How is a Concrete Batching Plant İnstalled?
Concrete is the heart of modern construction. Installing a concrete batching plant the very thing that feeds this heart is far more than just assembling piles of metal; it requires deep engineering expertise. The flawless integration of components such as site selection, capacity planning, automation systems, and operational safety is the key to the plant’s long-term and profitable operation.
In this guide, we explore how a concrete batching plant is installed from A to Z, including installation costs, timelines, and the critical engineering steps that boost efficiency. You will also discover how Bozdağ Engineering, with its extensive experience, delivers the most cutting-edge solutions in the industry.
Pre-Installation: Capacity, Type, and Site Selection (Key Decisions)
The foundation of a successful plant is proper planning. The decisions made at this stage will directly impact your long-term return on investment (ROI).
Determining Investment Goals and Capacity
The first question is: “How much concrete will you produce?”
| Parameter | Description | Example Capacities |
| Daily Production | Target production volume in cubic meters (m³). | 60 m³/hr, 100 m³/hr, 120 m³/hr. |
| Concrete Type | Ready-mix, road, precast, or special concrete mix? | Determines the mixer type (Planetary, Twin-Shaft). |
| Portability | Will it be permanent on-site, or moved frequently? | Requires choosing a Stationary, Mobile, or Compact Plant. |
📌 When determining capacity, not only current demand but also potential demand for the next 5 years must be considered. The plant configuration is customized according to these goals.
Critical Step: Concrete Plant Site Selection
Incorrect site selection can increase operational costs by up to 30%.
- Logistical Advantage: Closest possible distance to aggregate, sand, cement, and water supply points.
- Ground Reinforcement: A reinforced concrete platform resistant to heavy loads and vibration is mandatory. A ground survey must be conducted.
- Infrastructure Preparation: Adequate electricity lines (power panel), water, and drainage systems must be ready in advance.
Which Concrete Plant Type is Right for You?
There are three main plant types based on project needs. Choosing the right type directly affects installation time and operational ease.
| Plant Type | Application Area | Advantages |
| Stationary Plants | Long-term, high-volume facilities. (Dams, large housing projects) | High capacity, low maintenance, longest lifespan. |
| Mobile Plants | Road, bridge, or short-term projects that frequently change location. | Fast installation (10-20 days), easy transport (on a trailer chassis). |
| Compact Plants | Areas with limited space but requiring high efficiency. | The power of a stationary system + mobile flexibility. |
Mechanical Assembly and Installation of Critical Components
After planning, the plant components are brought to the site. This phase requires precision and full compliance with technical documentation.
Main Assembly Components:
- Aggregate Storage and Transport: Hoppers, weighing belts, mixer feeding system.
- Cement Management: High-capacity cement silos and screw conveyors.
- Mixing Unit (Mixer): The heart of the plant. Twin-Shaft or Planetary mixers are installed based on the concrete type.
- Precision Weighing Systems: Digital dosing systems for water, cement, aggregate, and chemical admixtures.
- Pneumatic and Hydraulic Systems: Air and pressure lines for the automatic control of gates, valves, and flaps.
🛠️ Installation Time: Varies from 30-45 days for stationary plants to 10-20 days for mobile plants.
Automation and Control Systems (Eliminate the Margin of Error)
A modern concrete plant operates fully automatically, based on a PLC (Programmable Logic Controller). Automation minimizes human error and guarantees consistent, high-quality concrete production.
- Software Control: Adjusts weighing precision, manages recipes, and records production reports in real-time.
- Power Infrastructure: Electrical, automation, and control panels compliant with industrial standards, such as those from Siemens or Schneider.
- Remote Access: Capability for remote connection and monitoring for immediate intervention in case of potential malfunctions.
Testing, Calibration, and Safe Commissioning
After assembly and automation connections are complete, a comprehensive testing process begins before the plant’s first production run.
- Precision Check: Weighing systems (aggregate, water, cement) are calibrated with high-precision scales. Dosing accuracy is verified.
- Synchronization Test: The simultaneous operation of the mixer, belts, and pneumatic gates is tested.
- Safety Protocols: Emergency stop buttons, pressure relief valves, and dust filtering systems are activated.
- Operator Training: Technical equipment training and documentation are provided for the correct and safe operation of the plant.
Concrete Plant Installation Cost and Timelines (Summary)
The installation cost varies significantly based on the plant’s capacity (m³/hr) and level of automation.
| Cost Item | Description |
| Mechanical Equipment | Mixer, hoppers, silos, belts, and weighing systems. (The largest item) |
| Automation/Electrical | PLC, software, power panels, and sensors. |
| Site Preparation | Concrete platform, ground reinforcement, and infrastructure costs. |
| Transport and Assembly | Transport of equipment to the site and labor for the expert assembly team. |
Bozdağ Engineering: Correct Installation, High Efficiency
The success of a concrete batching plant is measured by the engineering precision demonstrated at every step of the installation. As Bozdağ Engineering, we have been providing reliable solutions in the field of concrete plant manufacturing, installation, and service since 1982. With the right engineering design, you get a highly energy-efficient plant that operates with minimal downtime.
Bozdağ ensures the uninterrupted operation of your plant with its spare parts and technical support services. Contact us for optimal solutions, customized cost planning, and engineering support for your project!