ready-mix concrete plants

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Contents :

1- Introduction. 

2-  Components of a ready-mix concrete plant.

3       - Types of stations.

Introduction :

Reinforced concrete is the main component of construction projects around the world. It is one of the biggest cost elements in any construction project.

With the increase in the demand for ready-mix concrete and the high intensity of competition in the field of its manufacture , it was necessary to achieve competitive advantages that maintain the continuity of production of ready-mix concrete factories and increase their market share ( productivity - quality ) .

Taking into account the improvement of the environmental impact and the improvement of the efficiency of the use of resources to enhance sustainability , and then the ready-mix concrete factories were selected to participate in the provision of strategic engineering projects with international specifications .

The ready-mix concrete produced from concrete factories varies in its prices and components based on the required properties of the concrete mix and the performance required to be achieved according to the project requirements.

Concrete mixtures are the core of the production for which the factory was established in order to achieve certain strategic and economic goals . Thus, increasing productivity or improving quality without increasing costs may significantly affect the prices of these mixtures.

 

2 - Components of Central Concrete Batching Plant

 

1 - Feeding hopper :             

It is a 10-ton metal hopper with a 180-watt electric vibrator installed to prevent sand from sticking to the sides of the hopper.

The feeding hopper is used to collect sand and tooth to feed the churn belt

 

2 - Chun progression :             

It is the phrase for the conduct of a moving display 80 cm The transfer of material from the sands of the enactment of the hopper feeding into tanks materials using the engine circuit capacity of 15 k . Watt Italian - made from the production company ( VEMAT) Connected to fund gears ( gear box) , Italian - made from the production company ( TRAMEC) For by three conveyors German - made for the transfer of movement between them .

Moves to walk on the rod in both directions the right and left for road engine ( geared motor) Capacity of 1.5 k . Watt of the production company ( SITI) Italian can control the movement of traffic either manually or from through the control of post ( remote control) Of the production company ( FSL) British.

 

3 - Tanks material Upper: :               

  It consists of 4 tanks for storing materials from sand and a tooth, the capacity of each tank is 40 tons .

 

4 - Lower material tanks:             

It consists of 8 tanks each tank by the gate is controlled in open and closed for by piston antenna (   PNEUMATIC CYLINDER) Of the production company ( PNUMAX) Italian to control the amount of sand and age descending to the balance of materials .

5 - Balance material :             

The capacity of the material balance is 5  m3.

It contains a 4 - cell weight of type ( S-type capacity of each cell is 5 tons of company production PONGSHIN  Korean

 

6- Weight progression :             

The words for the conduct of a smooth display of 80 cm , and the transfer of materials from sand and the age of the balance of materials to the course of nutrition BATCH CONVEYOR)) Using the engine circuit capacity 18.5 K . Watt Italian - made from the production company (( VEMAT connected to a gearbox ( gear box) , Italian - made from the production company ( TRAMEC) For by three conveyors German - made for the transfer of movement between them .

7 - progress of nutrition :             

It is a belt with a width of 100 cm and it transports materials from sand and a tooth from the weight belt (( WEIGH CONVEYOR   to the waiting hopper HOLDING HOPPER)) using an electric motor capacity of 22 k . Watt Italian - made from the production company (( VEMAT connected to a gearbox ( gear box) , Italian - made from the production company ( TRAMEC) For by three conveyors German - made for the transfer of movement between them .

8 - Waiting for hopper :             

Is a for hopper metal capacity of 5 m 3 works as a recipient and complex sand and age of the progress of nutrition .

Equipped with a hydraulic gate that works with the mixer in order to maintain the mixing time .

 

9- Cement Scale :             

Is a for hopper metal capacity of 2 tons provider Bmahbs butterfly ( butterfly valve) Operates automatically for by operator electromechanical ( electro pneumatic drive).

It contains a 3 - cell weight of type ( SHEAR-type) Of the production company PONGSHIN Korean capacity of each cell 1 ton . 

It contains a rocking air ( pneumatic vibrator) and the number of (6) shock units ( aeration pad) In order to prevent the cement from sticking to the sides of the metal hopper .

10 - Water Balance :             

The term for hopper metal factory of sheet galvanized capacity of 750 liters provider Bmahbs butterfly ( butterfly valve) Operates automatically for by operator electromechanical ( electro pneumatic drive).

