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3. Concrete Production
CEL 141
General Outline
™Concrete Production
• Production Process
• Batching
• Mixing
Production Process
Mixing Transport
Curing
Batching
• Batching is the process of measuring and
combining the ingredients of concrete
cement, water, sand, aggregate) as per the
mix design or correct proportions.
Batching process
• Volumetric batching: Not preferred, Non
Engineered jobs
• Weigh batching: (based on Mass, IS456:2000
reommended)
Batching Process
• Weigh batching system facilitates simplicity,
flexibility and accuracy.
• The materials like aggregate and sand are
stored in bins and cement and cementitious
material (like fly ash etc) are stored in silos.
Batching Plant
Main components are:
• Balance or weighing system
• Aggregate bins, water storage tank, cement
silos, dispenser for admixtures
• Conveyors (or scrappers, hoists)
• Mixers
• Control panels
Functioning of Batching Plant
Batching Plant
Batching Plant
• Can be Cyclic or Continuous
• Can be Automatic or Manual
• Accuracy
• As per IS456 The measuring equipment shall
be within ±2% of the quantity of cement and
mineral admixtures being measured and
within ±3% of the quantity of aggregate,
chemical admixture and water being
measured.
PLANT CAPACITY
Capacity depends on:
• Size of the job
• Required production rate
• Required standard of batching performance
• Capacity of material handling system, bin size,
batcher size, and mixture size.
• So Q=min(Q1, Q2, Q3..)
INSTRUMENTATION AND
MEASUREMENT
• Mechanical level system, load cell etc for
measurements of mass.
• Controlling the discharge from storage and
weigh hoppers is through gates operated by
compressed air cylinders.
• Presetting of desired batch weights can be
done by digit switches/ rotating dials and
computers.
INSTRUMENTATION AND
MEASUREMENTS
• Electrical or microwave moisture gauges can
be used as aggregate moisture meters
• Water is most commonly measured through
flow meters.
• With the need of adequate calibration,
frequent regulatory routine and specialists
checks of weighing process are required
without too much difficulty.
Tolerances (individual Batch IS 4925)