Batching Plant Report

GROUP # 7
Department of Civil Engineering
BATC
HING
PLAN
T
Visit Report
Concrete Batching Plant
Practical Field Training
Table of Contents
Introduction:.........................................................................................................
Types of
Concrete
Batching
Plant:..................................................................................................................
Ready
mix
plant:.........................................................................................................
Central
mix
plant:.........................................................................................................
Detail
Description
about Plant:
.........................................................................................................................
Parts of
Batching
Plant:..................................................................................................................
Working of
Batching
Plant:..................................................................................................................
Group No. 07
MNS UET Multan
Operation
interface of
Plant:................................................................................................................
Concrete
classification:
.......................................................................................................................
Material used
in Concrete:
.......................................................................................................................
Concrete
Mix Designs
of Metro
Bus System
P-5:.................................................................................................................
Conclusion:
.......................................................................................................................
Group No. 07
MNS UET Multan
Abstract
&Acknowle
dgement
This report is consisting
of the case study of
"Concrete Batching Plant
located in Babur Chowk
near
Vehari
Chowk
Multan" in reference of
its working. In this report
there is brief discussion
on location of the plant,
different parts of Plant, Its
working, discussion about
the classes of concrete,
and material used etc.
This report can help the
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Group No. 07
MNS UET Multan
reader to understand the

process of batching of
concrete
and
its
procedure. Furthermore
there is a brief discussion
on the classes of concrete.
We are thankful to Sir
Muhammad Riaz Ahmad
who assigned the task to
learn about the concrete
batching plant. We are
especially thankful to the
HCS Company, Plant
operator
Muhammad
Iqbal and the Laboratory
engineers
who
gave
access and shared the
useful information about
the visit.
Group No. 07
MNS UET Multan
Group No. 07
MNS UET Multan
Concrete
Batching
Plant
GENERAL
DESCRIPTION:
Project Name:
Construction of
Metro Bus System, Multan
Location of Project:
Vehari chowk to Chowk
Kumharan wala
Consulted By:
Osmani & Co. (pvt)
LTD.
C
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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Location of Plant:
Babur Chowk near
Vehari Chowk Multan
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MNS UET Multan
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MNS UET Multan
I
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:
A concrete plant, also
known as a batch plant or
batching plant, is a device
that
combines
various
ingredients
to
form
concrete. Some of these
inputs include sand, water,
aggregate (rocks, gravel,
etc.), fly ash, potash, and
cement. A concrete plant
can have a variety of parts
and accessories, including
but not limited to: mixers
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Group No. 07
MNS UET Multan
(either tilt-up or horizontal

or in some cases both),
cement batchers, aggregate
batchers, conveyors, radial
stackers, aggregate bins,
cement
bins,
heaters,
chillers, cement silos, batch
plant controls, and dust
collectors (to minimize
environmental pollution).
The center of the concrete
batching plant is the mixer.
There are three types of
mixer: Tilt, pan, and twin
shaft mixer. The twin shaft
mixer can ensure an even
mixture of concrete and
large output, while the tilt
mixer offers a consistent
mix with much less
maintenance labor and cost.
Types of Concrete
Batching Plant:
There are two types of
concrete plants
1. Ready mix plants
2. Central mix plants
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MNS UET Multan
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A ready mix plant weighs
the sand, gravel and cement
in weigh batchers which
can be computer assisted.
All the ingredients then
combine in a confining
chute which discharges into
the ready mix truck.
Meanwhile, water is either
being
weighed
or
volumetrically metered and
15
Group No. 07
MNS UET Multan
discharged through the

same confining chute into
the ready mix truck. These
ingredients are then mixed
for a minimum of 10
minutes
during
transportation to the job
site.
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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Group No. 07
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:
There were two batching
plants at the site. Both have
1m3 capacity at a time. they
have some specification
Brand Name:
Bosure
Accuracy:
Depends
Power Supply:
24v
Display Type:
Digital
Model Number:
PLY1000
Parts of Batching Plant:

