Purchasing Guide of Mobile Concrete Batching Plants

Introduction

Many construction projects may face such challenges: unfixed construction site, short schedule, or the local supply of ready-mixed concrete is insufficient. A stationary concrete batching plant has a long construction period and it is difficult to move it after finishing and buying ready mixed cement will be limited by transportation distance or road conditions so that many contractors pay attention to mobile plant.

After reading this passage, it will help you organize the equipment’s working logic and which applications it is suitable for. You can also have a clear understanding of production capacity, working conditions, moving and conveying, total cost, and how to choose the best one.

 

I. What is a Mobile Concrete Batching Plant

A mobile concrete batching plant is a complete concrete production system, integrated onto a chassis or trailer frame. The whole set of equipment integrates aggregate loading, metering, mixing, and the control system. There is no need for large-scale civil construction. After completing construction at one work site, it can be disassembled and transferred to the next construction site to continue work. The core difference between it and the stationary concrete batching plant is not how much concrete can be produced per hour, but that the stationary concrete batching plant prioritizes long-term stable mass production. The mobile concrete batching plant prioritizes concrete production capacity and the feasibility of site relocation.

 

II. Comparison Between Mobile Concrete Batching Plant and Stationary Concrete Batching Plant 

	Stationary	Mobile
Flexibility	Is fragmented, with each unit placed independently.	integrated into the frame, reducing the number of separate parts.
Installation process	needs to pour a large area of equipment foundation and pre-embed ground bolts. The whole installation cycle often takes several weeks.	does not require complex foundation construction. After the equipment is in place, the pipeline connection is completed, and the calibration of the measurement system can be completed before trial production.
Transportation	requires almost all the components to be disassembled and transported in a large number of vehicles.	can be divided into a few transportation units according to the transportation specifications, and the trailer directly completes the transfer.
Venue conditions	has no strict restrictions on site space, but it must have a solid foundation.	has smaller requirements for the site area, but the ground bearing capacity and flatness need to meet the placement requirements of the frame.
Project cycle	more suitable for cross-year and year-round continuous production projects.	more suitable for short-term and phased construction tasks.
Application scenario	mostly used in fixed building materials industrial parks and long-term prefabricated component factories.	mostly used in line-type projects and multi-point scattered construction sites.

 

III. Where is “Mobile” Reflected

Many people will misunderstand that the mobile concrete batching plant can be driven around like a truck, which is not the actual situation. Its mobile properties come from the structural design of the whole set of equipment, not from its own driving power.

The whole set of equipment uses an integrated structure, and the silo, measuring unit, host and control cabinet are integrated as much as possible to reduce the scattered assembly parts on site. Most of the units rely on the trailer chassis as the supporting base, and most of the assembly work has been completed when the equipment leaves the factory.

This reduces the on-site installation workload and there is no need for on-site welding and a large number of steel structure splicing operations. After completing the work at one construction site, you can quickly complete the disassembly, packaging, and transfer to the new construction site.

The production and conveying systems for loading, weighing, and mixing are integrated with the frame. After the transfer is completed and the plant is repositioned, there is no need to rebuild the whole set of conveying lines.

 

IV.  How does a Mobile Concrete Batching Plant Work

Aggregate loading → material weighing → cement, water, and admixture batching → material mixing → finished concrete unloading. [ Picture]

Aggregate material hopper

Sand and gravel aggregates are loaded by external loaders to complete the supply, and the equipment has its own storage and conveying system to transport the materials to the measurement stage.

What needs more attention here is whether your site can match this loading logic. For example, whether the on-site material stacking space is sufficient and whether the loader operating space is sufficient.

Material Weighing and Batching

Different raw materials are weighed respectively, and then put into the mixing process. The accuracy of measurement directly affects the quality of finished concrete products.

It is worth noting that The weighing conditions may change after the equipment is relocated after the transfer and displacement. This is also the reason why the measurement must be reviewed after relocation.

Stirring and unloading

All raw materials enter the mixer to complete the mixing, and the mixer concrete is directly unloaded into the tanker and sent to the pouring site.

