Concrete Batch Plant Equipment Blog

Uncertain about which job site batch plant? Portable batch plants vs Self-erecting batch plants

Choosing a new concrete batch plant that suits your mobility needs can be tricky.

A new portable concrete batch plant’s price tag is often lower than a self-erecting mobile concrete batch plant, but…the winning choice often is the self-erecting batch plant. Here’s the breakdown:

This price difference often deters a concrete ready-mix producer from choosing the self-erecting batch plant option, but is that the best option when looking at continual cost over the life of the batch plant?

As construction projects grow in size it seems concrete ready-mix producers receive more requests to set-up a portable concrete batch plant on a contractor’s site. Having the ability as a ready-mix concrete producer to fulfill these demands is beneficial to both the contractor and producer. The contractor gains peace of mind that his production demands and delivery schedules will be met. The ready-mix producer gains increased revenue, maintaining daily contractor demands, and the need for less trucks to deliver the product.

The biggest question now is what style of plant should the ready-mix producer buy? Depending on how often the new concrete batch plant will be moved from site to site helps make the choice a little easier. The below chart gives an estimated overall purchasing and setup cost of a portable concrete batch plant and a self erecting concrete batch plant. If the goal is moving the new plant often, the choice becomes a little clearer.

Job Site Batch Plant	Portable	Self-Erecting
Basic base plant cost of a 12 yard batch plant with loader fed aggregate	$240,000	$285,000
Batch computer system	$32,000	$32,000
Foundation Mats	Not Available	$9,000
Factory Freight	$8,000	$6,000
Concrete Batch Plant Total:	$280,000	$332,000

Job Site Move On/Off Cost	Portable	Self-Erecting
Foundation estimated, including Demolition and haul-off	$28,000	$0
Estimated erection & freight	$23,000	$11,000
Job Site Cost Total:	$51,000	$11,000

Winner? Self-Erecting Batch Plants

Although the portable concrete batch plant’s initial cost is lower, the continual job site moving cost per location will make the self-erecting mobile concrete batch plant the superior choice.

4 Steps to Conveyor Belt Tracking — It doesn’t have be painful

Conveyor belt tracking can be frustrating. The key is to start with all of the conveyor components square with the conveyor frame. Ensure the tail pulley and head pulley are squared, as well as all of the return and troughing idlers. In most cases the troughing idlers center the belt on the head pulley and the return idlers center the belt on the tail pulley. The tail pulley should only be used for tension of the belt and not to track the belt.

OPERATING AND TRACKING CONVEYOR BELT

A) Before starting the belt conveyor, make sure all debris, tools and temporary bracing are clear of the belt. Caution should be exercised at all times around machinery, this is especially true when starting equipment for the first time.

B) If the belt has a tendency to run to one side or the other, it should be steered back on center in the same manner as you would steer a car.
C) While looking in the same direction as the belt travels (up the belt), all corrective action to center the belt is accomplished in the following manner:

1) If the belt tends to run to the right side, it would then require a left turn to return it to the center. Alignment should be started at the point where the turn starts. The right end of the return idlers should be pushed forward slightly or the left end should be pulled back slightly. Continue along the belt in the direction that the belt travels until the belt is centered. It is far better to move several idlers slightly than to move a few a large amount.

2) If the belt runs to the left side, the same principle is applicable, except you push the left side forward and/or pull back the right side.

3) If for some reason any of these steps cannot be completed, the alignment can be accomplished by tilting the idler slightly forward, taking note not to exceed a 2 degree tilt angle from vertical in the direction of the belt travel. This can be accomplished by placing shims under the backside idler mount bolt holes. This 2 degree limit is to avoid excessive belt wear.

4) The return idlers should be used for belt centering in spite of their flatness. Move return rolls forward and backward in the same fashion the troughing idlers were moved.

Tip: A un-squared belt splice can also throw you off, but you will easily see this problem when you start running the belt.

How To Calibrate a Badger Turbo Meter

Typically Badger Turbo meters are calibrated at the factory prior to shipment. The factory settings are 0.0208 for a 2″, 0.0417 for a 3″ meter and 0.1953 for a 4″ meter. To re-calibrate the meter you would complete the following (Amount delivered / Amount displayed) * .XXXX existing setting. The new four digit number is the new calibration setting you will input into the meter board.

TROUBLE SHOOTING PROCEDURE
Is the power light lit on the turbo meter scaler board?
If yes: Proceed to A.
If no: Check voltage across terminals 2 and 3 on scaler board. The voltage should be 120 volts AC if this voltage is not there the board is not receiving power to active it. There is a problem with the wiring or power supply to the board.

