A dry batch concrete plant mixes the dry ingredients of concrete (sand, gravel, aggregates, and chemical admixtures) together to create a dry ready mix for construction projects. These plants are a cornerstone of the construction industry, although many don’t understand the components used to manufacture and mix concrete. While a wet mix concrete plant will create ready-mixed concrete on-site, a dry batch plant design mixes the ingredients without water.

If you’d like to understand the process of dry batch concrete batching, this article will help guide you. Lontto is a leading block- and brick-making machine supplier, offering stationary and mobile concrete-making machines for small-scale commercial businesses. We’ve outlined the main components of a dry concrete batch plant, its advantages and challenges, and how plant manufacturers are improving each day.

Key Takeaways

  • A dry batch concrete plant's main components are an aggregate storage system, cement and SCM silos, conveyors, and various weighing hoppers and control systems.
  • Stationary dry batch plants offer higher production and storage, but are unable to move. Mobile plants are the opposite.
  • A dry batch plant has a cheaper initial investment than a wet concrete plant, but may produce lower-quality concrete mix.

What are the Components of a Dry Batch Concrete Plant?

dry batch concrete plant components

what are the components of a dry batch concrete plant

A dry batch concrete plant has several main components including an aggregate storage system, conveyors, silos, weigh hoppers, and mixers. Here is an in-depth guide to how each batching equipment component works to deliver your construction site ready-mix concrete:

Aggregate Storage System

The aggregate storage system holds the plant’s supply of important ingredients to create the dry mix of concrete. Aggregates make up around 60 to 80% of the concrete mix and are critical to creating a batch of concrete. While the specific aggregates may vary from batcher to batcher, generally it will hold either coarse or fine aggregates comprised of:

  • Sand
  • Gravel
  • Crushed Stone
  • Recycled Concrete

The storage system keeps these cement dry mix aggregates segregated until they are mixed and free from moisture.

Cement and Supplementary Cementitious Material Silos

The cement and supplementary cementitious material (SCM) silos hold the other 20 to 40% of the concrete mixer ingredients. These critical components include fly ash, micro silica, slag, and cement. The type of silo used can also vary depending on the environment or situation, such as horizontal silos which are used in constrained spaces, or portable silos for mobile concrete plants.

Conveyor System

When the aggregates are ready to be mixed with the cement-based material, they are transported from the storage system using a conveyor system. The most common type of conveyor system is a belt system, although screw and bucket elevators are also sometimes used. For high-production environments, however, belt systems are preferred as they can handle large volumes of aggregates.

Weigh Hoppers

The conveyor belt brings the necessary components of concrete to the weigh hoppers from the silos and aggregate storage. Next, the weigh hoppers precisely measure the amount of aggregate and SCM. In many dry batch plants, there may be multiple to weigh hoppers for each material. This allows for more specific measurements and reduces the risk of contamination.

Mixer

The final step completed by the dry batch concrete plant is to transfer the finely measured ingredients into a mixer truck. The cement mixer truck mixes the aggregates and cement together on the way to the site, which allows for efficient material handling when it arrives. This also makes a dry batch plant a smaller investment for businesses, as they lack a central mixer.

Types of Dry Batch Concrete Plantstypes of dry batch concrete plants

kinds of dry batch concrete plants

There are two main types of dry batch concrete plants: stationary and mobile. Each offers a practical choice for different production needs for construction projects.

Stationary Concrete Batching Plant

A stationary plant is designed for long-term use and high production of cement materials. While a stationary plant will lack wheels or towing system, this allows them to have heavy-duty silos, conveyors, and a bigger aggregate batcher and storage system. A stationary batching plant can also offer flexibility in production, with a custom design to match the production needs of your project.

Mobile Concrete Batch Plant

While stationary concrete plants excel in production and storage capacity, some construction projects require flexibility and easy-to-transport equipment options. A mobile concrete batch plant has a way to move them from site to site, usually a towing system or wheels. This makes them suitable for both large and small projects with varying needs for concrete.

Advantages and Disadvantages of Dry Batch Plants

Advantages of Dry Batch Concrete Plants Disadvantages of Dry Batch Concrete Plants
  • Lower Initial Investment
  • Reduced Construction Time
  • Lower Maintenance Costs
  • Lower Environmental Impact
  • High Bin Capacity
  • Inconsistent Concrete Quality
  • Limited Applications
  • Less Control Over Mixing

Technological Innovations for Dry Batch Plants

Technology has a profound impact on the efficiency of plants and may remove their disadvantages in the near future. Smart control systems and the integration of AI and IoT can boost the real-time monitoring capabilities of dry batch plants. These can save on costs in the long term by ensuring that concrete quality is consistent and downtime is minimized.

Current processes are also being studied for more efficient output and lower environmental impact. For instance, the Department of Plant Production and Agricultural Technology in Spain found that recycling aggregates and optimizing concrete dosages could reduce costs by as much as 17.8%.

Our team at Lontto prides itself on leading the industry with our advanced brick-making solutions. We offer 30 years of experience to match your construction needs with our high-tech equipment, and provide training for your recently installed Lontto brick-making machines. Request a quote and learn how our batchers can support your project today.

Concrete Patch Plant FAQs

What is the mixing ratio of Dry Batch Concrete?

The most commonly used mixing ratios are 1:2:4 and 1:6:12 — cement, fine aggregate, and coarse aggregate. These mixing ratios can vary depending on what you need for your specific project. For example, a high-strength dry batch would use a ratio that has more cement (around 1:2:3 or 1:1.5:3).

Some studies carried out by Umm Al-Qura University show that crushed aggregates may have a bigger impact on the strength of concrete compared to uncrushed aggregates, which can also alter the ratio required for a high-strength mix.

How do you maintain a Dry Batching Plant?

Maintaining a concrete batching plant at its full production capabilities requires that you:

  • Clean and replace filters regularly
  • Follow a daily inspection routine
  • Lubricate moving parts
  • Recalibrate weighing and measurement sensors
  • Update system controls

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chao zhang

Author: Chao Zhang

I am Chao Zhang, I have been working in the brick making industry for over 10 years. I have a deep understanding and research on various models of block making machines, especially automatic brick machines, concrete block machines, compressed earth block machines, clay brick machines, cement brick machines. I have a special understanding of this industry. I can help my clients choose the suitable brick machine and assist them in designing and building a brick production factory. If you want to know everything about brick making machines, please contact me. I am happy to help you.