It contains a number of 3 - cell weight of the type ( SHEAR-type) Of the production company PONGSHIN Korean capacity of each cell 500 kg .

11 - Balance of chemicals :             

It consists of 2 tanks made of stainless steel (stainless steel) in order not to interact with any of the chemicals and the capacity of each tank is 30 liters.

Each scale contains one weight cell of type (S-TYPE) Produced by the company PONGSHIN KoreanThe capacity of each cell is 100 kg.

Each tank contains a ball valve.ball-valveIt works automatically by an electric actuator.electrical engineer) to accurately control the amount of chemicals flowing into the mixer

 

12 - cement tank:

Cement tank capacity 150 tons .

connected to SCREW CONVEYOR For the transfer of cement to the balance of cement .

exist FILTER  at the entry port of the cement .

Containing the pressure relief valve  To remove excess pressure inside the tank .

It contains the stopcock butterfly for overcharged in the amount of cement Almedfqh to the balance of cement.

It contains the 8 aeration pad  Working on non - sticking cement tank .

Containing the level indicator  To measure the amount of cement located inside the tank.

13 -Air compressor

Produced by the company HAGGAR  Made of Italian components and local assembly. Capacity (500-100) liters.

It has 2 motors with a capacity of 5. (5.5-7.5) kilowatts.

14 - External washing machine :

It uses a pump high - pressure capability 4 k . Watt.

15- Electrical components:

All panels are equipped with cooling fans and ventilation filters

All cables connected to the paintings on the road Soki PLUG AND PLAY)) for easy disassembly and installation during the installation of the station and during maintenance .

all cutters ( circuit breakers) and ( contactors) (relays) and ( phase sequence and over and under-voltage) and (timers) and (overloads) From the production company Schneider Schneider  French

Cutter main of the production company ABB French.

All motors in the station is available with all the means of protection from ( SHORT CIRCUIT) and (OVER AND UNDER VOLTAGE) and ( phase sequence) and ( MECHANICAL AND ELECTRICAL INTRLOCK)

 

PLC UNIT:

Of the production company   FANUC Japanese license from the company GENERAL ELECTRIC  The US , which is characterized by precision and high speed implementation signals control ( control signals).

Chun belt operation panel:

Equipped with a remote control (REMOTE CONTROL(produced by the company)FSLBritish in addition to manual operation through the stop and start keys.

 

air plates :

All components of Italian-made air panels are produced by the company PNEUMAX

All cables used for the station are certified cables produced by El Sewedy Cables Company.

SCADA SYSTEM Of the production company INDUSOFT American.

  

16 - Mixer :(( mixer

The mixer is produced by the company Sicoma  Italian, including several types shown in the following table :

 

Mao 5000/3350 - - Mao 4500/3000 - -Mao 3000/2000 -  Mao 1500/1000 - cycle duration

134 m3- 120m3- 80m3- 40m3 - Output per - Mixing shaft -   nu mber of

Mixing blades

 

 

3 - Types of ready-mix concrete batching plants

 

1 - Standard Dry Plant Specifications (40 m3 / h ) ( B00)

 

Station model : Grand 60 / 36 - 3 rubble / (    B00) .

Station output :  wet 60 m 3 / hour .

(The output of the station varies depending on the design of the mixture)   .

Loading aggregates :  through a forklift (by the customer)   .

Aggregate storage bins :

Divided into 3 equal compartments - each with a capacity of 12 tons - with a total storage of 36 tons .

The width of the box inside is 2500 mm, to ensure safe loading of the forklift .

Aggregate weight hopper :

Capacity 2.25 m 3 , complete with 4 of the cells load, the capacity of each of them 2 tons .

Combined with one electric vibrator for sand hopper :

Complex with the progress of the carrier and one flat ( width 600 mm ) to achieve the process of mixing in advance of the material and one sand with prompt 3 kilo watts and with the engine 7.5 kilo Watt operates at speeds .    

