Construction Mirror Industry Features Details

Concrete Batching: Turning Ideas into Action

April 26, 2019

Concrete Batching Plant

Introduction

A concrete batch plant, also known as a batch plant or batching plant, is one of the significant components in any process of concrete construction, either it has to operate alike a central mixing plant onsite or is to deliver an offsite ready blended concrete to a project.For the concrete to last for long and for the attainment of the required stability, the components of concrete need to be blended in a definite proportion. Batching is defined as the procedure under which the measure or proportion of components such as cement, aggregates, water, etc. are evaluated on the grounds of either weight or volume for composing the concrete mix.The batch plant seems assisting in up grading the efficiency of work of the concrete and supports in reducing the trash of the substances such that one attains the entire required properties of both the concrete, fresh as well as hardened. Concrete batching plant is a mechanism which uses to mix and blend all the ingredients of concrete uniformly in order to obtain the concrete with the required stability and condition. Here is the attempt of providing the information on the kind of concrete batching plants, which should be possessed by the engineer operating on the site of construction.

Concrete batching plants are able to attain the ideal and efficient concrete’s batching. The measurement of the quantity of cement, sand, coarse aggregate, water, admixtures, etc. needed for a concrete mix design is undertaken by the concrete batching plants. The Batching of concrete can be done by either measuring the batching or volume batching. The above terms are self explaining terms, weigh batching is done based on weight of the ingredients, while volume batching is done based on the volume of the ingredients.

Concrete is the most pervasive element applied in the process of construction either in any part of the world. Concrete is considered as the second most consumed material on Earth, after the consumption of water. Concrete is undoubtedly comes under one of the most crucial ingredient for the evolution and development of human civilization. As per the study and analysis, the quantity of about one tonne of the medium is consumed on a yearly basis by each individual on the earth. The emerging rate of urbanization and complications of structures and frames has particularly elevated the value of the concrete industry in the development of economies worldwide. The nation ofIndia is expected to see positive markings in the times to come. The optimum rate of production for each type of concrete can be obtained by solving the model under the given constraints.

Studies conducted worldwide on the potential of concrete manufacturing and equipment industry indicate that the BRIC nations to be the next big growth market. India is today the second largest cement producer in the world. Now with the country expected to further scale up growth thanks to its focus on infrastructure development, not to mention NHAI’s ambitious plan of building 30 km of national highways daily in the coming years, the industry will see a lot of action. So much so that India could emerge outpacing the other BRIC nations.

Types based on their Mixers

Concrete batch plants are sub divided as the transit mix plant and central mix plant by considering the kind of mixers.

Transit Mix Plant/ Dry Concrete Batching Plant

Transit mix plant/ dry concrete batching plant measure the agglomeration and cement  with the support of either manual or digital scales. The fluid is also measured or volumetrically measured in separation with other components. After the measurement, all the components are then streamed in a transit mixer, which is transported to the site. All the components are then blended during transportation towards the site of construction. Water is either supplemented on the site or during the process of transportation depending upon location of plant and site.

 Central Mix Plant/Wet Concrete Batching Plant

Central mix plant/wet concrete batching plant weighs the entire required components including fluid. The components are blended in a mixer situated at a central location in the plant. After the process of blending got over, the concrete is streamed in to the agitator truck, which supplies it to the site. It should be taken into consideration that the truck must be in a state of mobility, so that the crystallization of concrete does not happen.

Types of Batching Plant Based on their locations

Concrete batching plant can be categorized on the basis of their locations as stationary concrete batching plant and mobile concrete batching plant.

Stationary Concrete Batching Plant

Stationary concrete batching plant as their name suggests are stationary and can be detected from a certain distant area from the site of construction. The concrete is batched and transferred with the support of the truck to the site of construction or on site. These batch plants have an advantage of convenient installation. They are big in their size in comparison with the mobile concrete batching plant. They have higher order and produce high grade quality of concrete. It should be noticed carefully that the truck reaches the site at the desired time. On the contrary, the solidification of concrete will start and hence inferior concrete will be delivered. They have the broad range of capacity of batching in comparison with the mobile concrete batching plants. The stationary concrete batching plants are usually applied for those commercial projects which have longer duration and where the request of concrete is higher.

