Concrete batching plants: the process of basic mixing systems

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26 September 2016
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Do you want to understand a little more in depth the basic mixing process for concrete blocks?

First of all we would like to mention that the vibro-compressed concrete elements used by Poyatos are used in practically every country in the world due to their high quality and economical value in housing construction.

There is also a wide range of aggregates which can be used for the production of different sizes and shapes of concrete units.

We will now take you through the process step by step:

Dosage for concrete batching plants

As you know, concrete is a mass made up of a mixture of cement, water, sands and gravel with fine aggregates, or sands and gravel with coarse aggregates, as well as different additives. Once they have set they acquire considerable strength. For this to take place the aggregates must be evenly distributed throughout the mix which is of primary importance to avoid the appearance of lumps.

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Dosage therefore entails the automatic control and exact measurement of the quantities of aggregates in order to comply with the specifications of quality control regulations.

Hoppers for sand and gravel storage

Once the first step has been finalized, the aggregates are stored in hoppers built by the client in concrete or metal prefabricated units. The aggregates are separated by type and size depending on the required mixing process.

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The number of hoppers required depends on the number of aggregates although in most cases a minimum of two hoppers is required – one for fine aggregates and another for coarse aggregates (these can be of sand and gravel or crushed stone respectively).

Volume-based dosage belt conveyors

These are also called feeders; they transport the material from each hopper via a horizontal collecting belt, or skip, to the mixer.

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A weighing belt is also used for each hopper in order to automatically monitor each aggregate on the control panel designed for this purpose.

Elevator belt or skip

The purpose of this belt is to elevate the measured aggregates to the mixer. At Poyatos these are custom designed for each project.

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Cement Silos

At Poyatos we recommend using bulk cement which requires a silo for correct storage. Silo capacity will vary depending on the daily planned consumption of your concrete batching plant as well as on the reliability of your cement provider (a 60-ton silo is usually required).

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Frames to support the mixer for your concrete block making factory

This is a metal or concrete structure that is used to support the mixer. This can be built to measure by the client or factory supplied.

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Mixers

The quality of the final product begins with the drum capacity; therefore it is important to pay special attention to the mix design and mixer capacity.

All the aggregates, cement and water are poured into the mixer which consists of a vertical axis and a centrifugal system equipped with blades and replaceable sheets of anti-abrasive steel.

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They are designed to prepare a homogeneous mix with the degrees of humidity and consistency that are required for the production of vibro-compressed pieces. This is a fast, optimum system for high-performance concrete and at verified low cost.

Water dosage timer

This is an automatic device which controls the quantity of water (pre-established for correct humidity levels) which the system requires in order to work automatically in optimum conditions.

Control desk

Lastly, the entire process of dosage and mixing in concrete batching plants is administered by an automatic system that controls the input of aggregates, cement dosage and the degree of humidity required by the process.

The system also provides a report on the consumption by unit of time and/or weight of sand, gravel, cement and water.

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