How To Set Up Ready Mix Concrete Plant?

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The installation method and process requirements of ready mix concrete batching plant is very important. And it can be divided into eight parts.

1)The main body of the JS series twin shaft concrete mixer and the metering system:

1. The installation shall conduct acceptance and surface treatment on the foundation, which must require leveling and alignment, marking, perpendicularity and flatness error ≤±0.5mm, diagonal error ≤±4mm, and there shall be no residual concrete and welding slag on the embedded parts.

2. Install the column in the machine room. The elevation error of each point on the upper-end face is required to be ≤±3mm, and the levelness error of the axis and diagonal is required to be ≤±3mm. Before the secondary grouting of the embedded bolt hole, the column in the machine room shall be erected with scaffolding for temporary fixing.

3. Lift the platform structure of the first floor of the compulsory concrete mixer as a whole (including mixer, reducer of the main engine, and main motor). Position the bolt hole with a positioning punch. After all bolts and connecting pins in all parts are installed, the hook can be loosened.

4. The whole structure of the two-storey platform of the concrete mixer is hoisting (including hopper, cement scale, water scale, and admixture scale). After all bolts and connecting pins of all parts are installed, the hook of the crane can be loosened.

5. Maintenance and walking platform installation of the first and second floors of the twin shaft mixer.

2)Cement silo and screw conveyor:

1. Cement silo lower body frame installation, the upper plane of the framework for horizontal alignment, diagonal horizontal error ≤3‰.

2. Install embedded bolts and secondary grouting, after the strength reached 80% to tighten the bolts.

3. The cement silo is hoisted and the bolt hole is positioned with the positioning punch. After all, bolts are installed, the crane can loosen the hook. Note: During installation, the crane and its operation mode are the same as when dismantled.

4. Verticality test shall be carried out, and the requirement of verticality shall be no more than 3‰. If necessary, gaskets can be used between the connecting surfaces of upper and lower bodies to adjust the verticality.

5. Installation of screw conveyor, screw conveyor installation Angle is 37°, the upper and lower joints should be installed tightly to prevent leakage of cement.

3)Belt conveyor system:

1. Alignment of the foundation to ensure that the belt conveyor axis and the mixer axis are in a straight line.

2. Install the belt conveyor bracket, test the straightness of the belt conveyor bracket in the length direction to meet the requirements.

3. Install the belt conveyor, adjust the levelness of the drum at both ends of the belt conveyor.

4. Install the aggregate receiving port.

4)Aggregate batching system:

1. Align the foundation to ensure that the axis of the batching machine and the axis of the twin-shaft compulsory concrete mixer are in a straight line.

2. Install the batching machine and align the aggregate batching machine horizontally in the direction of width and length.

3. Install embedded bolts and conduct secondary grouting.

4. Install the upper high baffle.

5)Water supply pipeline:

1.Install water storage tank, water pump, and control valve.

2. According to the drawing design and installation of all parts of the connecting pipeline and various accessories, to ensure that there is no leakage phenomenon.

6)Air supply pipeline:

1. Air pump, control cylinder, solenoid valve, and air source handling components should be installed.

2. Install and connect the air pipes according to the drawing design to ensure that there is no air leakage everywhere.

7)Admixture adding system:

1. Install the bottom admixture storage tank, pipeline pump, and pipeline, valve.

2. The installation and layout of the system should meet the requirements of the drawings, and the installation of the pipeline pump should meet the requirements of the manufacturer’s manual. The pipeline pump should be fixed firmly.

8)Electrical system:

1. Install the operating table, power cabinet, and control cabinet in the operating room.

2. Install control cables and power cables for each motor. During installation, all relays, contactors, switches, and starters shall be installed according to the drawings or the factory instructions of the components.

3. Install the control cables of each department. Put the cables in the cable tray, arrange them neatly without crossing, and hang the cable tag.

4. Install electric whistle, electric bell, and grounding, lightning protection electrical devices. When installing the grounding device, attention should be paid to the reasonable arrangement of the grounding control network. Dig a 2m deep pit around the control room, the main body of the mixer, and the cement silo, place the round steel pipe (Φ50) with a length of 1.5m into the ground and backfill with a flat iron after connection, and tamper it. The lightning protection device is safe and reliable.

5. Install the limit device of the moving parts. Before installation, it is necessary to ensure that the limit switch should be effective and responsive.

Install lighting in the machine room and each workplace room to ensure sufficient lighting for the operation and construction.