems customize your unique needs. Excellent control Systems offer data processing, quality control, production management, precise automatic dispensing, and products temperature controlling. Additional benefits include remote connectivity and operating as well as constant data collection and reporting for quality assurance and inventory control. More actual details as below:
- Monitors material fill and automatically adjusts
- High-Low Bin content indicators
- Integrated Programmable Logic Controller (PLC) provides tighter control of all plant functions
- Easily integrate custom batching equipment accessories
- Material distribution
- Water reclamation
- Silo monitoring
- Moisture monitoring
- Operate plant over a network or by modem
- Monitor production remotely
- Easy to learn and use
- Seamless Integration of systems
Concrete Batching Systems Process
Working process of concrete batching systems is dependent on 7 primary function:
1.Control value setting
Control system is very critical for any advanced machine. It makes operation fast and accurate. Before the whole system running, all demanding value customized should be input the computer calculating process, which will operate the components working accurately and cooperatively as preset demands.
Raw materials have to be fed into the individual feeding system.Ready mixing concrete batching system process starts from feeding aggregates into hoppers.
3.Storing and conveying
Storage and conveyance here refer to storage of cement, fly ash, etc.They have to be hold up quantity in bulk and transfer by screw conveyors to the weighing hoppers.
Powders as cement, fly ash and additives are added for binding of materials.These aggregates will be weighed individually as every design set in the control system. Cement, water and additive are transferred into the mixer unit after weighing them separately in the weighing hopper above the main mixer unit. Cement is transferred to the weighing hopper by screw conveyor.
Specific quantity of water is essential to any ready mix concrete, which will help cement bind evenly with aggregates. Water is pumped up into the weigh hopper.
After weighing the mixture will be transited into the main mixer unit and mixed and batched in the mixing unit.
For a specific time as set in the control unit, the products will be discharged into a transit mixer or a concrete pump.
All the above steps are carried out systematically. Each step is carried out for a specific time frame. The time frame starting from the weighing of aggregates to the discharge of the ready mix material is known as a batch time which is set into the computer beforehand.
Role Of Concrete Batching System In The Construction Industry
To meet customer expectations, the construction process keeps on modifying itself every year. Clients want the project to be completed before time. It is time-consuming to prepare ready mix concrete on the construction site.
Using a concrete batching system for your project can help you eliminate your construction cost. Each load of concrete is produced on-site or out-site and the production and delivery can be achieved in minutes when using a concrete batching system.
Batching machinery also help you adjust your concrete production as per requirement and thus make the most out of it.
There are several benefits that concrete batching plants have to offer to construction workers:
- The compact structure in the tailor hanging unit is focused on the concrete production process.
- The concrete batching system occupies small space, which is beneficial to the transfer movement.
- Concrete batching systems can be controlled both manually and automatically, which makes the operation straightforward and easy.
- The manual machine interface is easy to understand and has reliable work execution.
- The industrial computer framework can be controlled manually and automatically. As a result, operation is straightforward and easy.
- The capacity of the mixing system.
- The capacity of the mixing system is measured in cubic meters of concrete per hour. The capacity is dependent on various factors like size of mixer and number of mixers.
- Charging time
- Mixing time
- Discharge time
Also Read: RMC Plant Cost
LUTON Concrete Batching Systems
Ready mixed concrete batching systems are basically classified into three types based on the quantity of concrete production per hour,
- From less than 30 cu.m/hour
- From 30 to 60 cu.m/hour
- More than 60 cu.m/hour
LUTON from China provide all types of concrete mixing systems that are suitable for RMC, infrastructure, roads, rural, and metro applications. Each concrete batching equipment can be customized to your specific requirements by Luton’s advanced concrete batching plant controlling systems.
If you have any requirement, get in touch with us to assist you in finding the perfect batching plant.
LUTON is one of the most popular concrete batching system manufacturers, whose products are well known all over the world, focusing on developing, manufacturing and servicing concrete mixing plants, also providing integrated solutions for customers to build up their suitable plants.
LUTON manufactures a wide range of products, such as – stationary concrete batching systems, mobile (or portable) concrete batching plant, belt concrete batching plant, hopper concrete batching plant, dry concrete mix plant, wet concrete mix plant, etc.
Luton has an iron grip in the construction industry because of its advanced and accurate technology design and high quality of ready mix concrete batching plants. Luton is fully approved by customers for its –
- High quality materials
- Long component life
- Tailor-made service
- High productivity
- Comprehensive after-sales maintenance
- 20+ years industrial experience with pioneering design
- 18000+ plants manufactured and sold
All the above points place Luton Group in the leading position in the concrete equipment manufacturing industry.
Our components are reliable and of standardized construction, adaptable to various applications, either in a small project or in a large project.
Our fully-automatic design extends the life and service of equipment and reduces the operating cost.
If you would like to know more about concrete batching systems, our company and our other products, do not hesitate to contact us. We will provide you with our best possible information and help you achieve more outstanding performance than you expect.
Call us for more details.
Also Read: Self Loading Concrete Mixer
Technical Parameters Of Skip Hopper Type Concrete Batching System
|Mixing system||Twin-shaft concrete mixer|
|Aggregate feeder||Bucket (Skip hopper)|
|After-sale service||Erection & commissioning, operator training|
|Warranty||12 months after erection|
|Max. mixing size||80/60mm||80/60mm||80/60mm||80/60mm|
|Aggregate batching machine||PLD800||PLD1200||PLD1600||PLD2400|
|Storage bins quantity||2 or 3 or 4 sorts||3 or 4 sorts||3 or 4 sorts||3 or 4 sorts|
|Aggregate scale hopper||800L||1200L||1600L||2400L|
Technical Parameters Of Belt Type Concrete Batching System
|Mixing system||Twin-shaft concrete mixer|
|After-sale service||Erection & commissioning, operator training|
|Warranty||12 months after erection|
|Max. mixing size||100/80mm||100/80mm||100/80mm||120/80mm|
|Aggregate batching machine||PLD1600||PLD2400||PLD3200||PLD4800|
|Storage bins quantity||2 or 3 or 4 sorts||3 or 4 sorts||3 or 4 or 5 or 6 sorts||3 or 4 or 5 or 6 sorts|
|Aggregate feeding to mixer by||Belt conveyor|
Different Types Of Concrete Batching Systems For Sale
|Types (60m3/h)||Price Range||Suitability||Advantages|
|Stationary plant||$30,000-$180,000||Large scale projects
Long term supply
|Mobile plant||$40,000-$200,000||Small/medium size projects
Steady products quality
|Wet plant||$30,000-$180,000||Large scale
Long term supply
Steady products quality
|Dry plant||$25,000-$150,000||Long-distance site||Efficient, rapid, economical|
|Belt plant||$30,000-$180,000||Large scale projects
|Accurate, efficient, steady|
|Hopper plant||$30,000-$180,000||Small/medium size projects
Low maintain cost