What is a Wet Concrete Batching Plant?
A wet concrete batching plant is one of the most common concrete mixing plants. It is also known as a central ready mix concrete batch plant because the wet mixing production method is widely utilized in large central concrete mixing plants, commercial concrete mixing plants and private project usage sites.
In the wet concrete batching plant, all the raw materials are weighed and put into the mixing host. The central mixer mixes the coarse stone, fine stone, sand, cement, water, and additives to produce the final concrete of various preset composition rations. The finished product is then loaded into trucks and transported to the construction site.
Wet mixing plants are more sophisticated than dry mixing plants as they are able to meet the production requirements of various concrete products based on the various raw materials that are weighed and fed into the main mixing machine.
In wet mixing plants, the concrete is produced in the central plant and then transported to the construction site. Therefore, during transportation, the mixer truck or tank needs to be rotated continuously at a suitable speed to prevent the concrete from solidifying. Generally, the longest transportation time is about 4 hours.
The main components of a wet concrete batch plant include – raw material batching system, conveying system, weighing system, the main mixing system, raw material storage system, dust removal system, pneumatic system, etc.
Also Read: Dry Mixing Plants
Types of Wet Mix Concrete Plants
Wet concrete mixing plants are generally classified into two types: fixed stations and mobile (portable) stations.
Compared to fixed mixing stations, mobile concrete mixing plants are easy to install and can be transferred from one project site to another, and offer more flexibility.
Further, according to the feeding method, they can also be divided into hopper concrete mixing plants and belt concrete mixing plants. But regardless of the types of wet mixing plants, they all can be selected based on the different production capacities and according to the needs and requirements of individual customers.
Comparison Between Dry Mix Concrete Plant and Wet Batch Concrete Plant
Similarities between dry and wet batch concrete plant
- For both the dry concrete station and the wet concrete station, the composition is the same. Both the concrete plants are composed of a principle batching system, weighing system, host mixing system, central control system, cement storage system and dust removal system.
- Both the wet and dry concrete mix plants have two modes of control – automatic and semi-automatic, and the degree of full automation can be designed and realized according to the requirements of the customer.
- Safety systems and environmental protection have been integrated into the design and manufacturing of the wet and dry types of concrete stations.
Differences between dry and wet batch concrete plant
From the names of the two, we can understand that the biggest difference between the dry mixing installation and the wet mixing installation is ‘whether water is added in the mixing plant or during transit’.
The dry mix plant usually sees more break strength standard deviation and variations from load to load due to inconsistent mixing. Therefore, in the end, we got two different products from the wet concrete and dry concrete stations.
1. The different state and storage time
Since wet concrete is a complete mixture of all the raw materials including water, it can be directly used at the construction site before it is condensed. The concrete should not be stored for more than 24 hours.
However, dry concrete is a uniform mixture of dry raw materials and is supplied to users in bulk or in bags in a dry state. Before putting it to use, water or additives need to be added to the dry concrete and mixed evenly at the site. Being dry mortar, they usually have a storage period of 3 to 6 months.
2. Difference in production machinery
We can consider the wet concrete batching plant as a special dry concrete mixing plant. In simple terms, the wet mixing plant is just a dry mixing plant with a mixing host system (mixing machine). Whereas, the dry plant does not comprise a mixing machine.
3. Difference in sand treatment
During the production process, wet concrete does not require dry sand while dry concrete does. However, the grade of sand that is required is more scientific and precise. This determines the product quality and performance of the wet concrete mixing plant is more sophisticated than wet mixing plants.
4. Difference in transportation
In the dry mixing station, since water is not added to the dry aggregates at the plant, they need to be mixed with water additives in the mixing truck during transportation or after arriving at the project site.
As for the products of the wet concrete batching plant, all the ingredients are already weighed accurately in proportion and evenly mixed before it leaves the factory. The produced concrete can be directly put into use after being transported to the project site within the specified time.
