30
Mar

Self loading mobile mixer VS conventional concrete batching plant

Table of content

  • Concrete batching plant explained
  • Types of concrete batching plants
  • Requirements for batching plant installation
  • Additional equipment required for batching plant operations
  • Self loading mobile concrete mixer explained
  • Main differences between concrete batching plant and a self loading mobile concrete mixer
  • Conclusion 

A concrete batching plant, also known as a concrete mixing plant, is a machine that combines various ingredients such as water, cement, sand, and aggregates (rocks, gravel, etc.) to form concrete. These components are mixed together in predetermined proportions to create a batch of concrete, which can then be transported to construction sites for use in building projects.

Concrete batching plants come in different types and configurations, but the basic components and operations are similar. Here’s a brief overview of the process:

  • Aggregate storage and handling: The aggregates, such as rocks and gravel, are stored in silos or bins and conveyed to the mixing area via conveyor belts or other equipment.
  • Cement and fly ash storage and handling: Cement and fly ash are stored in separate silos and conveyed to the mixing area when needed.
  • Water and admixture storage and handling: Water and admixtures, such as chemical additives that modify the properties of the concrete, are stored in tanks and added to the mixture as needed.
  • Mixing: The components are combined in the mixing area using a mixer, which can be a stationary or mobile unit. The mixer can be of different types such as drum mixer or twin-shaft mixer.
  • Transporting: Once the mixture is ready, it is transported to the construction site using trucks or other vehicles.
  • Control system: The plant is typically controlled by a computerized system that monitors and adjusts the components, mixing time, and other parameters to ensure consistent quality.

Concrete batching plants can produce a wide range of concrete types, from standard to high-performance mixes, depending on the specific needs of the project. They are used in a variety of construction projects, including residential, commercial, and infrastructure development.

Types of concrete batching plants:

There are several types of concrete batching plants, each designed to meet specific requirements and applications. Here are some of the most common types:

Stationary Concrete Batching Plants: These plants are designed for high-volume production of concrete and are typically used for large-scale construction projects. They are stationary and have a higher production capacity compared to mobile plants. They can be used for producing both dry and wet mix concrete.

Mobile Concrete Batching Plants: These plants are designed for projects that require frequent movement from one location to another. They are compact, easy to transport and set up, and can be used for both dry and wet mix concrete.

Compact Concrete Batching Plants: These plants are similar to stationary plants in terms of production capacity but have a smaller footprint. They are ideal for small to medium-sized construction projects where space is limited.

On-Site Concrete Batching Plants: These plants are designed to produce concrete directly at the construction site. They are typically used for projects where transportation of concrete is difficult or expensive.

Ready-Mix Concrete Batching Plants: These plants are designed to produce pre-mixed concrete that is delivered to the construction site. They are typically used for large-scale construction projects, such as highways and high-rise buildings.

Continuous Concrete Batching Plants: These plants are designed for the continuous production of concrete, with a high degree of automation. They are typically used for large-scale infrastructure projects, such as bridges and tunnels.

The type of concrete batching plant chosen for a project will depend on various factors, such as production requirements, project location, and available space.

Requirements for the batching plant installation: 

The specific requirements for the installation of a concrete batching plant can vary depending on factors such as the local regulations and the specific needs of the project. However, some general requirements and considerations include:

Location: The site for the installation of the concrete batching plant should be selected carefully, ensuring that it is easily accessible for delivery trucks, has sufficient space for the plant and equipment, and is situated in an area with a stable foundation.

Environmental regulations: The installation of the plant must comply with local and national environmental regulations. This may include obtaining permits for air quality, water discharge, noise levels, and other environmental factors.

Equipment selection: The selection of equipment for the concrete batching plant should be based on the specific needs of the project, the desired production capacity, and the availability of resources.

Foundation: The foundation for the concrete batching plant should be designed to support the weight of the plant and equipment, as well as the weight of the concrete that will be produced.

Electrical and plumbing requirements: The plant must be equipped with adequate electrical and plumbing systems to ensure efficient operation.

Dust and noise control: The concrete batching plant should be designed to minimize dust and noise pollution. This may include using dust collection systems, enclosing the plant, or installing noise barriers.

Safety measures: The installation of the plant should include appropriate safety measures, including guardrails, warning signs, and emergency stop buttons.

Maintenance: The plant should be designed to allow for easy maintenance and repair. This may include providing access to equipment, ensuring adequate space for repairs, and providing training for maintenance personnel.

Testing and commissioning: The plant should be thoroughly tested and commissioned before it is put into operation to ensure that it is functioning correctly and efficiently.

It is important to note that the specific requirements for the installation of a concrete batching plant can vary depending on the State regulations at project’s location, size, and complexity. It is usually recommended to source a professional engineer or contractor to ensure that the installation is designed and constructed to meet your specific needs and requirements.

Additional equipment required for batching plant operations:

One would think that starting a concrete business using a batching plant is as easy as ordering one from the supplier, acquiring a suitable piece of land and all necessary permits, however it is not often the case.

In addition to the main components of a concrete batching plant such as the mixer, storage bins, and conveyor belts, several other pieces of equipment are required for the efficient and safe operation of the plant. Some of the common additional equipment includes:

Various Silos: In order to operate smoothly, a batching plant requires a continuous flow of aggregates in large quantities. It is almost impossible to organize efficient work of a batching plant using a concept of a Just In Time delivery. It is required to deliver and store large volumes of aggregates, cement and water at the site. In order to do so without compromising the quality of components, special silos are required. These are vertical storage tanks used to store and dispense cement and other aggregate materials.

