In the field of modern construction and infrastructure construction, the choice of concrete mixing process directly affects project efficiency, cost and environmental performance. As an innovative equipment, the dry mix concrete batching plant is reshaping the traditional construction mode with its unique process of “dry mixing aggregates first and then adding water on site”.
Material Feeding & Weighing
Aggregates (sand, gravel) are loaded into storage bins via loader or conveyor.
Cement is pumped from silos to the weighing system.
Precise batching: Each material is weighed separately (accuracy ±0.5%) before mixing.
Dry Mixing Process
Aggregates and cement are briefly mixed without water in a short-duration mixer (10-30 seconds).
No slurry formation occurs at this stage.
Discharge & Transportation
The dry mix is discharged into a transit mixer truck.
Materials remain in dry state during transport (no setting risk).
Water Addition & Final Mixing
Water is added inside the truck during transit or at the job site.
Mixing continues for 5-8 minutes to achieve homogeneity.
| Component | Function Description | Key Features |
| Aggregate Bins | Stores sand, gravel and other aggregates | – Divided compartments for different materials – Vibrators to prevent clogging |
| Cement Silos | Stores bulk cement | – Sealed design – Equipped with dust filters – Capacity 50-200 tons |
| Weighing System | Precisely measures materials | – Load cells with ±0.5% accuracy – Digital display for real-time monitoring |
| Conveying System | Transports materials between components | – Belt conveyors for aggregates – Screw conveyors for powders |
| Control Panel | Automated operation management | – PLC-based control – Recipe storage function – Production data logging |
| Dust Collector | Controls powder emissions | – Pulse-jet cleaning system – Filtration efficiency ≥99% |
| Discharge Hopper | Outputs mixed dry materials to transit mixer | – Adjustable gate control – Wear-resistant lining |
Small Mobile Dry-Mix Batching Plant
Integrated design, capable of rapid relocation, with a production capacity typically ranging from 20 to 60 m³/h.
Small-scale projects such as rural self-built housing and rural road repairs. For example, a Southeast Asian island nation utilised mobile equipment to address transportation challenges on the island.
Medium-Sized Fixed Dry-Mix Batching Plant
Requires a fixed installation site, equipped with aggregate silos and powder tanks, with a production capacity of 80–150 m³/h.
Supply of ready-mix concrete for urban areas, meeting the continuous production needs of medium and small-scale construction projects.
Large-scale environmentally friendly dry-mixing plant
Equipped with a pulse dust collection system and wastewater recycling device, compliant with EU CE environmental standards.
Large-scale projects such as industrial plants and bridge construction, such as a domestic expressway project using such equipment, with dust emissions below 20 mg/m³.
Suitable for high-rise buildings and commercial complexes, supporting flexible production of concrete at different strength grades.
In long-distance projects such as highways and tunnels, dry material transportation can reduce losses to within 2% (wet mix losses typically range from 5-8%).
In remote areas such as deserts and highlands, no reliance on precast plants is required, as mixing operations can be completed on-site. Application Scenarios for Dry-Mix Concrete Batching Plants
| Comparison Item | Dry Mix Plant | Wet Mix Plant |
| Mixing Process | Dry materials mixed at plant, water added in truck | Complete mixing with water at plant |
| Initial Cost | Lower (30-40% cost saving) | Higher (requires more equipment) |
| Energy Consumption | Lower (no wet mixing power needed) | Higher (continuous mixer operation) |
| Output Quality | Good for standard concrete (C15-C40) | Better for high-strength/special concrete (C50+) |
| Maintenance | Easier (no mixer cleaning needed) | More demanding (regular mixer cleaning) |
| Suitable Projects | – Remote sites – Small/medium projects – Fast-track construction | – Large commercial projects – High-precision applications |
| Transport Distance | Longer (up to 90 minutes) | Shorter (≤60 minutes) |
| Water Control | Added at job site (flexible adjustment) | Fixed at plant (precise measurement) |
| Space Requirement | Compact (no mixer needed) | Larger (requires mixing tower) |
| Environmental Impact | Higher dust potential (requires dust control) | Lower dust (materials wet dur |
Lower Investment Costs
Equipment Cost Savings: Eliminates the need for essential components of wet-mix plants, such as mixing main units and water tank systems, reducing initial investment by 20%-30%.
Lower Civil Engineering Requirements: No large mixing platforms required, reducing foundation construction costs by over 15%.
Case Data: A medium-sized dry-mix plant (60 m³/h) has a total investment of approximately 1.2 million yuan, while a wet-mix plant of the same specification requires 1.6 million yuan.
Outstanding Energy Efficiency
Electricity Consumption: No mixing main unit operation, only power supply required for the conveying/weighing system, resulting in energy consumption 40-50 kW·h/m³ lower than wet-mix plants.
Fuel savings: Transport vehicles can flexibly control water addition timing to avoid fuel waste caused by unnecessary transportation.