 Mobile Concrete Batching Plant

Sometimes the stationary concrete batching plant is situated at such a distant place that the transportation cost of the concrete enhancesand thus results in the higher cost of construction. In such cases, the mobile concrete batching plants are much efficient and popular. The compact batching plant, has the storage of material, weighing, mixing, and discharging units. It posses the adaptable motion and in such way can be delivered to the site of construction. In the same way, the batching of concrete is carried forward on the site. After the installation of plant, the contractor can regulate the making of concrete as per the job is in the requirement.

Ready Mix Concrete

RMC can be referred to the Ready Mix Concrete which is the ideal blend of the concrete manufactured within a factory known as batching plant based on a particular procedure and is transported to the site operational in a transit vehicle. RMC is usually preferred over on-site the blending of concrete due to the accuracy of the composition, thus reduce the confusion on the work site.

Applications

  1. Used in the construction of bridges, dams etc. used in the construction of overhead roads, pools, multi stories building etc.  It can be directly used at the site of construction, it helps to the greater element of automation and precision concrete mixing.
  2. A much up graded quality and more basic conformity and enhance the standardization and acceleration which is done ten times swifter in comparison with the site of mixed concrete.

Safeguard for quality control: RMC Plant

The quality control in RMC plant can be divided into the following categories:

 Forward Control

Mentioned below are the safeguards, which are taken before the production in the RMC plant are known as forward control. It will include:

  • Storage of adequate materials
  • The quality testing of the materials and its monitoring
  • Mix design modifications (as per in-charge engineer)
  • Pre maintenance of the plant
  • The equipment calibration procedures must be carried out to achieve the higher accuracy as per design mix.
  • The condition check of plant and transit mixer.

 Immediate Control

This will involve the steps undertaken at an instant either at the time of the delivery period. This involves the following production period or during measures:

  • Accurate weighing of the batched data
  • Examining the assembled concrete both visually and by tests. This is done during the production and the delivery. The verification is performed for uniformity, workability and the fluid adjustment.
  • Conducting the changes in the plant either on a manual basis or automatically so that the registered issues can be declined.

Practicable index of misconception in plant production of RMC

The major errors that can be avoided that are noticed after the production:

  • Proper training and managing the designers who come up with the calculations and drawings.
  • The identification has to be mentioned specifically in the tender.
  • The responsibility must be defined in a proper and effective manner from both the groups of management.
  • There must be effective interaction between the parties (client, producers, PMC and TPI).
  • Technicians and the labor available on the site of construction need to be given the proper training.

The RMC plant, unlike the normal concrete (manufacture on site), will be needed a larger amenity. It will incorporate the gathering of tools, cement batches, conveyors and aggregate bins, cement bins etc. Half of the entire production is carried out within the plant and the second half is done outside the plant. Even though RMC is an industry that is emerging and gaining popularity, it confronts some problems with the occupational protection. The segment of labor and employer confronts the risk at both the time, i.e. during the manufacturing and delivery at the construction site.

Market Survey of Ready Mix Concrete Plant

Ready Mix Concrete Batching Plant Market - Increase in the Global Construction Activities to Boost Growth

The segment of RMC in India is extending at a swift pace of rate 25-30 per cent on a yearly basis, the employment is still in its emergence – the gap between the organized and unorganized sector wise. Under the industrialized nations, the ready mix concrete forms the percentage of about 70-75 of the market share. With India building up its infrastructure and cities see a spurt in verticalization the sector of ready mix is anticipated to perform a progressively commanding role chiefly because it is seen as the most viable suggestion to accelerate the process of construction.RMC is being also increasingly preferred alternative for the most real estate developers because site mixed concrete relied upon the availability of labor. 

