What Is A Stationary Concrete Batch Mix Plant?

A stationary concrete batch mix plant is a large-scale equipment used for centralized production of concrete. Because of its fixed operation location and strong production capacity, it is mainly suitable for long-term stable concrete production scenarios, such as large-scale construction projects, bridge construction, prefabricated component factories, commercial concrete production enterprises, etc. Stationary concrete batch plant measures and mixes raw materials such as cement, sand, water and admixtures according to a preset mix ratio, and finally produces concrete that meets quality requirements. It is an indispensable infrastructure in modern building industrialization.
 

2. Core component systems and functions of stationary concrete batch mix plant:
(I) Raw material storage system
- Cement silo: usually a cylindrical steel structure tank, the capacity is designed according to production needs (such as 50 tons, 100 tons, etc.), equipped with dust removal devices and material level sensors to prevent dust pollution and monitor the inventory in real time.
- Aggregate silo: used to store aggregates such as sand and stone, mostly adopts a partition design (generally divided into 3-6 silos), and uses partition walls to distinguish materials of different particle sizes. A discharge port and a vibration device are set at the bottom to ensure smooth discharge of aggregates.
- Admixture tank and water tank: store liquid admixture and mixing water respectively, mostly closed tanks, equipped with metering pumps or flow meters to control the amount.

(II) Measuring system
- Aggregate metering: use belt scales, electronic scales or cumulative scales to accurately weigh sand and stone, with the error controlled within ±2% to ensure accurate mix ratio.
- Cement and powder metering: use screw conveyors with electronic scales to achieve quantitative transportation and weighing of powder, with an accuracy requirement of ±1%.
- Water and admixture metering: control the amount of addition through flow meters or weighing metering tanks, with an error of no more than ±1%.

(III) Mixing system
Mixer: It is the core component of the concrete batching plant. Common types include:
- Forced mixer: It forces materials to be mixed through the rotation of blades. It is suitable for dry hard, semi-dry hard and plastic concrete. It has high mixing efficiency and good uniformity, such as the JS series twin-shaft mixer.
- Free-fall mixer: It is rarely used in stationary concrete plants. It mainly achieves mixing through the falling of the material by its own weight. It is suitable for fluid concrete.
The mixing capacity is selected according to production needs. For example, the JS1000 main machine can mix 1 cubic meter of concrete each time, and with different configurations, it can form a production capacity of 50-200 cubic meters per hour.

(IV) Control system
- Automation control cabinet: integrated PLC (programmable logic controller) and touch screen to achieve full process automation control, including one-click operation of raw material metering, transportation, mixing and unloading.
- Management software: can be connected to the ERP system to record production data (such as mix ratio, output, raw material consumption, etc.), generate reports, and facilitate quality traceability and cost management.
- Safety monitoring: equipped with overload protection, fault alarm, dust concentration monitoring and other functions to ensure the safety of equipment operation.

(V) Conveying and unloading system
- Aggregate conveying: mostly use belt conveyors or plate chain elevators to transport aggregates from the silo to the metering device or mixing main machine.
- Powder conveying: cement, fly ash and other powders are sent from the storage silo to the metering tank through screw conveyors or pneumatic conveying (compressed air).
- Concrete unloading: After mixing, the concrete is unloaded into the concrete mixer truck or batching machine through the unloading door under the main machine. Some stations are equipped with a unloading hopper lifting device to adapt to transportation tools of different heights.
 

3. Typical characteristics and advantages
- High production efficiency
The production capacity can reach 50-200 cubic meters per hour, which is suitable for large-scale continuous production. For example, the average daily output of commercial concrete mixing stations can reach thousands of cubic meters.

- Strict precision control
The metering system adopts electronic weighing, combined with automatic control, the error of raw material ratio is small, and the indicators such as concrete strength and durability are guaranteed to be stable.

- High degree of automation
The whole process from batching to mixing is automated, reducing manual intervention, reducing labor intensity, and avoiding human operation errors.

- Environmentally friendly design
Equipped with dust collectors (such as bag dust collectors) and noise isolation devices, some stations are equipped with wastewater recovery systems (recycled after sedimentation), which meet environmental protection requirements.

- Flexible configuration
The main machine model, number of aggregate silos, powder silo capacity, etc. can be adjusted according to needs to adapt to different project scales and concrete types (such as high-performance concrete, waterproof concrete).
 

4. Application scenarios and typical cases
- Large-scale construction projects:
Such as high-rise office buildings and residential quarters, which require long-term and stable supply of concrete. Stationary concrete mixing stations can be directly set up near the construction site to reduce transportation losses.
- Infrastructure projects:
In the construction of bridges, tunnels, and highways, the amount of concrete used is large and the grades are diverse. Stationary concrete plants can adjust the mix ratio as needed, such as the production of C30-C60 concrete.
- Prefabricated component plants:
Used to produce prefabricated parts such as floor slabs and bridge box girders, which require high concrete density and uniform performance. The precise measurement and forced mixing of stationary concrete batching plants can meet the process requirements.
- Commodity concrete enterprises:
As a commercial production base, they supply concrete to multiple construction sites and reduce costs through large-scale production. For example, large domestic commercial mixing stations are usually equipped with 2-3 sets of stationary concrete mixing equipment.
 

Through the above analysis, as a key equipment for building industrialization, the high efficiency, precision and environmental protection characteristics of stationary concrete batch mix plants are constantly promoting the development of concrete production towards standardization and scale.