However, it should be noted that during transportation, the concrete in the mixer or truck should be rotated at an appropriate speed to prevent the concrete from solidifying.
Also Read: Twin Shaft Mixer
Advantages of Wet Concrete Batching Plants
Equipped with a powerful concrete mixer, the wet concrete batching plant can perform uniform mixing of concrete and can produce different kinds of concrete for satisfying the requirements of different construction projects.
Wet RMC plants are environment friendly as it is equipped with a dust elimination system and waste material treatment system.
There is a wide range of wet batching plant models available that are suitable for medium and large construction projects such as high-speed rail, dock, airport, etc.
The wet concrete batching plant has a relatively straightforward working mechanism, which enables the requirements of various users to be met with just one wet concrete mixing plant.
It is capable of continuously producing concrete products of various standards, which makes it efficient. Builders can save a lot of production time if they install a wet RMC plant in the project site. The emergence of RMC plant has contributed to the modern engineering construction industry being fast and efficient.
2. High measurement accuracy
In modern engineering, the measurement accuracy requirements of concrete mixing plants have become higher with the demand for more improved concrete quality. The wet concrete batching plant has separate measurement systems specially for aggregate weighing, powder, and liquid weighing.
The measurement processes utilized are also real-time and with the use of high-precision sensors and control systems, they can detect and adjust aggregate measurements. This helps to realize the accuracy and stability of both separate measurement and cumulative measurement of wet concrete batching plants.
3. Perfect mixing quality
Wet concrete mixing plants are equipped with a twin shaft mixer. The twin mixers are perfect for mixing the materials through extrusion, shearing, and flowing. This allows the materials to be fully impacted and squeezed.
During the process of mixing, the blades of the mixing shaft flip up and down. This drives the material in the mixing chamber to tumble and stir, interlacing each other in the collision.
On the other hand, the movement of the shaft pushes the material along the direction of the rotating shaft, keeping it moving and stirring continuously from one rotating plane to another rotating plane.
4. High degree of automation
The wet concrete batching plant is equipped with mixing control equipment and industrial computers. The control device data is first fed into the industrial computer and the execution signal is displayed through the panel or PLY program controller, thereby ensuring continuous normal operation.
Cameras for monitoring can be set in key parts, such as the discharge port and the mixing host. This helps detect problem that occurs in a certain part and resolve them in a short span of time.
5. Design of broken arch
The bottom of the cement silo is designed like a broken arch to effectively avoid the accumulation and blockage of powder and to increase the production efficiency of concrete.
6. The dust elimination system
The mixture of various aggregates such as cement, sand, fly ash creates a lot of dust and pollution. The dust removal system is required to reduce the dust pollution that is generated during the work of the concrete station.
The suspended particles in the cement bin can be effectively absorbed by the dust removal equipment installed on the top of the cement bin. Today, dust removal systems are an absolute necessity to reduce the pollution to the surrounding environment.
7. The waste water system
The waste water treatment system is another important factor from the environment point of view. Reasonable waste water treatment is needed to protect the environment and at the same time develop the economy in a healthy way.
Therefore, when designing the wet concrete batching plant, it is equipped with a waste water treatment system to treat the contaminated water before releasing it to the drainage system.
Also Read: HZS60 Concrete Batching Plant
Technical Parameters Of Wet Concrete Batching Plants
|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|
|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|
Wet Mixing Concrete Batching Plants for sale
The cost of a wet concrete batching plant can range from $5,000 to $500,000, depending on various factors such as – type of batching plant, production capacity, additional features of the equipment, and other factors.
One of the foremost factors affecting the price of the plant is – whether it is a stationary concrete batching plant or a mobile (portable) concrete batching plant.
While considering the cost of a batching plant as a whole, the price of the equipment is not the final cost. There are other costs that have to be considered while making a cost calculation such as – the cost of freight, insurance and installation cost, water and electricity cost, labor cost, maintenance cost, and so on to arrive at the final cost.
