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CONCRETE BATCH PLANTS
Uur KARAHAN
2010706030
CE 579GRADUATE SEMINAR
Prof. Dr. S. Semih TEZCAN
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What is Concrete?
The Concrete Production Process at aStationary Batch Plant
Environmental Objectives and Performanceof Batch Plants
Classifications of Batch Plants
Agenda
Batch Plant Certification
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WHAT IS CONCRETE?
Concrete is manufactured by mixingcarefully controlled proportions ofportland cement, coarse aggregates(gravel, crushed stone or slag), fine
aggregates (sand) and water.
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BATCH PLANTS
Concrete batch plants are used in thepreparation of ready mixed concrete. Such
plants typically include a supply ofcement, water, aggregates and admixtures.At the batch plant these mix ingredientsare measured by either mass or volume
and introduced in the mixer. To produceconcrete of uniform quality, the
ingredients must be measured accuratelyfor each batch.
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Portable Plants
Portable plants as the namesuggests are able to berelocated relatively easily.In general, they have a
cement silo and anoverhead bin for one or twoaggregates. They typicallymove to the constructionsite in cases where thedistance the trans-mixershave to travel is too far.
Classification By Mobility
These plants operate from the same location for arelatively long period of time.
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Central Mixing or Wet Batching
The dry batch process differsfrom wet batching only in thatthe constituent materials areweighed and then discharged
"dry" into the drum of thevehicle used to transport themix.
Classification by Mix
Water and any admixture are addedsimultaneously with the dry materials, and then
the mixing process takes place in the transportvehicle.
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Shrink Mixed Concrete
Concrete that is partially mixed in a plant mixerand then discharged into the drum of the truckmixer for completion of the mixing is calledshrink mixed concrete. The amount of mixing that
is needed in the truck mixer varies and should bedetermined via mixer uniformity tests. Generally,about thirty turns in the truck drum, or about twominutes at mixing speed, is sufficient to
completely mix shrink-mixed concrete.
Classification by Mix
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THE CONCRETE PRODUCTION PROCESS AT
A STATIONARY BATCH PLANT
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THE CONCRETE PRODUCTION PROCESS AT
A STATIONARY BATCH PLANT
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ENVIRONMENTAL OBJECTIVES ANDPERFORMANCE OF BATCH PLANTS
Batch plant operators should be cognizant ofthe environmental impact of their plants. At a well-managed concrete production plant, the main areasof environmental significance are kept under
constant review to ensure that local and nationallaws are being followed.
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External appearance:
The aim here is to ensure that plant
operations are landscaped and screened from thesurrounding industrial, commercial, residential orrural community so that the impact on the localenvironment is reduced.
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ENVIRONMENTAL OBJECTIVES ANDPERFORMANCE OF BATCH PLANTS
Traffic Control and Cleanliness:
The aims here are to ensure that traffic will
avoid sensitive areas, vehicles are maintained in aclean condition and that concrete spillage on publichighways is avoided.
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Plant, office buildings and staff facilities:All buildings, plant and machinery are to be
maintained regularly and repaired as necessary.Office buildings are cleaned and cared forinternally and have adequate toilet facilities forstaff and visitors.
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ENVIRONMENTAL OBJECTIVES ANDPERFORMANCE OF BATCH PLANTS
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Dust Control:Batch plant operators must use
appropriate technology to ensure that dustemissions are in line with local and nationalregulations. Where required, dust monitoringshould be undertaken for environmental, healthand safety purposes. Guidelines should beprovided to staff on the procedures that must befollowed to reduce dust production. The batch
plant can also be retrofitted with filters and otherequipment to reduce the amount of dust thatescapes from both cement and aggregates in the
batching process.
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ENVIRONMENTAL OBJECTIVES ANDPERFORMANCE OF BATCH PLANTS
Water management:
Here the aims are to improve the quality ofeffluent discharge, reduce volumes of discharge,and restrict water usage and wastage.Procedures should be adopted for controlling theuse and wastage of water at the plant.
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Noise and vibration:Batch plant operators should try to
ensure that plant, vehicle noise and vibrations arekept to a minimum. This can be achieved througheither plant design or the use of appropriatetechnology.
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ENVIRONMENTAL OBJECTIVES ANDPERFORMANCE OF BATCH PLANTS
Waste management:
The goal here is to introduce procedures andworking practices which reduce the production ofwaste. In cases where waste production cannot beavoided, the plant operator should try to provideenvironmentally sound treatment and disposal
methods or find markets for its use as a resource.04.05.2012 18
Fuel, oil and admixture storage:The goal here should be preventing the
pollution of surrounding surface and groundwaters from accidental spillage of fuel, oil oradmixtures from storage tanks either above or
below grade. Routine inspections are to be made forleaks or spillage from these storage facilities.
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ENVIRONMENTAL OBJECTIVES ANDPERFORMANCE OF BATCH PLANTS
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Communication:
Employees should be fully aware of theirresponsibility to the environment. All employeesshould receive training to increase their awareness
of their responsibility to the environment. Theyshould also be encouraged to give high priority tosite care and good housekeeping.
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BATCH PLANT CERTIFICATION
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To achieve certification, a licensed
professional engineer must inspect each plant forcompliance with the requirements of a designatedchecklist. Certification goes beyond the workings ofthe actual plant, covering proper aggregate storage
to avoid contamination, water for batching,admixtures, etc.
Scale calibration is very important, andcertification requires the scales to be accurate
within 0.20% of scale capacity throughout therange of measurement. Certification also extendsto record keeping and proper ticketing for eachload.
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BATCH PLANT CERTIFICATION
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Specifications for Ready Mixed Concrete:
*all pertinent information must be on eachload ticket,
*such as the mix number,
*the truck number,
*the job address,
*the name of the contractor or purchaser,
*the time the truck was loaded,
*the mix design being supplied with adescription, etc.
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QUESTIONS & VISIONS
oazii University
ivil Engineering Department04.05.2012 23
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