Water Chillers: These are used to cool the water used in the concrete mixing process, especially in hot climates or when the concrete mix requires a specific temperature range.

Dust Collectors: These are used to remove dust and other small particles generated during the batching process to prevent pollution and maintain a clean working environment.

Air Compressors: These are used to supply compressed air for various applications in the batching plant, such as cleaning and controlling pneumatic valves.

Concrete mixer trucks: These are used to transport concrete from the batching plant to the construction site. Batching plants can not operate without additional equipment that will deliver concrete to the pouring area!

Front wheel loaders or other loading equipment: Front wheel loaders are used to load aggregates, such as sand, gravel, and crushed stone, into storage bins or hoppers. They can be equipped with different types of buckets, such as high-capacity buckets for large volumes or narrow buckets for precise placement.

Some of this equipment can be quite costly, for example an average mixer truck can cost around $150 000 and the average price of a front wheel loader is around $100 000.

The average concrete batching plant will need at least one wheel loader and 2-3 concrete mixers to operate, bringing the minimum additional cost of the business, apart from the actual plant, land, permits etc., to at least $400 000!

Self loading mobile concrete mixer explained:

A self-loading mobile concrete mixer is a versatile and efficient machine used for producing and transporting concrete on construction sites. It is designed to eliminate the need for a concrete batching plant as well as a separate concrete mixer and transportation vehicle, as it can do both tasks on its own.

The self-loading mobile concrete mixer is equipped with a mixing drum and a built-in loading bucket that can scoop and load materials such as sand, gravel, and cement into the mixer. The mixing drum is mounted on a chassis, which also houses the engine, transmission, water supply system and other components.

Carmix self loading concrete mixers are autonomous machines that are operated by a single person. The process of loading and mixing, as well as discharge of concrete is operated from inside the cabin. Carmix has a 300 degrees rotating drum to facilitate pouring of concrete especially in tight spaces.

Self-loading mobile concrete mixers are powered by diesel engines, and they come in a range of sizes, from small units that can mix and transport only 1,5 cubic yards at a time, to larger units capable of producing and delivering up to 6 cubic yards of fresh concrete at a time.

One of the main advantages of self-loading mobile concrete mixers is their flexibility and mobility, allowing them to be used in a wide range of construction projects, from small residential projects to large-scale infrastructure projects. They are also designed to be easy to operate and maintain, making them an ideal choice for contractors and construction companies of all sizes.

Main differences between concrete batching plant and a self loading mobile concrete mixer:

While both concrete batching plants and self-loading mobile concrete mixers are used for mixing and producing concrete, there are some key differences between the two.

Production capacity: Concrete batching plants are designed for high-volume continuous production, with some plants capable of producing hundreds of cubic yards of concrete per hour. Self-loading mobile concrete mixers are typically used for projects that don’t need to make continuous large pours. Self loading concrete mixer is capable of producing up to 10 cubic yards of concrete per hour, which is more than enough for most of the construction projects with minor exceptions, such as high rise buildings, river dams etc. Even so, there is always a possibility to use a number of self loading concrete mixers and reach a desired high concrete output.

Mobility: Self-loading mobile concrete mixers are designed for maximum mobility, as they can be easily moved from one job site to another. Concrete batching plants, on the other hand, are typically stationary, with all the necessary equipment housed in a fixed location.

Material handling: Self-loading mobile concrete mixers have a built-in loading bucket that can scoop and load materials such as sand, gravel, and cement, eliminating the need for a separate loader. Concrete batching plants typically require a separate loader to move materials from storage bins to the mixer.

Control system: Self-loading mobile concrete mixers typically have a simple and user-friendly control system that allows operators to adjust mix design, mixing speed and discharge the concrete where needed. Concrete batching plants have a more complex control system that monitors and controls various parameters such as the aggregate feed rate, cement dosage, and water flow rate.

Cost: Self-loading mobile concrete mixers are generally way less expensive than concrete batching plants, as they are smaller and require less equipment. Concrete batching plants can be quite costly, especially for larger plants that require a significant amount of equipment.

Overall, both concrete batching plants and self-loading mobile concrete mixers have their advantages and are well-suited for different types of construction projects. Choosing the right equipment will depend on factors such as project size, mobility requirements, and production capacity.

Conclusion:

In conclusion, it is important to note that all construction projects are unique in one way or another and require a flexible and efficient approach when it comes to concrete supply.

Of course there are some larger industrial sized projects that will require the use of one, or sometimes even multiple concrete batching plants to satisfy the need for concrete. However it is worth noting that such projects account for no more than 10% of all the construction projects in the USA. Most of the time, mobility, flexibility and cost are the most important factors to consider when planning for the project. In this sense Carmix self loading concrete mixers are a more flexible and cost effective solution, yet providing the same quality of concrete in large quantities.

This concept is still new in the USA, however in most of the other countries around the world Carmix is a go-to approach when considering any construction project, especially in remote and hard to reach locations. 

It is always worth considering all the possibilities and calculating the actual cost of implementing one or another approach to concrete production. We always encourage our customers to work together and examine what are the pros and cons of using Carmix at their project. We provide all our expertise to each and every customer to benefit the most from using Carmix at their project. It is worth pointing out that as good as Carmix is, it is also very important to organize the whole production process in a professional manner! We are always here to help and are ready to walk you through the whole process until you reach the maximum result with Carmix!