Wet concrete plants for sale provided by the Luton Group meet the well-defined parameters of quality such as – Strength, Capacity, and Functionality. Our team of excellent professionals is involved in meeting the demands of our valuable clients. There are several series of plants for sale that are only sold at producer’s price, including:
- LUTON Mini concrete batching plant for sale
- LUTON small concrete batch plant for sale
- LUTON Mobile concrete batching plant for sale
- LUTON stationary concrete batching plant for sale
- LUTON dry concrete batching plant for sale
- LUTON wet concrete batching plant for sale
- LUTON belt concrete batching plant for sale
- LUTON hopper concrete batching plant for sale
If you have any requirement, contact us for more details. LUTON provides a wide range of choices to meet your construction demands.
Also Read: HZS90 Concrete Batching Plant
Top 5 Famous Wet Mix Concrete Batch Plant Manufacturers in China
SANY is a construction machinery and equipment manufacturer, which was founded in 1989. It is the fifth-largest engineering machinery manufacturer in the world.
Some of the products manufactured by SANY are:
- Concrete mixing equipment
- Excavating machinery
- Hoisting machinery
- Road construction machinery
- Coal machinery
The Luton Group established in 1999, specializes in research and development and manufacturing in the construction field.
Luton Group is one of the most popular manufacturers in the field of construction products globally with a focus on construction equipment.
The products are popular not only for their perfect control character, accurate proportioning, remarkable products characteristics but also for the development trend of their construction equipment.
Some of the most popular products manufactured by the Luton Group are:
- Concrete mixing plant
- Stabilized soil batching station
- Asphalt mixing plant
- Precast concrete batch station
- Belt conveyor
- Aggregate mixer
- Concrete pump
- Self-loading mixer
- Dry mix motor plant
- Crushing plant
The future of Luton Group seems bright as it is expected to lead a dramatic change in the concrete manufacturing industry with the quality of products and new development trends in the construction industry.
Xuzhou Construction Machinery Group Co., Ltd. (XCMG Group) was founded in 1943 and engages in researching and manufacturing various construction machinery including:
- Hoisting machinery
- Mining machinery
- Road machinery
- Piling machinery
- Concrete machinery
- Tunnel machinery
Fujian south highway machinery co., Ltd, also known as NFLG, was founded in 1997. NFLG is an enterprise engaged in the field of equipment manufacturing.
Some of the machinery manufactured by NFLG are:
Construction material mixing machinery
A concrete batching station is one small branch of all businesses.
ZOOMLION founded in 1992 is a construction machinery and agricultural machinery manufacturer, with one of its first products being concrete pumps.
They are a continuously innovating enterprise that designs and produces infrastructure machinery and equipment that cater to:
- Project construction
- Energy engineering
- Environment engineering
- Transportation engineering
Top 5 Famous Wet Concrete Plant Manufacturers around the World
Liebherr is a German-Swiss-based multinational equipment manufacturer based in Bulle, Switzerland although its main production facilities and origin are in Germany. They are involved in the manufacture of products and services for the construction and mining sector.
The products range of the company includes:
- Refrigeration and freezing equipment
- Mining equipment
- Material handling equipment
- Concrete machinery
- Aerospace and transportation system
The cement mixing plant is one small branch of its business.
Putzmeister, with its base in Germany, is a global leader in the manufacture of construction and mining machinery since 1958. Putzmeister constantly creates innovative machinery for pumping, distributing, placing, storing, transporting construction materials including concrete, high-density soil and mortar, and so on.
MEKA has been a concrete machinery supplier for over 30 years since its founding in 1987. It manufactures different types of concrete plants, road concrete solutions, ready concrete batching plants, and precast applications with recycling systems and fiber dosing equipment.
KYC Machine Industry Co.