Control system

The operator sets the concrete formula through the control system, and the equipment automatically completes the batching and production process, and the operating status of the equipment can be checked at the same time.

 

V. What Projects are Suitable for Mobile Concrete Batching Plants?

This is a crucial part of the whole selection judgment. Not all construction sites are suitable for mobile concrete batching plants. It should be judged in combination with the objective conditions of the project itself.

1. Temporary engineering projects

The road construction project stretches for dozens or even hundreds of kilometers, and the concrete pouring points continue to move forward along the road. The mixing station moves forward with the construction progress, which can shorten the transportation distance of concrete.

For field construction of bridges and dams, the construction site is far away from the town, and there is a lack of stable commercial supply in the local area. The are also temporary construction camps and temporary supporting infrastructure. The site will be removed after the end of the construction period, which is not suitable for the construction of fixed mixing facilities.

2. Remote field projects

The construction site is far away from the local commercial concrete mixing station, and it takes a long time for commercial mixer trucks to go back and forth. There is a time limit for the initial setting of concrete, and performance deterioration may occur before the pouring point after long-distance transportation.

The logistics conditions of some mountainous and field construction sites are poor, it is difficult for tankers to enter the site, and it is difficult to ensure the continuous supply of externally purchased concrete. There are no large-scale commercial concrete enterprises in the local area, and the concrete supply gap can only be filled by building a plant on site.

3. Projects with distributed points and phased implementation

Some large-scale projects will be divided into multiple work areas, and each work area is separated from the others and far apart. If only a set of stationary concrete batching plants is built, the cost and time required for long-distance transportation of mixer trucks across regions will increase.

The project is built in multiple phases, and the construction site changes at different stages. After completing the task of one work area, the mobile concrete batching plant can be moved to the next work area for further use without the need to purchase multiple sets of equipment.

4. Construction sites with limited on-site infrastructure

The construction site does not have the conditions to pour a large area of permanent equipment foundation, and can only provide temporary hardened ground. The operation space available on site is too small to accommodate a complete set of stationary concrete batching plant.

The water and electricity of the construction site are all temporary connections, the supporting facilities are simple, and the width and carrying capacity of the entrance road are limited.

5. The site is not suitable for choosing a mobile concrete batching plant.

The mobile concrete batching plant is not a universal solution. In some working conditions, it may not be worth the cost.

If the project cycle is long and requires year-round continuous mass production of concrete, the stationary concrete batching plant will be more suitable. The project point is permanently fixed, and there is no need to relocate equipment in the next few years, so there is no need to pay additional costs for mobile properties.

The project continues to have a high continuous demand for concrete output, the maximum capacity of mobile equipment and the stability of continuous operation are weaker than those of fixed equipment at the same level. The project has little need for relocation, and the advantages brought by mobile design cannot be fully utilized.

 

VI.  Production Capacity and Output-Related Considerations

The actual output is not equal to the rated production capacity.

The cubic meters per hour marked on the equipment parameter table belongs to the rated nominal production capacity. This value is a theoretical index measured under ideal working conditions, and most equipment models and specifications use it as the basis for labeling.

When you get the equipment selection parameters, you can’t directly take the nominal production capacity as equivalent to the concrete output that can actually be obtained from the construction site.

The proficiency of the operator, whether the on-site material supply is cut off, and the ground vibration of the construction site will all affect the actual hourly output. In most cases, the actual output will be lower than the rated value written on the nameplate.

 

Match the actual needs of the project

Sort out the total daily amount of concrete required for the project, and pay attention to the instantaneous demand during the peak period of pouring.

Some projects do not use much material most of the time, but there will be a short-term surge in material demand during the centralized pouring stage. Selecting equipment based on average daily output, the equipment will not be able to keep up at all during the peak stage.

It is also necessary to judge the length of time the equipment needs to operate continuously in combination with the overall construction period.