Rubble emptying :

Through the conveyor belt of the mixture (Chevron) (width 600 mm), assembled with an 11 kW motor operating at high speeds .

cement weighing hopper

500 kg capacity, complete with 3 load cell system of 500 kg each

Combined with vibrator, to ensure fluidity of cement through butterfly valve, with pneumatic actuator .

rotary cement conveyor :

Rotary Concrete Conveyor, 219 mm in diameter, 3 m; To transfer the cement from the cement silo to the cement weighing hopper.

Rotary Concrete Conveyor, diameter 219 mm, 9 m; To transfer the cement from the cement weighing hopper to the truck mixer .

Water meter

Galvanized water supply pipeline = 2 inches.

2-inch butterfly valve, with electric actuator.

Water flow meter, 2 in.

2 inch flexible coupler.

 

Air compressor : (supplied by the customer) .

500 liter tank air compressor, combined with twin electric motor 5.5 kW x 2 .

Cabin control in the mixing : ( be supplied from by the client )

Cabin mixing with the system operation, and the components of control station, the dimensions of 2 × 2 meters .

Operating System :

The station is fully automated through a programmable logic control panel system, in order to operate and control the parts of the mixing station, along with a computer display .

The system also provides daily and monthly reports in addition to manual control if necessary .

Electric motors for station parts :

All electric motors are assembled with safety devices against increase in temperature, voltage and current .

 

2- Technical features of the dry plant 60 m3/h, design     B00

Table of Contents :

Section 1: Loading, weighing and unloading aggregates .

Section 2: Loading, weighing and unloading of cement .

Section 3: Terminal Automation System .

Section 4: General information .

 

1- Loading, weighing and unloading aggregates :

1 -1 loading debris through the pavement slope .

The loading of aggregates is carried out using a forklift, through the ramp created (by the customer).

1-2 aggregate storage bins

Total storage 36 tons, with 3 compartments of 12 tons each .

The main storage body is made of a sheet of mild steel, with a steel angle bar and channels for reinforcement .

Complete with pneumatic cylinders to open and close the discharge gate .

1-3 aggregate weighing hopper

The capacitance is the same as the designated capacitance, and is connected to one (1) electric vibrator.MVE 100/3) for the sandbox .

Complete with four (4) load cells (each of 2000 kg) .

In addition to one (1) flat belt conveyor (width 600 mm) with a 7.5 kW motor operating at high speeds .

1-4 mixing conveyor

Its main support frame is of channel steel or square tubes, with a chevron belt (400/3) width of 600 mm for adequate material handling, driven by an 11 kW motor operating at high speeds .

 

2- Loading, weighing and unloading cement :

2 -1 Rotary Cement Conveyor

Diameter 219 mm of rotary type, with helical segmented die-back blades for consistent output, and driven by a heavy-duty gearbox motor .

2-2 cement weighing hopper

500 kg capacity, with three (3) load cells for high precision weighing .

Butterfly valve gate for degassing, to which a pneumatic actuator is attached to open and close, along with the vibrator .

 

3 - water meter

Water supply pipeline = 2 inches.

2-inch butterfly valve, with electric actuator.

Water flow meter, 2 in.

2 inch flexible coupler.

4- Station automation system :

Allows system automation station sequence control in materials for all steps, from order preparation for the production of concrete ready - to deliver concrete in a consistent / high efficiency .

Provides the program all reports daily and monthly special production plant and kept the components of the mixture of being called when needed it, you can monitor inventory and use of materials and a list of commands , trucks and tickets and to it .

It allows the system operation is easy to through screen graphics, in addition to the development of operating automated or manual .

5 - Information General :

 

All electrical and safety fixtures comply with relevant state regulations .

All materials are in accordance with the American Society for Testing and Materials code .

All welding operations are carried out in accordance with the code of European standards .

The station will be finished with a primer paint, and a suitable color for the final paint according to the customer's requirements .

(Sketch)

  

 

2- Africano 2 . Mixing Station Specifications 

Capacity : 30-50 m3 / h

hopper :

• The body of the hopper is made of steel, and is installed in 3 electronic cells of the center hole type ( Pongshin ).

• the structure of a solid with a level of Negotiable adjustable, for installation ( design Tleskubi ) during transport and operation .

• Weight range = zero - 10,000 kg for each one .

• Effective dry volume = 9 cubic meters .

• door discharge which works manually 1.

• An electric vibrator is installed in the cone of the hopper .