KYC Machine Industry, founded in 1950, has not failed to provide products and services in the construction machinery industry. The products of this manufacturer ranges from – concrete plant, mixer, scaffolding, and conveyor system to environment equipment.
Schwing is a German-based company with worldwide manufacturing facilities in Austria, Brazil, the USA, and India.
They offer an entire spectrum of ready-mix concrete technology, which includes:
- Covered truck-mounted concrete pump
- Truck mixer
- Truck mixer pump
- Concrete mix plant
- Concrete recycling plant
- Cleaning system for mixer
- Environment and industry pump system
Factors to Consider When Purchasing a Satisfying Wet Mix Concrete Plant
While choosing a wet concrete batching plant, it requires careful consideration of various aspects such as – weighing pros and cons, looking into the financial matters, and so on.
So, what are the decisions that one should consider before buying a concrete mixing plant? Let’s have a look.
1. Construction environment, batching plant capacity, and other related factors
When purchasing a concrete mixing station, the construction environment is the primary factor to be considered. Some questions that need to be answered are:
- What would be the size of the construction site?
- Accordingly, what should be the size of the equipment?
- What is the anticipated quantity of concrete required for the project?
- Will you primarily be making concrete batching plant in full range capacities?
- In terms of traffic, how busy is the area near the construction site?
- What is the distance between the conveying vehicle and the construction site?
2. Reliability of the equipment
The quality of the concrete produced is dependent on the reliability of the equipment. The following aspects need to be considered to understand the reliability of the equipment:
- Check the various features of the equipment
- Inspect the control system of the equipment
- Check the customization options
- Evaluate the parameters of the product to ensure that they meet your specifications and requirements
3. Conduct cost analysis of the batching plant
With the wide range of concrete mixing plants available in the market, it is advisable to make a systematic budget and cost analysis, including the following aspects:
- Transportation costs
- Installation costs
- Site preparation costs
- Electrical and plumbing costs
- Tax amount, if any
4. Performance/Cost Ratio
When considering the financial aspects, it is unwise to focus on just the price of the mixing plant. A complete cost analysis needs to be conducted to come to a proper understanding of the cost-effectiveness of the plant. A right balance between the technical performance of the equipment and the o financial implication should be considered to figure out which concrete mixing plant can bring you more revenue and less cost.
5. Selection of the main machine
While selecting the main mixer of a concrete mixing plant, you need to make careful and repeated examinations. One needs to pay attention to the following points:
- Reliability of the concrete mixer
- Ability to produce good quality concrete
- Strong overload capacity
- High production efficiency
- Adaptability to the mix various commodities
6. Look out for aggregate options
It is important to figure out the different types of aggregates and the sizes that you can obtain. This will help determine the number of batching hoppers required in the mixing station. That is why it is an important factor to be considered when purchasing a concrete mixing plant.
7. Look for the manufacturers
Choosing a reliable and well-known manufacturer of your equipment is also an important factor. Some points to be considered are:
- The technology used
- Quality of materials used to build and assemble the equipment
- The efficiency and review of the after-sales services provided by the manufacturer
- Does the manufacturer provide training on the safe and efficient handling of the equipment and regular maintenance and upkeeping of the concrete plant?
While choosing a concrete mixing station, it is important to search for the best combination of quality and price, i.e., there should be a right balance been the price and quality. To get the optimum result, the equipment should be of the superior quality and at an affordable price.
Do not hesitate to contact LUTON in case you have any questions regarding our concrete plants. Reach out to our experts who will assist you in making the right choice.
How Does A Wet Mix Concrete Plant Work?
The working process of wet mix concrete plant can be divided into six steps:
1. Controlling value input
When starting the control system of the wet mix plant, it displays the operation interface on the operation screen and the system program will start to initialize the program, including
- The value of the formula
- The attenuation of the cement
- The grade of the concrete
- The production efficiency
2. Raw material storing
Cement, water, and additives are stored separately in cement silos, water storage silos, and additive silos. Other aggregates (including coarse stone, fine stone and sand blasting, etc.) are stored temporarily in the batching silos. Of all the silos, the cement silo storage system is additionally equipped with an air pressure safety detection system, an alarm system, and a dust collection system.