The latest market of research registers over the global ready mix concrete batching plant marketprovides an analysis of the most important trends expected to impact the market outlook from 2018-2022.As per the study and analysis of Technavio analysts, the global market of ready mix concrete batching plant will grow at a CAGR of around 6% during the anticipated period. The growth in construction infrastructure and development activities globally is a major factor responsible for driving the growth of market.

The numerous new projects of construction in many of the developed and emerging economies is towards the boom after a long duration of recession under the sector of construction. The cessation of the residential housing in the US has grown significantly in the year of 2017. The effect of recovery in the US economy has led to optimization among the home buyers, resulting to increase in request for the single new and multi-family homes. It is anticipated too that the restricted demand from the recession period will also push up the demand in the housing market.

Global Ready Mix Concrete Batching Plant Market Segmentation

 The global ready mix concrete batching plant market is segmented into the following applications (non-residential constructions and residential constructions) and key regions are the Americas, APAC, and EMEA. In 2017, APAC held the largest share of ready mix concrete batching plant market, accounting for close to 46% of the global share. The market in this region is anticipated to support the rapid growth during the forecast period. The major demand driving factor for the ready mix concrete batching plants in the region is the rapid economic growth and evolution in the several countries in APAC such as China, India, and Indonesia.

Technological Advancementsin handling processes

Concrete batching plants have undergone the rapid evolution and development of geared towards enhancing their performance and efficiency. Modern plants have the automated control systems that control over the procedure of blending. The mechanism of motors and pumps are controlled with the help of programmable logic controllers (PLC) or computer guided controls, which assures that the ingredients of concrete are calculated with the precision and the process of blending is ideally controlled. The plants of the recent times have numerous sensors such as moisture content sensors, which perceives the volume of fluid in the concrete mix and ensure that the mixture has the required water content. The entire plant has various sensors used to detect issues such as voltage, current, pressure, weight, to guarantee the quality of high mixture.

Preserving the uprightness of Concrete Equipment

For the effective operation of the concrete equipment, there rises a need of the careful maintenance routines that should be followed rigidly. All the active units need to be corrected to assure that they contribute the higher Quantities of the required ingredients of concrete mix. The batching plant is made up of motors, conveyor belts and other machineries, which runs the different materials. It is mandatory to carry out the operations of routine maintenance such as greasing, oiling, cleaning, changing bearings and the other moving parts and replacing the worn out parts. This will ensure that a high the mixture of high quality is secured.

Complications and solutions of Concrete Batching

The concrete batching in general, operates in business field as a technique of mixing and blending. Various components such as mixer, cement batchers, aggregate batchers, bins, chillers etc. are been applied for batching plant. The ultimate objective of applying the procedure of planning is to have a formation of concrete. Ready mix concrete is what a product that is manufactured in batching plant. The procedure of the dry concrete batch plant may be much time taking unless and until the manufacturers are equipped with all the required ingredients to make the final product. Though, with the application of the computer aided control, the problems may be solved. Under the assistance of computer, the operator is able to make the accurate measurement of the input constituents and combined together with all the accessories for the safer operation.Understanding the accuracy of measure with the accessibility of the computer system concrete batching plant process becomes much convenient. Be it the ready mix plant or central mix plant, computer provides accurate ingredient loaded in plant for the further process. Moreover, the self-loading plants are customized with the fully and semi automatic to control the process.Another problem isovercoming with timing problem, apart from mixing, the process of timing is also another restriction that the user can go through. The stuff which is combined together at the plant, the process of mixing has to be done at that plant, so the travelling time is of prominent value. Sites which are far distant from each other is able to influence the quality of the product, so a centralized concrete batching centre will work.Thus, it can be concluded that construction areas need to complete the process in the given deadline, the use of technologies and process will help in overcoming the concrete batching complications.

 

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