Dry type concrete batching plants represent a different approach in the concrete production where the ingredients are initially mixed without water. The method has clear merits, primarily from a logistic, economic, and environmental perspective, in the case of transporting concrete to the site and mixing during transport.
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Dry batching plants are especially preferred where distance from the plant to the point of application is considerable, as the ultimate mixing occurs during transit. They are usually used in mega construction projects such as dams, mass housing, highways, and bridges. Polygonmachine emphasizes their use in quick construction and infrastructure development programs. They can also be used in dry regions, where water supply is scarce, or regions where water usage is controlled.
This section provides a comparative analysis of on-site mobile and traditional stationary concrete batching plants. It focuses on their advantages and disadvantages in terms of installation, preparation time, labor requirements, and overall project flexibility. This comparison is critical for strategic decision-making in equipment procurement.
These plants are designed for portability and rapid on-site setup. By dosing concrete directly at the construction site, they reduce delays and manual effort, eliminating the need for external truck deliveries and extensive on-site labor. Polygonmachine emphasizes its mobile and compact solutions for clients needing fast, on-site concrete production.
Parameter Specification Production Capacity 30 – 150 m³/h Mixer Type Pan, Planetary, Twin Shaft Mixer Capacity 0.5 – 3.33 m³ per cycle Mixer Motor Power 18.5 – 2×55 kW Aggregate Hopper Volume 4×2.5 – 4×25 m³ Aggregate Weighing Hopper 0.75 – 4.5 m³ Cement Weighing Hopper 300 – 1,800 kg Water Weighing Hopper 160 – 1,000 liters Additive Weighing Hopper 15 – 100 liters Air Compressor 300 – 1,200 liters, 4 – 15 kW Cement Silo Capacity 50 – 500 tonnes (optional) Control System Fully Automatic (PLC-based) Total Motor Power 45 – 205 kW Required Area to Operate 400 – 2,500 m² Aggregate Feeding System Ramp or Pre-Feeding System Aggregate Transfer Conveyor Belt conveyors or skip hoist systems Weighing Accuracy ±1% for aggregates, ±0.5% for cement and water Automation Components Siemens & Schneider brand electronic components and PLC3D concrete printing plants represent a revolutionary advancement in the construction sector. This technology enables the automated, additive manufacturing of concrete structures directly on-site, offering unprecedented design freedom, accelerated construction timelines, and reduced material waste.
3D concrete printing plants are specialized systems designed for additive manufacturing using concrete. Typically, they involve a robotic arm or gantry system that precisely extrudes a specially formulated concrete mix to build structures layer by layer.
The process begins with a digital design (CAD file). The 3D printer, usually integrated with a mobile batching unit, receives a hyper-precise concrete mix. The printer then moves along a predefined path, extruding the concrete at a controlled flow rate and speed to construct the structure layer by layer. Built-in site positioning systems such as laser alignment tools ensure perfect coordination with CAD files. Real-time monitoring via integrated sensors and HD cameras ensures quality assurance and allows for remote operation and adjustments based on environmental conditions.
Parameter Specification Printing Technology Extrusion-based additive manufacturing Printer Types Gantry systems, Robotic arms, Mobile crawlers, Track-mounted systems Build Volume Up to 40,000 x 1,350 x 3,250 mm (L x W x H) Print Speed Up to 500 mm/s (e.g., CyBe G 3DP) Nozzle Types Circular (10–40 mm), Rectangular/Square (width: 10–50 mm, thickness: 10–20 mm) Layer Dimensions Width: 30–80 mm; Height: 6–15 mm; Maximum unsupported overhang: up to 85.5° Material Delivery System Positive displacement pumps with continuous flow Control System PLC-based automation with slicing software integration Reinforcement Options Fiber reinforcement, Welded wire meshes, Integration of rebar Concrete Mix Requirements High buildability and extrudability; may include admixtures like nano-silica, fly ash, superplasticizers Power Requirements Varies based on printer size and type; specific power ratings depend on equipment specifications Operational Footprint Dependent on printer type; mobile units require less space, while gantry systems need larger areas Applications Residential housing, Infrastructure components, Architectural elements, Precast modules, On-site constructionRoller Compacted Concrete (RCC) is a special, stiff, and extremely dry concrete mix that is compacted by vibratory rollers. RCC plants are special batching plants that produce this special concrete mix, which is highly suitable for heavy-duty pavements, dams, and other massive infrastructure projects that need durability and quick construction.