A: Is the pulse light on the scaler board blinking when water is run thru the meter?
If yes: Proceed To Step A2.
If no: Proceed To Step B.

A2: Possible problem with board or signal getting to batch control. Turn power to meter off, take jumper wire and attach to terminal 2 (power terminal) on scaler board. Turn power to meter back on and tap other end of jumper wire to terminal 8 on scaler board. Observe counter
on batch control or manual station.

If Counts Appear: If a count appears every time power is applied to terminal 8 the counter and the wiring between the meter and counter are ok. If this is the case it is possible that there is an issue with the scaler board. Recommended solution: Replace scaler board.

If Counts Do Not Appear: If counts do not appear every time power is applied to terminal 8 there is an issue with the counter or wiring to counter. Recommend solution: Trouble shoot to determine issue with counter or wiring.

B. If pulse light does not blink when water is run thru the meter and the board power light is ON proceed as follows. Turn power to meter off and record calibration number. Set calibration number on board to 9999. Disconnect wires going to terminal 1 and 2 from meter transmitter(Green and black wires coming from underneath board). Attach jumper wire to terminal one, turn power to meter back on. Tap jumper wire to terminal 2.

If pulse light blinks: If pulse light blinks when doing this then board is working properly,
proceed to Step C.

If pulse light does not blink: If pulse light does not blink when doing this there is an issue with the scaler board. Recommend solution: Replace scaler board.

C. If pulse light blinks after completing step B, hook wires back up to terminals 1 & 2, leave calibration switches at 9999 and proceed as follows. Remove bronze head assembly and inspect rotor and spindle for damage or wear, inspect to make sure no blades are damaged or worn. Spin rotor by hand and observe for blinking pulse light on scaler board or counts on batch control. If rotor is damaged, worn or does not spin freely: Rotor and spindle need to be replaced. If rotor is not damaged or worn and spins freely and no pulse is generated when rotor is spun:

D. Check to see if water flow (GPM) is within specification for proper meter operation. Also verify water line strainers are not plugged. If neither of these is the cases proceed to E.

E. If the meter is receiving sufficient flow and the turbine is in good condition there may be an issue with the transmitter. Recommended solution: Replace transmitter.

Once all tests are complete return calibration number back to recorded settings

6 Ways Central Mix Concrete Batch Plants Make More Money

Liddell Comanche Dual Lane Plant Drawing

A central mix concrete batch plant has a considerably higher initial cost than a dry concrete batch plant. As in any business, the ready-mix producer must receive a return on their investment or why spend the money. So, the question is, why central mix when the initial cost is so much higher? Here are 6 reasons a central mix concrete batch plant contributes to higher profits in the long term.

1- Truck maintenance. A mixer truck that only rotates its drum at 1 to 2 rotations per minute for agitation will require substantially less maintenance than a mixer truck rotating its drum 16 or 20 rotations per minute for 5-minute durations 4 to 6 times each working day to mix the product. This reduction uses less fuel, and drastically lowers the wear and tear on the motor, drum, and drive system.

2-Higher strength. A mixer truck is designed for multiple purposes: receive the material into the drum, mix the material, transport the load on streets, highways, and job sites, and auger the finished product out of the drum for use. Mixer trucks complete a multitude of functions to do their job. Mixer truck manufacturers, because of the multiple functions needed and limitations on height, width, and weight, compromise on design of individual functions to ensure the truck can complete all the functions needed. One of these key functions is mixing the material. A concrete tilt mixer only has one job, mix concrete, and it does it very well.

3- Quality concrete. Today’s world of high liability, elaborate mix designs, and numerous admixtures, the ready-mix industry still heavily relies on the mixer driver to produce the finished product. A central mix batch plant allows the batch plant operator to not only batch the load, but mix and check the load to ensure all quality standards are met.

4-Faster loading. A typical dry concrete batch plant will load a truck in 3 to 4 minutes. A central mix concrete batch plant will load a truck in 1.5 to 2 minutes. This means on average a dry batch plant will load 18 trucks per hour, while a central mix batch plant will load 34 trucks per hour.

5- Environmental impact. Cleaner mixer trucks from loading with wet materials and dust elimination reduces the use of cleaners and acids, which are expensive and can be harmful to the environment. Ready mix truck engines operate at a high RPM to charge and mix the material in the drum. A central mix plant can reduce that high RPM time by 1/2, reducing fuel cost and lowering the environmental impact.

6- Cleaner trucks. Central mix plants provide almost total containment of dust and the mixer truck drum being loaded wet remains much cleaner than a mixer being loaded with dry materials. Annual jackhammer labor to clean out drums is dramatically reduced with central mix as well.