A concrete batching plant works on the basic principle of combining various ingredients such as sand, aggregates, water, cement, and additives to prepare it for application at a construction site.
The dry batching plant operates on the same concept. Components like sand, cement, additives, and aggregates are weighed separately. They are then sent to a transit mixer to prepare ready mix concrete. Water is added into the transit mixer, and the concrete is mixed inside the transit mixer on the way to the work site.
Dry concrete mix is extensively used in various projects, including residential and industrial. The use of dry concrete mix has increased with the growing demand for concrete. It is widely used for infrastructural projects, such as concrete foundations, slabs, driveways, sidewalks, patios, and floors.
The dry mix is generally used for small to medium volume placements or for worksites with limited vehicular access.
The dry batching plant comes in two types: stationary and mobile. The stationary concrete batching plant is larger than the mobile version. Its operation is similar to the mobile version.
Patrons who want to use concrete at a single location prefer the stationary type of plant, while those who need to change the work site frequently prefer the portable version.
The dry batching plant comes in two types: stationary and mobile. The stationary concrete batching plant is larger than the mobile version. Its operation is similar to the mobile version. Patrons who want to use concrete at a single location prefer the stationary type of plant, while those who need to change the work site frequently prefer the portable version.
Apollo Inffratech is a prominent company involved in manufacturing and supplying high-quality Dry Batching Plants. The company also offers a wide range of high-tech concrete construction equipment such as Block Making Machines, Ready Mix Concrete, Pipe Making Machines, Slip Form Pavers, and more.
The organization has earned the reputation and trust of customers worldwide by providing machines made with cutting-edge technology, timely deliveries, and the support of an advanced manufacturing system, excellent R&D capabilities, and skilled engineers.
Modern construction aims to achieve better performance in an eco-friendly and cost-effective way. The use of dry-batch concrete helps meet these criteria by offering unique advantages.
However, dry-batch concrete is best suited for specific applications. Contractors often use both dry-batch and wet-batch concrete where they are most appropriate to achieve high overall performance for their projects.
What is Dry Batch Concrete?
Dry-batch concrete, also known as dry-mix or dry-pack concrete, is a concrete mix without water. The mix consists of cement, aggregates, and sand blended in correct ratios in a plant, then transported to the construction site on a truck. The final mixing and agitation with water occur in the mixer truck during transportation.
This is unlike wet-mix concrete, which is mixed in the batching plant and transported to the construction site in a ready-made mix.
Dry-mix cement contains the same elements as a standard concrete mix but has less water. Therefore, dry concrete is mainly used for applications where it will come into contact with the ground and draw the necessary water to bind the mortar (hydration process). Ideal applications include building foundations, base layers for roads, driveways, paving stones, trench filling, and other similar uses.
Wet mix, on the other hand, works effectively in high-volume areas being developed from the ground up, such as building a house or other new construction.
Advantages of Dry Batch Concrete
Dry-mix concrete offers several unique advantages, such as:
Improved strength and durability
Despite having a reduced cement percentage, dry-mix concrete has excellent strength and durability. The combination of aggregates and a small amount of cement ensures structural stability and appropriate binding. Dry mix concrete can withstand enormous weights, resist deformation, and handle harsh weather conditions, ensuring long-lasting and durable buildings.
Cost-effectiveness
When compared to typical concrete mixtures, dry-mix concrete is a more cost-effective choice. Furthermore, the efficient mixing and placing process requires fewer laborers, contributing to cost savings.
Long storage time
Dry-mix concrete offers more flexibility regarding storage time. Contractors can fill numerous bags of dry mix concrete and use them as needed. During application, a high-velocity hose is used to lay the dry mix before adding water.
Simple to use
Dry-mix concrete is pre-mixed and bagged, making it simple to transport and store on-site. Therefore, there is no need for on-site machinery, saving time and money.
Rapid construction
Dry-mix concrete enables quick and efficient construction. As it is a dry combination, it can be easily spread and compacted with specialized equipment. The lack of water in the mixture reduces the need for curing, allowing for fast construction progress, saving both time and money.
Eco-friendliness
Dry-mix concrete is an environmentally friendly alternative due to its low cement composition. Since cement manufacturing has a high carbon footprint, using dry mix concrete helps reduce environmental impact. Additionally, by properly utilizing aggregates, it minimizes the demand for natural resources, making it a sustainable solution for construction projects.
High quality and consistency
Dry-mix concrete is manufactured under regulated conditions, ensuring consistent quality and strength. It also eliminates the possibility of differences in mix proportions affecting the final product’s strength and durability.
Minimized waste
The pre-mixed nature of concrete eliminates the need for excess material, reducing waste and saving money. It also lessens the environmental impact of on-site mixing and waste generation.
Disadvantages of Dry Batch Concrete
Some disadvantages of dry-mix concrete include:
Inconvenient for complex structures
Due to the short workable period of dry-mixed concrete, it is unsuitable for large-scale projects or complex structures. It hardens quickly and cannot be reused once set.
Requires sufficient water availability on-site
Dry-mix concrete needs water on-site, which can be challenging in areas with low water availability. This may lead to project delays and increased costs.
Limited applications
Dry-mix concrete is not suitable for all construction types. It is primarily used for structural purposes and should not be used for aesthetic or surface finishes.
Dust and respiratory risks
Dry-mix concrete can produce significant dust during mixing and application, posing a respiratory hazard to on-site workers. Proper safety measures must be implemented to ensure worker safety.
How is Dry Batch Concrete Produced?
Traditional concrete mixing plants use a concrete mixer to mix all elements, such as sand, cement, aggregates, and water, after they have been weighed to maintain precise ratios. However, there is no concrete mixer in a dry-mix concrete batching plant. It operates as follows:
- Aggregates (sand and stone) are weighed by an aggregate batching machine and then supplied by a belt conveyor to an aggregate collecting hopper.
- Water, cement, and additive scales are on top of the aggregate collecting hopper. Water, cement, and additives are weighed by the corresponding scale and then discharged into the aggregate collecting hopper.
- A concrete transit mixer truck collects all the materials from the hopper. The transit mixer mixes all ingredients on the way to the work site. When the transit mixer arrives at the job site, the concrete is ready to use.
What is the Mixing Ratio of Dry Batch Concrete?
The mixing ratio of dry-mix concrete might vary depending on the project's specific requirements. However, a popular dry mixing ratio is 1:6:12.
To demonstrate this mixing ratio, consider the following hypothetical amounts of dry-mix concrete components:
If the cement used is 50 kg, the amount of fine aggregate (sand) will be 300 kg, and the amount of coarse aggregate will be 600 kg.
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