A concrete plant can have a
variety of parts and
accessories, including but
not limited to:
1. Mixers
(either tiltup
or
horizontal or
in
some
cases both),
the center of
the concrete
batching
plant is the
mixer.
2. cement
batchers
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Group No. 07
MNS UET Multan
3. aggregate
batchers
4. conveyors
5. radial
stackers
6. aggregate
bins
7. cement bins
8. heaters
9. chillers
10. cement silos
11. batch plant
controls
12. and
dust
collectors (to
minimize
environment
al pollution
The concrete batch plants
can be categorized into 4
parts:
i.
Aggregate feeding
ii.
Powder
feeding
(fly ash, cement
and
expanding
agent)
iii.
Water
and
admixture
for
mixing
the
materials
iv. Conveyance
and
storage
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Group No. 07
MNS UET Multan
1. Aggregate Feeding
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In this part of batching

plant there are 4 hoppers in
which aggregates are filled.
The aggregate and sand are
generally transferred to a
conveyor by using a front-
end loader to move the

material from the ground
storage piles to a hopper
that dumps onto the
conveyor. The emissions
are generated as the
material falls from the
bucket of the front-end
loader into the hopper. In
some cases, the piles may
be placed on top of underground hoppers, which are
fed by gravity instead of
front-end loaders, or the
front-end loader may dump
the aggregate directly into
the overhead bins
41
Group No. 07
MNS UET Multan
If the exact dimensions of

the
hopper
are
not
available, the hoppers are
generally about 12 feet by
12 feet, and about 10 feet
tall. The bottom of the
bucket of the front-end
loader can be assumed to be
3 feet above the top of the
hopper when dumping
material. There may be
more than one hopper, and
the hoppers may be used
for different materials (e.g.
sand
vs.
aggregate).
Therefore, the emission rate
may not be the same for
each hopper.
2. Powder feeding:
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In this part cement is filled

in it. Emissions are
generated by the filling of
the cement weigh hopper

from the cement and
supplement
silos.
The
exhaust from this source is
usually vented through a
cartridge filter in the side of
the weigh hopper, or
through a central bag house.
This source can be assumed to
operate for 37.5 minutes out
of each hour for truck-mix
facilities, and for only 30
minutes out of the hour for
central-mix
facilities.
Therefore the modeled hourly
emission rate can be reduced
by a factor of 37.5/60 and
30/60 for truck-mix and
central-mix
facilities
respectively.
43
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MNS UET Multan
3. Water tank:
In this section water is
filled for the concrete
mixing. The water is fresh
and
drinkable.
The
temperature of water is
controlled with the season
changing. It is kept as
designed for the mix
design.
4. Admixture tank:
In this section admixture is
stored and supplied via
pipes during the mixing of
concrete. Different types of
admixtures are used in
different concrete designs.
They are
accelerators,
retarder etc. for example
Ultra AG 200, Rheobuild
850, 0.75
44
Group No. 07
MNS UET Multan
Working of Batching
Plant:
Batching concrete is a
process whereby cement is
mixed
with
coarse
aggregate (graded crush)
and fine aggregate (sand
particularly pit sand) as
well as with water. This
depends on the type of the
batching
plant.
Some
concrete batch plants are
mobile while others are
rather massive that they
cannot be easily mobilized.
The Schematic flow chart
of the whole process is
given below
45
Group No. 07
MNS UET Multan
The
concrete batch plants can be

categorized into 4 parts:
aggregate feeding, powder
feeding (fly ash, cement
and expanding agent),
water and admixture for
mixing
the
materials,
conveyance and storage.
When the control system of
mixer is connected to an
electricity
source,
the
operation interface of the
man-machine
interaction
will appear and system will
begin
to
process
initialization
which
includes
the
formula
number, concrete slump,
46
Group No. 07
MNS UET Multan
concrete
grade
and
productivity. Each silo and
weighing hopper is tested
according to weighing
system. Its control system
will output the signal of the
amount of material to
prompt the operator to
decide whether to start the
control program or not.
47
Group No. 07
MNS UET Multan
The belt conveyor is

