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This section provides an overview for concrete batching plant as well as their applications and principles. Also, please take a look at the list of 10 concrete batching plant manufacturers and their company rankings. Here are the top-ranked concrete batching plant companies as of December, 2024: 1.CEMCO, Inc, 2.ASTEC INDUSTRIES, INC., 3.Stephens Mfg. Co., Inc..
Table of Contents
A concrete batch-type plant is an equipment used to produce concrete by mixing aggregate, cement, water, and admixtures in a batch process.
Concrete can be produced in batch or continuous systems, but the batch system is more accurate and produces a better-quality product. Each material is measured and added from each feeder, and mixed in a mixer for a predetermined period of time to produce fresh concrete.
The plant is generally installed near the site of demand, from where it is transported by mixer truck to the construction site. Fresh concrete hardens over time, so it is important for the plant to control time, and the plant is responsible for supplying the required quantity, at the required time, and with consistent quality. The plant makes meticulous production plans that can flexibly respond to demand.
For large-scale construction projects such as dams and tunnels, dedicated plants may be built near the construction site. This can be handled very efficiently. Mobile equipment is available for use in small-scale construction projects. One set of equipment can be mounted on a trailer, and the equipment can be moved to the construction site for each material to be supplied efficiently. Various sizes are available depending on the size of the project.
The quality of concrete depends on the mixing ratio of materials, which is specified in JIS A 5308 Ready-mixed Concrete. Three types are available: ordinary, lightweight, and pavement. The roles of each material are shown below:
Cement is a setting and solidifying material. It hardens and bonds aggregates.
Water assists the cement to harden and determines the softness of the fresh concrete. The ratio of water to cement affects the strength and workability of the concrete. A low water-cement ratio increases strength but reduces workability.
Aggregates, such as gravel and sand, account for 70-80% of concrete by weight. Aggregate is a filler, but its role is to reduce shrinkage and heat generation, and to impart stiffness and abrasion resistance. The size of the aggregate influences quality and other factors.
Admixture materials include admixtures. Admixture is a material added in large quantities, such as an expander, to improve quality. Admixtures, such as AE water reducers, are added in small quantities to improve quality.
The plant consists of material feeders, storage facilities, weighing equipment, and mixers. Aggregate, cement, water, and admixture are weighed one batch at a time, fed into the mixer, and kneaded to produce a precise, uniform quality product.
Material feeders are installed at the top of the plant. Aggregate is mostly fed automatically using a turn head. Cement is generally fed automatically by a screen conveyor or chute.
Storage facilities for storing materials are installed at the top of the plant. The material is automatically controlled and discharged by detection signals.
Weighing equipment weighs the input materials on an accurate scale. The accuracy of the scale is defined by JIS standards, and load cells with higher accuracy are generally used.
A mixer is a device for mixing materials. There are various types of mixers. They include a tilting mixer shaped like the drum of a mixer truck, a tub-shaped pan mixer, and a forced dual-shaft mixer. Recently, forced twin-shaft mixers are widely used. This type of mixer is capable of mixing both hard and soft slumps in a short time.
The slump value of fresh concrete is a measure of its softness before hardening. The higher the slump value, the softer the fresh concrete. Softer concrete has the advantage of being easier to work with, but its strength is reduced.
To measure the slump, place the fresh concrete in the specified slump cone, lay it down on a flat surface, and slowly pull out the cone. The height of the slump cone is the height of the concrete as it is lowered from its original height (300 mm). A large slump value causes adverse effects such as reduced watertightness, reduced durability, and increased drying shrinkage, so JIS has established a standard value.
Large-scale equipment can produce homogeneous fresh concrete in large quantities. Each batch allows for accurate weighing of materials and superior quality.
Automation of weighing and in-plant transport is possible, enabling efficient production.
Since the plant can be located near the construction site, there is no need to transport the material long distances by mixer truck. Required quantities can be quickly supplied.
*Including some distributors, etc.
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ASTEC Industries, Inc., established in 1972, is a manufacturer of specialized equipment for asphalt road building, aggregate processing, oil, gas and water well drilling, and wood processing based in the United States. The company offers a diverse product line that includes asphalt mixing plants, rock crushers, screening plants, pavers, and drilling equipment. It caters to industries such as infrastructure, aggregates and mining with a broad network of clients worldwide. Recently, it has expanded its technology platform with the acquisition of MINDS Automation Group Inc., a major player in plant automation control systems and cloud-based data management in the asphalt industry.
Stephens Manufacturing was started in 1957 in Tompkinsville, Kentucky. Stephens is a manufacturer and distributor of concrete-related equipment. Categories include ready mix plants, precast plants, central mix plants, RCC, environmental, and material handling. Ready mix batch plants that generally have quicker installation. Precast plants are custom built. Portable mixers mix RCC and other mixes. Environmental components include dust collectors, reclaimers, and wash down racks. Material handling includes batchers, bins, hoppers, silos, conveyors, and vertical pigs. Stephens offers assistance in customer problem solving and delivers to customers globally.
Semix Global is based in Ankara, Turkey, and is a manufacturer of truck mixers and concrete batching plants established in 2006 as a part of the SEDA Group. The company offers truck mixers for mixing and transporting concrete to work sites, cement silos for storing bulk quantities of cement, and concrete batching plants for mass production operations. It also offers various concrete mixers, including planetary, single shaft, and twin shaft models. The company’s products are mainly used in construction operations, as well as in Turkish infrastructure projects.
Vince Hagan Company, founded in 1956, is a manufacturer based in Sunnyvale, Texas, specializing in concrete batching plants and equipment. The company introduced and patented the first mobile concrete batching plants and now offers systems for both mobile and stationary applications, as well as containerized models designed for ocean shipping. Additionally, it provides various concrete batching equipment, including dust collectors and mixers. The company also provides services such as computer automation, and turnkey erection and startup. Among its notable projects is the deployment of a batching plant for the Tec-Crete Transit Mix Corporation in New York City.
Ranking as of December 2024
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | CEMCO, Inc |
19.4%
|
| 2 | ASTEC INDUSTRIES, INC. |
15.3%
|
| 3 | Stephens Mfg. Co., Inc. |
12.3%
|
| 4 | LYROAD |
10.5%
|
| 5 | Semix Global |
8.6%
|
| 6 | ERIE Strayer |
8.4%
|
| 7 | Promax Beton Santralleri |
7.7%
|
| 8 | Vince Hagan Company |
7.1%
|
| 9 | MCT Italy S.r.l. |
5.6%
|
| 10 | JEL Concrete Plants |
5.2%
|
Derivation Method
The ranking is calculated based on the click share within the concrete batching plant page as of December 2024. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
United States of America
|
2 | 100.0% |