 

Guarantee of production continuity

Even if the equipment itself is in good condition, if the supply of sand, stone, and cement raw materials is intermittent, production will still be forced to stop.

There should be enough raw material stacking space on site to ensure that the raw materials can be continuously replenished. At the same time, it is necessary to plan the configuration quantity of the concrete mixer trucks, so as to avoid a situation where there is no mixer truck to receive the concrete after mixing is completed.

 

VII. Site Conditions and Foundation Layout

1. Site selection and ground conditions

Ground bearing capacity is a priority indicator for verification. The total weight of the mobile concrete batching plant is transferred to the ground through the frame, and insufficient ground bearing capacity can cause local subsidence, which will affect the measurement accuracy.

The site should be as level as possible. If the ground is tilted, the frame is subjected to uneven forces, andthe weighing readings may be inaccurate. At the same time, the site needs to have good drainage. Rainwater accumulation can soak the ground and soften the foundation.

There is no need to make a thick reinforced concrete permanent foundation according to the standard of a stationary concrete batching plant, but it is necessary to confirm whether the existing ground can meet the basic conditions for equipment placement.

2. Land use, traffic and supporting resources

When evaluating the site, you can’t just look at how much space the host of the mixing station itself occupies. It is also necessary to reserve space for aggregate storage and tanker maneuvering for tankers to reverse and turn, and take into account the entry and exit channels of raw material transport vehicles. Confirm the conditions for power and water supply in advance, and confirm that the the basic utilities required by the equipment are available on site.

3. On-site layout and debugging process

From the perspective of decision-making, you only need to know that after the equipment arrives the site, you need to go through the following steps: site preparation, pipeline connection, measurement check, and trial production.

 

VIII. Transportation and relocation

Relocation capacity is the core advantage of mobile concrete batching plants over fixed equipment, but this does not mean that relocation does not require preparation.

1. Points to pay attention to in the transportation process

During the preliminary evaluation, you need to confirm whether the road conditions at the project location are suitable for the transportation of the equipment. The weight and overall dimensions of the equipment after splitting need to meet the relevant requirements of local road traffic. It is necessary to consider in advance whether the roads, bridges, and tunnels along the route may create transport restrictions, and whether the relocation will require additional procedures and costs.

 

2. Relocation work between projects

At the selection stage, it is necessary to recognize a reality: having the ability to move ≠ being able to be disassembled and transferred with zero-time transfer. Changing the site will result in a series of tasks such as disassembly, transportation, repositioning, recalibration, and testing, which will require labor, equipment, and time. When comparing the plans, this part of the time and cost should be included in the evaluation.

 

IX.  Compared with Other Concrete Supply Schemes

When making selection decisions, in many cases, it is not to choose between mobile concrete batching plants and stationary concrete batching plants, but to weigh self-built mobile stations, fixed stations, or directly purchase ready-mixed concrete.

1. mobile concrete batching plantcompared with stationary concrete batching plant

The focus of mobile equipment is on the convenience of relocation, and the focus of fixed equipment is on continuous mass production. If the project cycle is short and the point changes frequently, the mobile type will be preferred; long-term fixed point mass production will give priority to the fixed type.

2. mobile concrete batching plantcompared with purchased ready-mixed concrete

When the scale of materials is small, the operation of directly buying ready-mixed concrete is simple, saving the trouble of building a full set of stations. If the single material volume is large and the project construction period is long, the self-built mobile station can not be bound by the production schedule of the external mixing plant and can control the pouring operation time by itself.

 

X.  Overview of Operation and Maintenance

1. Daily operations

After the equipment is put into use, a basic inspection needs to be done before each start to ensure that the material supply keeps up with the production rhythm. After operation, necessary cleaning should be performed to avoid the accumulation of concrete lumps.

2. Routine maintenance

There are several systems that need continuous attention: mixing host-related parts, conveying mechanisms, weighing and metering systems, and hydraulic and electrical control systems. Field construction sites are dusty, and these parts are more easily affected by the environment.

