A Stationary Concrete Batching Plant is a concrete production facility that is installed in a fixed location for a long time. It is mainly used for large-scale, continuous concrete production tasks. To build a fixed concrete batching plant, it is necessary to carry out site selection and site preparation, equipment installation and supporting facilities construction. The construction process requires attention to details to ensure the safe operation and efficient production of the mixing plant.
Fixed concrete plants are a type of concrete production equipment, usually composed of a concrete mixer, a batching system, an aggregate storage container, a weighing system, a conveying system and an automatic control system, including one or more concrete mixers, a hopper for storing raw materials, a conveyor belt and a concrete discharge hopper. Unlike mobile mixing plants, the equipment of rmc plants is installed in a fixed location and used to produce large quantities of concrete to meet the needs of construction sites and concrete production plants.
Concrete mixing batching plants usually have high production capacity, accurate batching control, and automated batching and weighing systems to ensure the stability of concrete quality. The design focuses on the durability and long-term stability of the equipment, making them suitable for large-scale construction projects such as highways, bridges and large housing, long-term construction works and large-scale concrete production in infrastructure construction.
According to production capacity, ready mix concrete batching plant can be divided into small, medium, and large concrete mixing plants, such as HZS25, HZS50, HZS75, HZS90, HZS120, HZS180, HZS240, etc. The production capacity of small-scale concrete mixing plants is 25-50m ³/h, medium-sized concrete mixing plants is 50-100m ³/h, and large-scale concrete mixing plants exceed 100m ³/h. You can choose different mixing plants according to your concrete production needs.
According to the different feeding methods of aggregates, precast concrete plants are divided into bucket concrete plants and belt concrete plants. In a bucket concrete mixing plant, a bucket (or tipping bucket) is used for feeding, and the aggregate is lifted by an elevator and poured into the mixer. In a belt concrete mixing plant, a belt conveyor is used to continuously feed aggregates into the mixer. When choosing bucket and belt plants, factors such as production scale, budget, site conditions, and material requirements must be considered.
The site should be flat, dry, with unobstructed geographical conditions, and have enough space for equipment installation and raw material storage. Select a suitable site for the installation of the concrete batch plant equipment. Select a location not too far from the construction site, preferably within 10-15 kilometers, to facilitate concrete production and transportation.
Because concrete transportation is the main service of the rmc plant, the mixing plant is near the road. At the same time, it should be noted that the road has sufficient width, height and loading capacity to ensure the transport of raw material supplies on time. The plant should select a site with flat terrain, no slope or small slope to ensure a stable foundation. Especially for large concrete plants, the bearing capacity of the foundation is very important.
Design the overall layout and specific equipment configuration of the plant based on factors such as production capacity, raw material types, and project requirements. The on-site layout should be reasonable to ensure that the batch mix plant can correctly complete the system assembly. Prepare the supporting base plates for each component in advance, as well as the concrete foundation for the mixture storage tank and powder material supply system.
Reasonably arrange the mixer, batching system, storage bin, conveying system and other equipment in the mixing station according to the project scale and production needs, to ensure the smooth operation process. At the same time, it is necessary to ensure that there is sufficient space in the storage area for raw materials (cement, sand, gravel, water, additives). All kinds of raw materials should be classified and stored to avoid confusion. The name, specifications, and quantity of the raw materials should be indicated. Sufficient installation and construction electricity should be provided at the installation site, and a sufficiently large room should be provided as a temporary warehouse for installation.
The concrete mixing batching plant should be equipped with professional drivers, inspectors, mechanical and electrical maintenance personnel, special operation personnel, and organize a construction team composed of civil engineers, equipment installation personnel, electrical and automation control personnel, etc. Before installing and debugging equipment, it is necessary to organize and train relevant personnel to improve their skills and safety awareness. The project department of the construction unit should apply for the document on establishing a batching plant. This includes establishing mixing plants, quality and safety management organizations, management rules and regulations, etc.
Develop and implement environmental protection measures such as dust suppression, noise suppression, and wastewater treatment to ensure that wastewater undergoes sedimentation, purification, filtration, and other processes before discharge. To prevent dust from scattering, a dedicated person is arranged to sprinkle water on the production site every day to reduce dust. All kinds of garbage and waste should be stored in fixed locations and dumping is strictly prohibited.
Develop a safety management plan, equip with fire and emergency equipment, and conduct regular safety inspections. Develop corresponding emergency plans and measures, and possess the ability to resist disasters. Develop a detailed construction plan, supervise the construction process, ensure that each link is completed on time, conduct regular on-site inspections, and solve problems that arise during the construction process.