initiated to transmit the
aggregate to the weighing
hopper; the valve of the fly
ash and cement tank should
be opened and the screw
conveyor
and
motor
initiated to transmit them
into the weighing hopper;

the control valve of the
water sump and admixture
sump needs to be opened to
make water and admixture
flow into the weighing
hopper. Once the weight of
all material types meets the
needs of specific amounts,
the door of the weighing
hopper
is
opened
automatically.
The
materials will then be
mixed by a concrete mixer.
Once the setting time is
over, the loading door of
the concrete mixer opens
and the concrete flows into
a concrete mixer truck.
48
Group No. 07
MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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Group No. 07
MNS UET Multan
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MNS UET Multan
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Group No. 07
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Group No. 07
MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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MNS UET Multan
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Group No. 07
MNS UET Multan
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Group No. 07
MNS UET Multan
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73
Group No. 07
MNS UET Multan
n
g
.
Operation interface of
Plant:
All the operation process is
controlled by computerized
batching controller. In this
project Bosure model PLY
1000 is being used. Its
description is given below.
PLY1000
batching
controller
is
mainly
applicable
to
the
construction industry in the
concrete mixing plant or
station, to control multiple
scales (8, including bone
scales, cement scales, water
scales, scales liquid outside
agent, fly ash scales,
alternate
scales)
more
material
automatic
weighing bin automatic
batching
system
automatically
mix
the
ingredients.
PLY1000
batching
controller is based on a
variety of control theory
(productivity and structure)
and various types of
concrete mixing station
concrete mixing plant and
design; with loading rack
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Group No. 07
MNS UET Multan
chassis, improving the

overall structure level.
According
to
user
requirements,
connected
with the printer.
The controller uses an
advanced integrated circuits
and high reliability devices,
modular design, with high
weighing accuracy, simple,
affordable,
and
high
reliability.
Hardware design using the
latest highly integrated
high-speed CPU, ensuring
the reliability PLY1000
batching controller and
real-time
processing
capabilities,
high-speed
data acquisition 24 AD,
greatly
improving
the
accuracy of weighing and
batching. Unique antijamming design, so that the
controller can be used
reliably in harsh field
environments.
PLY1000
batching
controller with RS-232
serial communication port,
convenient and reliable
connection with the PC, to
achieve
greater
management
capabilities
and screen display function,
the control system to meet
the needs of different users.
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Group No. 07
MNS UET Multan
Following are the properties

of this model.
Material
weight
static
weighing
display
Single,
dynamic
weighing
more
material
weight
control
Material
mixing
process control
Mixing
concrete
discharge control
Recipe management
Plate
number
control
Manual, automatic
batching
control
mode
Continue to produce
the
production
pause, start after
Digital
calibrated
scales
(including
school and college
zero
end)
convenient
(to
school or school
alone zero end)
Fixed drop, drop the
optional automatic
tracking
compensation
in
two ways
Directly set 11,
commonly
used
parameters, the print
function, available
with a standard
printer,
aggregate
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MNS UET Multan
77
cumulative
measurement scales
four
kinds
of
materials can be
achieved on fast
slow feed
Cement warehouse
scales three radio
can be accumulated
automatically
broken arch
Water
weighing
control, time control
was outside agent
scales, ash scales,
weighing
two
alternate positions
cumulative or radio,
a
communication
function,
RS-232
serial
communication port
and
PC
communication
The clock display
and production time
record
The
abnormal
situation of alarm
and self-processing
functions
Square cumulative
total production and
control functions
Group No. 07
MNS UET Multan
In this picture all the

functions are controlled
with the buttons. These are
explained as
1. First of all type of
concrete is saved
with specific name
and order such as
A1, A2, A3, D1 and
D2.
2. Next quantity of
concrete is fed
which is to be
batched for example
1m3, 0.5m3 etc.
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MNS UET Multan
3. For each class of

