DCM96

Cement Silos: Large vertical storage tanks where cementitious material is stored. This material is fed into the
silos via blow up pipes.
Aggregates Bins: Separate compartments for storing different types of aggregates such as sand, gravel, or
crushed stone. Typically, these bins are organized for various sizes of aggregates.
Water Tanks: Reservoirs that store water used for mixing concrete. Some tanks contain recycled water.
Weighing System: Weigh hoppers complete with Scales and load cells that precisely measure the correct
proportions of cement, water, aggregates, and additives based on the desired concrete mix design.
Conveyor Belts: Systems used to transport materials like aggregates from storage bins to the mixer.
Screw Conveyors: Systems used to transport the cementitious materials from the silos to the cement weigh
hoppers.
Mixing Unit: The central part of the plant where materials are combined and mixed. The mixer may be a tilting
drum, planetary, pan or a twin shaft.
Control System: A computerized system that automates the entire batching process, ensuring accurate
measurements, mixing times, and overall plant operation.

A. Material Storage
Cement Storage: Cement arrives at the batching plant via bulk cement trucks and is pumped into the silos
pneumatically. The cement silo is equipped with filters and pressure release systems to prevent overpressure
and dust emission.
Aggregate Storage: Aggregates are delivered by trucks and stored in large storage bins or aggregate bays. These
bins or aggregate bays are often divided into compartments for different sizes and types of aggregates.
Water and Additives Storage: Water is stored in tanks and additives (admixture (like accelerators, retarders, or
plasticizers)) are stored in separate containers or dosing systems. Additives are usually fed into the mix in small
quantities to alter specific properties of the concrete.
B. Material Proportioning and Weighing
Aggregates Weighing: The control system initiates the batching process by opening gates in the aggregate bins,
allowing the correct proportions of different aggregates to be transferred onto a weigh belt or directly into the
weighing hopper. Load cells measure the exact amount of each aggregate, then sends a signal to the control
system to close the aggregate gates.
Cement Weighing: The cement is released from the silo through a screw conveyor, into a dedicated weighing
hopper, again using load cells to ensure precision. Once the loadcells have the correct reading a signal will be
sent to the control system to switch off the screw conveyor therefore stopping the weigh hopper from filling.
Water and Additives Dosing: Water is pumped from the storage tank to a weighing system and measured by
weight using load cells. A temper water system is also installed ensuring small additions to the water content
can be made. Similarly, additives are dosed based on the mix design, ensuring they are proportioned
accurately. Additives are also pumped from the storage tanks and into a weigh hopper, where they will also be
weighed using load cells.
C. Material Transfer to the Mixer
After weighing, the control system ensures that the materials are transferred to the central mixing unit. This
transfer can happen in several ways:
Conveyor Belt: Aggregates and other materials are moved via a conveyor belt ( the batch belt) directly into the
mixer.
Cement and Additives Transfer: Cement and additives are delivered into the mixing chamber via screw
conveyors or direct hoppers.
D. Mixing Process
Once all materials are inside the mixer, the actual mixing begins. The type of mixer (e.g., drum mixer, twin-shaft
mixer, Planetary mixer or Pan mixer) determines how the mixing process works.
Twin-Shaft Mixer: Uses two horizontal rotating shafts with paddles to ensure quick and thorough mixing, ideal
for high-performance and high-volume concrete production.
Drum Mixer: Rotates to mix the ingredients and is often used in portable batching plants for simpler operations.
Planetary mixer: A planetary concrete mixer works by using a multi-arm mixing mechanism that rotates around
a central axis, like the motion of planets around the sun, hence the name. The mixer typically has a stationary
drum, and several mixing blades attached to rotating arms. These blades move in both rotational and orbital
paths to ensure thorough mixing of the concrete. This design allows for highly efficient mixing as the materials
are constantly being pushed and pulled in different directions, resulting in uniform distribution of aggregates,
cement and water.
Pan mixer: A pan concrete mixer works by mixing concrete ingredients in a circular, flat-bottomed pan. The
mixer has rotating blades or paddles, which are either fixed or mounted on rotating arms. As the blades turn,
they mix the concrete ingredients—such as cement, sand, water, and aggregates—by scraping and stirring
them in the pan. Some pan mixers have a stationary pan while the blades rotate, while others have both the pan
and blades rotating. The design ensures thorough mixing, making it ideal for producing high-quality concrete
with consistent texture. Pan mixers are commonly used for smaller batches and specialized mixes.
Mixing Time: The control system regulates the mixing time based on the concrete specification and consistency
needed. Typical mixing times range from 30 seconds to a few minutes.
Slump Test: Prior to the concrete being discharged, an operator may check the slump (workability) of the
concrete using a slump cone to verify if the mix meets design specifications.
E. Concrete Discharge
Into a Mixer Truck: Once mixing is complete, the concrete is discharged from the mixer into the chute of a
concrete mixer truck. The truck’s rotating drum keeps the concrete agitated and fresh during transportation to
the construction site.
On-Site Delivery: If the plant is located on a construction site, the mixed concrete might be discharged directly
into a pouring point or into smaller transport equipment like wheelbarrows or dumper trucks.

Automated Control: Modern batching plants are equipped with computerized control systems that manage the
entire production process. Operators input the desired concrete recipe, and the system automatically controls
the feeding, weighing, mixing, and discharge processes.
Batch Reports: The control system logs each batch’s composition and production data for quality assurance
and compliance purposes. This ensures that every batch meets the required specification.

Stationary Batching Plants: These are large, permanent installations designed for high-volume concrete
production. They are often used for long-term projects such as infrastructure or large-scale building projects.
Semi – Mobile batching plants: A semi-mobile concrete batching plant is a versatile type of concrete
production facility designed for partial mobility. Unlike fully mobile plants, semi-mobile plants are not fully
mounted on a trailer but are designed to be relocated with some assembly required. They often consist of
modular components that can be transported to different sites. These plants can be set up and taken down
relatively quickly, making them suitable for projects that require flexibility but may last longer than those served
by a fully mobile plant. Semi-mobile plants typically offer a larger production capacity compared to fully mobile
plants, making them suitable for medium to large-scale construction projects. Like mobile and static plants,
they produce concrete on-site, reducing transportation costs and ensuring fresher concrete. They can be
equipped with various features and options, allowing customization for specific project needs, such as
different mixer types or additional storage capacity. Overall, a semi-mobile concrete batching plant strikes a
balance between mobility and production efficiency, making it ideal for projects that require a flexible yet
robust concrete supply solution.
Mobile Batching Plants: These are smaller, portable units that can be transported to different job sites, ideal for
short-term projects or those in remote areas

Dust Control: Batching plants are equipped with filters and dust collectors, particularly at the cement silo and
weighing points, to reduce dust emissions.
Water Management: Recycled water can be used to minimize waste. The plant must also manage any excess
water used for cleaning or aggregate washing to prevent environmental contamination.
Noise Reduction: Enclosures and barriers may be installed around noisy components like mixers and conveyor
systems to minimize noise pollution. Insulated cladding is installed around the plant to reduce the noise
pollution.

Operator Training: All plant operators are trained in safety measures, including handling of materials,
machinery operation, and emergency protocols.
Equipment Maintenance: Regular inspections and maintenance schedules ensure the safe and efficient
operation of all plant components, reducing the risk of breakdowns or accidents.
Emergency Systems: Plants are equipped with emergency stop systems and fire suppression measures due to
the presence of electrical equipment, motors, and moving parts.