According to the geological survey results, the site was excavated and the foundation was reinforced. Basic engineering includes excavation, buffering, steel reinforcement binding, and concrete pouring. In basic engineering, steel bars are tied and concrete foundations are poured. Comprehensive maintenance shall be carried out on the rmc plant site as needed to ensure normal construction and safe construction standards. Construct a drainage system to ensure smooth on-site drainage and prevent rainwater accumulation from affecting equipment stability.
The steel structure frame of the concrete batcher should be installed first as the foundation to support various equipment. The installation of the steel structure should use a lifting machine to ensure the accuracy and safety of the construction. Raw material storage warehouses such as cement silos, aggregate silos and admixture silos are built according to the project design. In the construction process of the structure, the power system and the automatic control system should be installed at the same time.
When installing the main mixer, it should be hoisted on the beam, connected with bolts, and fixed stably and firmly. The installation accuracy of the mixer should ensure the coordination between the mixer and the mixing system and the material conveying system. The installation location of the batching system should be a place convenient for operation and maintenance, and the impact on the overall layout should be considered. After the installation is completed, debugging is required to ensure the stable operation of the batching system. The installation location of the auxiliary equipment should be a place convenient for operation and maintenance, and the impact on the overall layout should be considered.
After installation, comprehensive equipment debugging and testing are required. Check the electrical system to ensure that all cable lines, distribution boxes, control cabinets, and other equipment are properly connected. The PLC control system is the core control system of the stationary cement batching plant and requires detailed debugging of the control system. Test the material conveying system, check whether the hopper and conveyor can smoothly transport various raw materials, and carry out actual concrete mixing operations to check the mixing quality of the mixer.
Start each device one by one for operational testing. The debugging content includes electrical system, control system, weighing system, etc. After the system debugging is completed, conduct a trial run. It usually takes 8-12 days to test production efficiency, equipment stability, concrete quality, etc. Invite relevant departments or third parties to conduct inspections to ensure that all equipment in the batch concrete mixer meets construction standards and environmental requirements. During the formal operation period, concrete mixing and transportation should be carried out according to the production plan, and a complete operational management system should be established.
Clean the main parts of the batch mix plant, such as the motor and reducer, regularly and check the appearance of the equipment (mixer, conveyor belt, electrical equipment) for damage, cracks and looseness. Inspect the lubrication system of the equipment and change the lubricating oil in a timely manner. Inspect the connections of the electrical circuits, switches, control cabinets and other equipment to ensure that there are no abnormalities.
Check the mixing blades, bearings, gearbox, and other parts of the mixer for wear and damage. Regularly check the accuracy of the batching machine to ensure accurate measurement. Check the tension, friction, and wear of the conveyor belt. Regularly inspect and replace parts that are prone to wear, such as horizontal conveyor belts, as well as important components such as mixer gearboxes and bearings. Replace or repair as necessary.
Timely detect equipment abnormal signals through monitoring systems and manual inspections. Establish a mechanism for handling equipment malfunctions, promptly diagnose and repair equipment failures. Depending on the severity of the malfunction, parts may need to be replaced. To reduce the occurrence of malfunctions, please regularly perform preventive maintenance on the equipment.
♦ If professionals encounter precision issues while operating equipment during installation, mixers, batching machines, and other devices may not function smoothly. Professional personnel are required to operate, strictly follow installation standards, and conduct on-site inspections and debugging.
♦ Frequent malfunctions or shutdowns during operation may reduce production efficiency, therefore it is necessary to conduct regular maintenance and inspections, and establish a spare parts inventory.
♦ If the quality of concrete is unstable, problems such as inadequate strength and poor workability may occur. To accurately mix ingredients, ensure even mixing, and conduct regular quality inspections.
♦ Electrical system failures are the most common issue in fixed concrete batch plants. Regularly inspect the electrical system and install electrical protection devices to prevent equipment damage.
♦ If the service life of the equipment is too long, problems such as wear and aging will occur, affecting the mixing efficiency of the mixer. The equipment should be regularly maintained, and worn parts should be replaced in a timely manner.
♦ The production process of the concrete batch plant equipment requires manual operation, and improper operation can lead to safety accidents. Regular safety production training and maintenance training should be conducted to enhance employees’ safety awareness and maintenance skills.
The construction of stationary concrete batching plants is a key factor in ensuring stable concrete production and improving construction efficiency. The plant adopts a precise batching system and efficient mixing process to produce high-quality concrete, improving efficiency, reducing rmc plant setup cost, ensuring the long-term stable operation of the concrete batch plant, and providing a guarantee of high-quality concrete for construction projects.
EPDAS is a professional concrete plant manufacturer. We have a professional technical team. If you need it, please contact us immediately and we will customize a batching plant that best meets your project needs. We will have professional technology to install it on site for you, reducing your ready mix concrete setup costs!
