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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