3. Raw material feeding and weighing
In producing concrete, there are three types of raw materials required: aggregate (including coarse stone, fine stone, sand, etc.), powder (including cement, fly ash, etc.), and liquid (water, additives, etc. All these raw material types are supplied with individual feeding systems.
Before the raw materials are transported to the main mixer, each raw material is accurately weighed and measured. Each weighing system is equipped with tension or pressure sensors and a control system.
The control system is capable of compensating and controlling some of the raw materials lost during the transmission process through a certain algorithm. This further ensures the accuracy of the raw material ratio.
4. Raw material conveying
Trucks transport the aggregates in the raw materials to the production site. After being temporarily stored in the aggregate hopper, they are sent to the main mixer. The water is supplied to the main mixer using a pump, where it is mixed with additives and other materials, and then sent back to the main mixer. Water and additives are transported by pumping, the transportation of aggregate is performed by bucket elevator or belt elevator, and the transportation of cement is performed by screw conveyor.
5. Raw material mixing
Mixing is the most important process of the entire wet concrete mixing plant. All raw materials are weighed individually and transported to the main mixer. The mixing unit generally consists of a single or twin horizontal mixing shafts and blades or star-shaped vertical shafts. These shafts are powerfully driven by the power of the motor. It mixes the raw materials thoroughly and evenly by rotating and rolling, and finally forming a concrete product that meets the concrete standards.
6. Product unloading
The finished concrete is finally discharged from the discharge port located under the main mixer, loaded into a transport truck, and quickly transported to the construction project site. This process needs special attention because the concrete product should be transported to the place of use within 30-40 minutes for direct use. Usually, a mobile concrete mixer can be used to complete the transportation.
Components of Wet Mix Concrete Batching Plant
The main components of a wet mix concrete mixing station are:
The feeder unit is one of the most important components of the concrete mixing station. These are feeder hoppers built side-by-side for storing and feeding coarse aggregates and sand.
The different hoppers bins are made to hold aggregates of different sizes or sand into each individual compartment. The purpose of storing each material (size-wise) into separate bins is so that each material can be weighed separately as per desired mix ratio.
Aggregate weighing conveyor
The weigh conveyor is generally located below the aggregate feeder. The purpose of the weighing conveyor is to weigh the aggregates one by one and then transfer them into the mixing unit.
This is suspended and hung on load cells. Weighing systems are crucial and an essential part of the mixer design. They are periodically calibrated to ensure the quality and grade of the concrete produced.
The function of the charging conveyor or skip is to carry the weighed aggregates to the mixing unit.
Cement weigh scale
The cement weigh scale weighs cement from the cement silo in the required quantity which is then transferred to the mixing unit via a screw conveyor. This is to weigh the cement before dispatching it into the mixing unit.
Water and additive weigh scale
The water weigh scale gets water from the water pump, which holds and weighs the water according to the recipe preset in the control panel. The weighed water is then transferred into the mixing unit.
Additive weigh scales are suspended on load cells. They are meant to weigh the additive material and dispatch it into the mixer.
Cement silo/hopper with screw conveyor
A cement silo is to store large volumes of cement brought by the bulk trucks. The silo is usually provided with safety accessories. A screw conveyor placed at the bottom of the cement silo, of suitable diameter and length, is provided to enable the transfer of cement into the cement weigh hopper.
Some small capacity plants are installed with a cement hopper, whose opening is big for enabling adding cement from bags. Screw conveyors are provided to transfer cement from the cement hoppers into the weigh hopper.
The main mixer is the most crucial central part and heart of the concrete batch plant. This is where all the weighed ingredients are batched/mixed thoroughly for a fixed time. The concrete produced is then discharged into the transit mixer or a concrete pump.