1: ( optional ): the door of discharge , which operates air compressed is available also .

Sir Carrier :

The length of the walk = 10.4 meters .

Belt width = 600 mm .

Gears of intermediate landing = diameter 89 mm at 40 degrees .

Capacity : 250 tons per hour .

The entire length is covered with an eco- friendly cover .

Link BIOS address vulcanizing completely .

Simple system for adjusting the " take " tension .

Engine carrier uses engine 7.5 kilo Watt operates at speeds .

Link rubber slope, diameter 500 mm .

 

rotary cement conveyor :

Rotary conveyor diameter 219 mm x 8000 mm length .

It has a rated capacity of 55 tons / hour .

Unit payment using the engine for service hard 7.5 kg Watt, with box gears .

Connected with a cement separator ramp .

Cement swivel strut installed .

Slope separator for cement bag .

During transport, it can be linked to the length of the structure of the body of the carrier .

 

water meter

Line pipe galvanized for the supply of water = 2 inches .

2- inch butterfly valve , with electric actuator .

Water flow meter , 2 in .

2 inch flexible coupler .

Control Manual, from the through - screen digital .

Pump water electrical 380 volt, priming a self 7.5 kilo watt .

 

axis of symmetry :

Heavy duty agricultural axle .

Track width = 2100 mm .

Loading capacity = 8000 kg .

 

electrical parts :

Main electrical panel , used with insulating protection IP55.

Emergency stop button .

Screen " panel results " digital developed large .

All engines electrical shielded fully with all requirements of safety necessary .

Balance Digital, with the points set .

The capacity of electrical classified by about 30 kilo watt, 380 volts, 50 Hz .

 

Special Features :

Low maintenance .

Ease of transportation .

Ease of installation in the least time for installation ( speed in installation and operation ).

No need to be the presence of foundations .

The cost of labor and skill required low .

Less requirements for an area free of land .

 

Africano 3 . Mixing Plant Specifications

Capacity : 50 - 65 m3 / h

 

hopper :

The hopper body is made of steel, and installed in 3 electronic cells of the center hole type ( Pongshin ).

The structure of a solid with a level of Negotiable adjustable, for installation during transport and operation .

Scale weight = zero - 10,000 kg for each one .

Effective dry volume = 9 cubic metres .

Discharge door operated by compressed air sliding valve .

An electric vibrator is installed in the cone of the hopper .

 

Sir Carrier :

The length of the walk = 10.4 meters .

Belt width = 600 mm .

Gears of intermediate landing = diameter 89 mm at 40 degrees .

Capacity : 350 tons per hour .

The entire length is covered with an eco- friendly cover .

Link BIOS address vulcanizing completely .

Simple system for adjusting the " take " tension .

Engine carrier uses the engine 11 kg Watt works at speeds .

Link rubber slope, diameter 500 mm .

 

rotary cement conveyor :

Rotary conveyor diameter 219 mm x 12000 mm length .

It has a rated capacity of 55 tons / hour .

Unit payment using the engine to service the arduous 11 kilo Watt, with box gears .

Connected with a cement separator ramp .

Cement swivel strut installed .

Slope separator for cement bag .

During transport, it can be linked to the length of the structure of the body of the carrier .

 

cement weighing hopper :

Capacity of 4500 kg, with a number of 3 units of cells loading high precision .

Valve discharge 250 mm, with the operator mechanic working air compressed .

Electric vibrator .

Chemical balance : ( optional )

30 liters, with one (1) unit of high precision load cells .

Pump Chemical 1.1 kilo Watt .

Valve discharge 60 mm, with the operator mechanic working air compressed .

 

water balance :

Balance galvanized, capacity of 2000 liters .

Number 3 units of cells loading high precision .

Valve discharge 150 mm, with the operator mechanic working air compressed .

Pump water electrical 380 volt, priming a self 7.5 kilo watt .

 

axis of symmetry :

Heavy duty agricultural axle .

Track width = 2100 mm .

Loading capacity = 8000 kg .

 

electrical parts :

Grand automated system , to be installed to be fully automated , with the ability to print .

Main electrical panel , used with insulating protection IP55.

Screen " panel results " digital developed large .

All engines electrical shielded fully with all requirements of safety necessary .