concrete there is
separate mix design.
It is saved in the
system in weights.
For example water,
cement, aggregates
and admixtures. For
aggregates there are
4 buttons which are
directly linked to the
hoppers of different
size aggregate in
different quantities.
For the each class of
concrete
the
aggregate weight of
each size out of 1m3
is saved in it.
4. Similarly for each
class, weight of
cement, water and
admixtures
are
saved
in
the
controller.
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MNS UET Multan
When there is required of

any class of concrete
simply class is instructed
and quantity is put. The
aggregates of required
weight are dropped into the
conveyer then it is lifted up
into the mixer. Cement is
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Group No. 07
MNS UET Multan
weighted from its tank and

dropped into the mixer.
Similarly
water
and
admixtures came out of
required
weight
and
dropped into the mixer. The
mixing time is specified for
each class of concrete. For
example for A1, A2 it is 35

seconds. For A3 it is 37
seconds and for D2 it 45
seconds, Barrel mixing time
about 1 minute.
When mixing is completed
concrete is dropped into the
concrete transit mixer and it
takes it to the site. The
concrete slump is also
controlled here. For each
class concrete it is saved in
it.
Water content is controlled
for concrete with season.
For example in the winter
and rainy season the
aggregates are in SSD
condition so less water is
required.
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MNS UET Multan
Concrete classification:
Due to different strength in
the
different
designed
members
concrete
is
classified into different
classes. These are as
follows.
A1 for retaining
wall. Its slump
value is 80-100 mm,
setting time is about
90 minutes, 7 days
compressive
strength is greater
than 70% and 28
days strength is
3000 psi
A2 for pile cap,
transom. Its slump
value is 120 mm,
setting time is about
90 minutes, 7 days
compressive
strength is greater
than 70% and 28
days strength is
4000 psi
A3 for Piles. Its
slump value is 180
mm, setting time is
about 90 minutes, 7
days compressive
strength is greater
than 70% and 28
days strength is
4000 psi
D1 for Girders. Its
slump value is 14082
Group No. 07
MNS UET Multan
150 mm, setting

time is about 90
minutes, 7 days
compressive
strength is greater
than 70% and 28
days strength is
5000 psi
D2 for girders. Its
slump value is 140
mm, setting time is
about 90 minutes, 7
days compressive
strength is greater
than 70% and 28
days strength is
6250 psi.
Material used in
Concrete:
The material used in this
project for concrete is given
below
1.
83
Crush
Sand
Cement
Admixtures
Crush aggregate:
Group No. 07
MNS UET Multan
The crush used here is

Margla and Sargodha. It has
three different sizes. They
are 5mm, 10-16 mm and
16-25 mm. its unit weight is
2.425 g/cc.
2. Sand:
The sand used in the project
is larnispur sand.
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MNS UET Multan
3. Cement:
Three types of cements is
being used in this project.
These are
Mepal Leaf cement,
Comp. strength at
28
days:
10000 Psi
Pak cement
Fauji cement of
compressive
strength of 10,000
Psi
Every type of cement is
complies with almost all
kind of specifications and
codes ASTM, BS, EN
codes are followed by them.
4. Admixtures:
Two types of admixtures
used in the project which
are as follows.
Ultra AG 200
Rheobuild 850
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Group No. 07
MNS UET Multan
86
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MNS UET Multan
Concrete Mix
Designs of Metro
Bus System P-5:
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Group No. 07
MNS UET Multan
Summary of Mix Design:
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Group No. 07
MNS UET Multan
Conclusion:
From my case of study I am able to know about the manufacturing process of concrete batching
plant. It was very helpful to us to learn about their parts, working process. We also learnt about
the different classes of concrete used in the metro bus system Multan, its mix design,
proportioning of material by weight and compressive strength of concrete also. But some faults
we noted there was no exact water content used. Similarly there was no calculation for aggregate
if it is saturated due to rain. The other thing was that there was lot of dust on the aggregates
which may affect the properties of concrete.
89
Group No. 07
MNS UET Multan

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GROUP # 7

Department of Civil Engineering

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

reader to understand the

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

(either tilt-up or horizontal

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

Department of Civil Engineering

MNS UET Multan

Concrete Batching Plant

Practical Field Training

discharged through the

Department of Civil Engineering