Another important component of the wet concrete batching plant is a compressor. All the pneumatic operations of the RMC plant are controlled using a compressor. Some of the operations are –
- Opening and closing of cylinders – control the feeder gates
- Opening and closing of the mixer gate
- Opening and closing of butterfly valves fitted with weigh hoppers
The control panel helps control the working of the machine. Modern machines are equipped with a PLY panel for ease of use. The print mix material recipes can be saved in the PLY control panel.
Fast and accurate measurements of the ingredients required for batching can be achieved by the control system. The growing demand for high-quality and accurate concrete makes it important to produce the right quality concrete efficiently without wastage. The control systems process and devices are designed to achieve more accurate measurements continually.
Concrete Batching Plant Mixing Time
Wet Concrete batching plant mixing time refers to the time taken by the mixer in a concrete batching plant to mix all the concrete mixture together. In general, the mixing time of a concrete batching plant is about 60 seconds. In the automatic control system, the mixing time can be modified according to actual production needs.
The total time for mixing concrete per batch is calculated by adding the loading time, mixing time and discharge time together.
1. According to different concrete strength requirements
Determine the mixing time according to the strength requirements of the concrete.
2. According to particularity of the concrete
≤C30 The mixing time of concrete with impermeability and various additives is increased by 10-15 seconds on the basis of 30 seconds.
C30-C60 The mixing time of concrete with impermeability and various additives is increased by 20-30 seconds on the basis of 60 seconds.
3. According to different slump of the concrete
If the slump is within the specified range (150mm-220mm) , the mixing time is set according to the first article above.
The mixing time of dry hard concrete is increased by 20 seconds on the basis of the time specified in the first article above.
Find your excellent wet mix concrete batch plant
Contact us if you are looking for the right cement batching plant manufacturer: LUTON.
Luton wet concrete batching plant series ranges from 25m3/h, 35m3/h, 50m3/h, 60m3/h, to 240 m3/h. These types of products are popular among the customers all over the world.
All you need to know about the benefits offered by Luton wet concrete batching plants:
- It offers the shortest installing time in the mobile batching plant market.
- It employs the simplest uninstalling steps without wires linking.
- It uses the most flexible electric controlling system that provides two types of operation: manual and automatic.
- The two horizontal shaft mixers use provide continuous mixing ability and excellent performance on dry, half dry, and plastic concrete products.
- We use the strongest steel structure for all our plants, ensuring working reliably.
- The most compact structure ensures both space saving and production efficiency.
Luton Group is a leading wet concrete batching plant supplier in China. It is a professional manufacturer; integrating research and development, production, and sales. Luton is your best choice for concrete mixing equipment.
Our company produces all kinds of cement batching plants, including stationary concrete batching plants, free foundation concrete batching plants, dry concrete batching plants, wet concrete batching plants, belt type concrete batching plants, hopper type concrete batching plants, mini concrete batching plants, large concrete batching plants, and so on.
If you would like to know more about our company and our products, do not hesitate to contact us. We are here at your service and would love to hear from you.
- What is a Wet Concrete Batching Plant?
- Types of Wet Mix Concrete Plants
- Comparison Between Dry Mix Concrete Plant and Wet Batch Concrete Plant
- Advantages of Wet Concrete Batching Plants
- Technical Parameters Of Wet Concrete Batching Plants
- Wet Mixing Concrete Batching Plants for sale
- Top 5 Famous Wet Mix Concrete Batch Plant Manufacturers in China
- Top 5 Famous Wet Concrete Plant Manufacturers around the World
- Factors to Consider When Purchasing a Satisfying Wet Mix Concrete Plant
- How Does A Wet Mix Concrete Plant Work?
- 1. Controlling value input
- Components of Wet Mix Concrete Batching Plant
- Concrete Batching Plant Mixing Time
- Find your excellent wet mix concrete batch plant
- Contact Us