Actual comparison: In a project with a monthly output of 5,000 m³, the dry-mix plant’s electricity costs were 12,000 yuan lower than those of the wet-mix plant.
High production flexibility
Quick formula adjustments: Water addition volume can be adjusted in real-time during transportation (e.g., to adapt to weather changes).
No waste risk: Dry materials can be stored in the mixer truck for 2-4 hours before water addition, avoiding waste from wet concrete hardening.
Adaptable to special scenarios: In desert or water-scarce regions, water can be transported centrally, increasing dry material transport efficiency by 50% per trip.
Maintenance Convenience
No scaling issues: The dry mixing process avoids cement paste adhering to equipment, reducing cleaning time by 70%.
Fewer wear parts: No high-frequency replacement components such as mixing blades or liners, reducing annual maintenance costs by approximately 30,000–50,000 yuan.
Easy maintenance: Open-structure design allows for quick inspection of critical components (e.g., belt conveyors, load cells).
Environmental compliance advantages
Dust control: Pulse dust collection systems (e.g., PPC96-6 type) can control dust concentration to ≤15 mg/m³ (national standard requirement: 20 mg/m³).
Lower noise levels: No loud noise from mixing main units; boundary noise ≤65 dB (wet mixing plants typically ≥75 dB).
Zero wastewater discharge: No wet operations throughout the process, completely eliminating wastewater treatment issues from machine washing.
Limited mixing uniformity, with concrete strength variability in dry mixing plants being 10-15% higher than in wet mixing plants.
Solutions:
Extend the mixing time of the mixer truck to ≥8 minutes (standard is 5 minutes).
Add polycarboxylic acid superplasticiser (dosage 0.2%-0.5%) to improve flowability.
Regularly calibrate the weighing system (once a week, with error control within ±0.5%).
Challenges in low-temperature environments: Below -5°C, dry materials are prone to moisture absorption and clumping, affecting flowability.
Solutions:
Install electric heating plates (power 2-3 kW/m³) in aggregate silos to maintain material temperature ≥5°C.
Use anti-freeze dry powder additives (e.g., calcium nitrite-based anti-freeze agents).
Reduce transportation time to ≤30 minutes (in extremely cold regions, insulated mixer trucks are recommended).
Strict dust control requirements: cement/fly ash conveying processes are prone to dust generation.
Solutions:
Equipment level: use fully enclosed screw conveyors + negative pressure dust collection systems.
Management level: install spray dust suppression devices (automatic spraying for 10 seconds every 2 hours).
Monitoring level: install online dust monitors (automatic alarms when levels exceed standards).
Q1: Is the strength of dry-mixed concrete lower than that of wet-mixed concrete?
A: Strength depends on the precision of water-cement ratio control. High-quality dry-mixing plants can achieve an error margin of ±1% through electronic metering systems, resulting in strength comparable to that of wet-mixed concrete.
Q2: Can dry-mixing plants be used for ready-mix concrete sales?
A: They are suitable for small and medium-sized customers in dispersed regions, such as county-level markets; large cities still primarily rely on wet-mixed concrete for ready-mix supply.
Q3: How can dust pollution be reduced?
A: Select equipment equipped with pulse bag dust collectors and regularly inspect the sealing strips of the mixing main unit to ensure operation under negative pressure conditions.
Q4: Are there time restrictions for transporting dry-mixed concrete?
Dry materials can be stored for 2–4 hours without water; after adding water, pouring must be completed before initial setting (typically within 1.5 hours). In hot weather, it is recommended to shorten this to within 1 hour.
Q5: How can normal operation of the dry-mixed concrete plant be ensured in low-temperature winter conditions?
Heat the aggregate silos (maintain material temperature ≥5°C); use anti-freeze dry powder additives; install insulation layers on transport vehicles.
Q6: What is the minimum installation area required for a dry-mixed concrete plant?
Minimum area requirements (for a 60m³/h plant):
Fixed-type: 30m × 25m (including material storage area)
Mobile: 15m × 12m (container modular design)
Q7: How is the quality of dry-mixed concrete tested?
On-site slump test (recommended control range: 120 ± 20mm); sample retention for test block production (7-day/28-day strength testing); regular calibration of weighing systems (error ≤ ±0.5%)
Q8: What is the service life of dry-mixed concrete batch plant equipment?
Steel structure main body: 10–15 years
Electrical system: 8–10 years
Wear-resistant components (e.g., spiral blades): 2–3 years
Dry mix concrete batching plant is an ideal choice for small and medium-sized projects, remote projects and environmental protection priority projects due to its low cost, high flexibility and easy maintenance. It is recommended that industry practitioners reasonably choose the type of equipment based on the project scale, transportation conditions and environmental protection standards. EPDAS is a professional supplier of concrete batching plants. Contact us for the latest solutions!