3. Spare parts and technical support

Some parts are consumable parts, which will gradually wear out during production. In the preliminary selection stage, spare parts availability and technical support from the manufacturer should be taken into account. Judge whether the supplier can provide the corresponding support to reduce the risk of downtime later.

 

XI.  Cost-Related Considerations

To judge the cost of a mobile concrete batching plant, we should not only focus on the purchase price of the equipment, but also include all kinds of expenses for the whole project cycle.

1. The procurement cost of the equipment itself

It includes the main equipment of the mixing station, different optional modules, control systems, and other supporting auxiliary components. Different configuration versions will widen the gap in procurement costs.

2. Site-related input

Ground compaction and hardening treatment, although there is no need for a thick permanent foundation, will still incur costs. The water and electricity connections at the construction site and the repair of the entrance road are often easily ignored.

3. Transportation and relocation expenses

The transportation cost of the equipment to the construction site for the first time. In the middle of the project, cranes, trailers, and labor will all incur expenses for cross-site relocation.

4. Operation and maintenance expenses

Electricity costs for production operations. Labor costs for on-site operation and maintenance personnel. Daily maintenance and replacement of worn parts are all continuous expenses.

The equipment with the lowest purchase quotation does not necessarily correspond to the lowest overall total cost of the project. For some low-priced equipment, the hidden expenses caused by subsequent spare-parts consumption and failure downtime will be higher.

 

XII.  Common Mistakes in the Planning Stage

• Don’t directly take the rated production capacity of the equipment nameplate as the actual output scale that can be obtained at the construction site to determine the equipment specifications.
• Only look at the total areaof the project shown on the drawing, and ignore the instantaneous material demand during the peak pouring period.
• Underestimating the limitations caused by the on-site ground bearing capacity and traffic conditions, and finding that the site conditions did not meet the requirements of use after the equipment was in place.
• The storage and continuous supply of aggregates and powders were not planned in advance, and the supply of raw materials was frequently interrupted in the production process.
• The estimated workload of the relocation is insufficient, thinking that mobile equipment can be transferred quickly at zero cost, and the actual relocation period is seriously delayed.
• Obviously, the project is fixed for a long time and does not need to be relocated, but the mobile concrete batching plantis still used, resulting in extra costs for the mobile attributes that it cannot be used.
• Only comparing equipment procurement quotations, and do not calculate the total costs of the site, relocation, and maintenance.

 

XIII. Frequently Asked Questions

Q1: What is a mobile concrete batching plant?

A complete set of concrete production equipment integrated onto a chassis or frame. Compared with the stationary concrete batching plant, it can complete disassembly and transfer, and adapt to short-term and location-changing engineering projects.

 

Q2: How much concrete can a mobile concrete batching plant produce per hour?

The equipment will be marked with the rated hourly production capacity, which is calculated under ideal working conditions. The actual output at the construction site will be affected by various conditions such as loading efficiency, personnel, mixer truck connection, on-site environment, etc. In most cases, it is lower than the parameters on the nameplate.

 

Q3: Which projects are suitable for mobile concrete batching plants?

Line-type temporary projects such as field roads, bridges and dams, remote construction sites that are far from urban areas and lack commercial supply, multiple scattered construction areas, phased projects, and construction sites with limited site infrastructure conditions. Long-term fixed-point mass continuous production projects are not suitable.

 

Q4: Does the mobile concrete batching plant need an equipment foundation?

There is no need to pour the thick reinforced concrete permanent foundation of the stationary concrete batching plant, but the ground must be compacted and hardened to ensure sufficient bearing capacity and flatness,with adequate drainage. If the ground conditions do not meet the standard, it will cause subsidence and interfere with measurement accuracy. The specific ground-treatment plan can be determined according to the site conditions.

 

Q5: What is the difference between a mobile concrete batching plant and a stationary concrete batching plant?

The core differences are concentrated in relocation ability and civil construction needs. The mobile type focuses on convenient transfer, and the civil construction workload is small; the fixed type favors long-term mass production, with large investment in early infrastructure construction and difficult relocation.