American Concrete Institute (ACI) has defined roller compacted concrete (RCC) as: “concrete compacted by roller while in its unhardened state, stiff enough to support a roller.” RCC can also be described as dry, very stiff concrete with consistency similar to damp gravel.
It contains far less water than regular concrete, so the mixture is drier and will not slump. Its consistency is more like wet gravel.
Like asphalt, it is placed by a paver and compacted by rollers. The roller compacted concrete is externally consolidated or compacted by large vibratory rollers. The fully compacted and hardened RCC properties are similar to those of traditionally placed concrete.
RCC even attains higher flexural strength than ordinary concrete, with strength developing quickly in excess of 5.5 MPa. Its high flexural, compressive, and shear strength allows it to withstand repetitive, heavy loading without failure.
Parameter Specification Production Capacity Up to 800 tons/hour Mixer Type Twin-shaft continuous mixer Mixer Capacity 2×5.0 m³ per cycle Mixer Motor Power 2×90 kW Aggregate Bins 4–8 compartments, each with 20–75 m³ capacity Aggregate Feeding System Ramp or pre-feeding system Aggregate Transfer Conveyor Belt conveyor system Air Compressor Included; piston or screw type, 7.5 kW Cement Weighing Hopper 2×2,500 kg capacity Water Weighing Hopper 2×1,200 kg capacity Additive Weighing Hopper 2–6 units, each with 20–60 kg capacity Cement Screw Conveyor 1–8 units, diameter 323 mm Control System Fully automatic, PLC-based system Operational Features Intelligent automation, compact design, modular components, cost efficiency Applications Highways, airport runways, municipal roads requiring continuous high-volume outputConcrete and mortar mixers are essential equipment in the field of construction that aids in achieving a well-mixed blend of materials such as cement, water, sand, gravel, and other admixtures. The selection of mixer is of the utmost significance in the quality and strength of the concrete and the general safety of the project.
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Polygonmachine offers a wide range of concrete and mortar mixers, including Pan, Planetary, Single Shaft, Twin Shaft, and Cone mixers. Each mixer type is suited for a specific concrete type or end-user application.
Drum Mixers:
These mixers employ a rotating drum for mixing the materials. Blades within the drum lift and fall the material in order to mix. Because of their uncomplicated structure, simplicity in operation, and low price, they are apt for small-scale works. The quality of mixing is inferior, and production capacity is restricted, so they are not suitable for the production of high-standard concrete.
Pan Mixers:
They possess a heavy circular mixing pan, typically with blades or paddles mounted on a vertical shaft. In most modern designs, the pan is stationary and star-shaped blades rotate, often assisted by a scraper arm to mix all materials with high shear force. They mix more quickly and uniformly than drum mixers. Ideal for precision-intensive applications such as precast concrete products, wall mortar, tile adhesives, and colored concrete.
Planetary Mixers:
A unique sub-type of the pan mixer, planetary mixers achieve intense mixing action. One or two central mixing stars (equipped with multiple paddles) not only spin around their own axes but also revolve around the mixer center, creating a counter-current effect with high shear forces for uniform particle coating in a short time. Due to their high shear force and fast mixing cycles, they are used for special mixes like high-performance concrete, fiber-reinforced concrete, and ultra-high-strength concrete. Preferred for small to medium batch sizes where quality is more important than quantity.
Twin Shaft Mixers:
With two horizontal mixing shafts, oppositely rotating intermeshing blades intensely mix the batch. Their final strengths are extremely high mixing intensity and speed. With heavy-duty gearboxes, wear-resistant liners, and strong steel construction, they are built. It is the most popular mixer type for high-capacity ready-mix concrete production. They achieve high homogeneity in very short cycles and are therefore the first choice for ready-mix concrete plants and large infrastructure projects.
Single Shaft Mixers:
These mixers typically have mixing blades on a single horizontal or vertical shaft. They offer flexibility for various concrete and mortar applications. Polygonmachine supplies them with auto lubrication systems and easy maintenance access.
Cone Mixers:
A twin-cone mixing device used to mix dry powders and granules gently and thoroughly. It consists of a pair of cone-shaped containers fused at their widest diameters and a central rotating shaft that is fitted with agitators or mixing blades. As the cones turn in opposite directions, powders or granules are intensively mixed and circulated inside the container. Ideal for gentle and thorough mixing of dry powders and granules without inflicting injury to fragile particles. Variable speed controls for customized mixing.
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