 

The compressor air : ( is supplied from by the client )

7.5 hp, 300 liter tank .

Cabin mixing : ( be supplied from by the client )

1.5 x 2 metres .

 

Special Features :

Low maintenance .

Ease of transportation .

Ease of installation in the least time for installation ( speed in installation and operation ).

No need to be the presence of foundations .

The cost of labor and skill required low .

Less requirements for an area free of land .

 

Mixing station operation manual :

1. Before operating the machine, make sure of that all parts of animation has been lubricated and lubricated as correct .

2. When you have has been the weight of cement and aggregates, always then run the BIOS carrier before discharge .

3. You must be not always discharge rate of 50% of the content of the water first; So as to avoid loading overload on the engine oriented cylinder .

4- The rubble, cement and water should be emptied at the same time, in order to avoid dust and dirt .

5. In each cycle in step weight, make sure of that all gates are responsive to put it right .

6. do not absolutely welded in the machine, so as to avoid damage to cells loading .

7- Keep the machine clean at all times .

8. If an event of any malfunction or injury, you must press the button stop emergency in the fastest time possible .

9- At the end of each working day , be sure to unplug the machine before leaving .

10. During transport, do not need to increase the speed of walking for 30 km / h .

 

Specifications of Ready Mix Concrete Batching Plant - Africano 4

Capacity : 50 - 65 m3 / h

 

hopper :

The hopper body is made of steel, and installed in 3 electronic cells of the center hole type ( Pongshin ).

The structure of a solid with a level of Negotiable adjustable, for installation ( design Tleskubi ) during transport and operation .

Scale weight = zero - 10,000 kg for each one .

Effective dry volume = 9 cubic metres .

Discharge door operated by compressed air sliding valve .

An electric vibrator is installed in the cone of the hopper .

Sir Carrier :

The length of the walk = 10.4 meters .

Belt width = 600 mm .

Gears of intermediate landing = diameter 89 mm at 40 degrees .

Capacity : 350 tons per hour .

The entire length is covered with an eco- friendly cover .

Link BIOS address vulcanizing completely .

Simple system for adjusting the " take " tension .

Engine carrier uses the engine 11 kg Watt works at speeds .

Link rubber slope, diameter 500 mm .

 

rotary cement conveyor

Rotary conveyor diameter 219 mm x 9000 mm length .

It has a rated capacity of 55 tons / hour .

Unit payment using the engine to service the arduous 11 kilo Watt, with box gears .

Cement swivel strut installed .

During transport, it can be linked to the length of the structure of the body of the carrier .

cement weighing hopper

Capacity of 4500 kg, with a number of 3 units of cells loading high precision .

Valve discharge 250 mm, with the operator mechanic working air compressed .

electric vibrator

Chemical Balance : ( Optional ) :

30 liters, with one (1) unit of high precision load cells .

Pump Chemical 1.1 kilo Watt .

Valve discharge 60 mm, with the operator mechanic working air compressed .

 

water balance :

Balance galvanized, capacity of 2000 liters .

Number 3 units of cells loading high precision .

Valve discharge 150 mm, with the operator mechanic working air compressed .

Pump water electrical 380 volt, priming a self 7.5 kilo watt .

 

axis of symmetry :

Heavy duty agricultural axle .

Track width = 2100 mm .

Loading capacity = 8000 kg .

 

 

electrical parts :

Grand automated system , to be installed to be fully automated , with the ability to print .

Main electrical panel , used with insulating protection IP55.

Screen " panel results " digital developed large .

All engines electrical shielded fully with all requirements of safety necessary .

 

The compressor air : ( is supplied from by the client ) :

7.5 hp, 300 liter tank .

Cabin mixing : ( be supplied from by the client )

1.5 x 2 metres .

 

Cement silo specifications and accessories :

55 ton capacity

Silo Supporting Lists , from a clip HEB, with corner reinforcements

Access ladder included

Tube fill in diameter 100 mm

Handrail included

Maintenance platform under the unloading gate is included

Valve butterfly diameter 300 mm, with the operator mechanic manual

level indicator

pressure relief valve

Aeration ring: 8 aeration points to increase cement flow when needed

Filtration unit : A cement filter is installed above the silo cover , in order to reduce cement particles in the atmosphere