ORIENTAL STRUCTURAL ENGINEERS PVT LIMITED

( 30 Cum Batching Plant)

1 Introduction

In its simplest form, concrete is a mixture of paste and aggregates (sand & rock). The
paste, composed of cement and water, coats the surface of the fine (sand) and coarse
aggregates (rocks) and binds them together into a rock-like mass known as concrete.

After the aggregates, water, and the cement are combined, the mixture remains in a
fluid condition for about four to six hours which permits transporting, placing and
finishing in its final location, then the mixture starts to harden. All Portland cements are
hydraulic cements that set and harden through a chemical reaction with water.

The proportioning of a concrete mix design should result in an economical and practical
combination of materials to produce concrete with the properties desired for its intended
use, such as workability, strength, durability and appearance.

2 Central Mixed Concrete

Central-mixing concrete batch plants include a stationary, plant-mounted mixer that

mixes the concrete before it is discharged into a truck mixer. Central-mix plants are
sometimes referred to as wet batch or pre-mix plants. The truck mixer is used primarily
as an agitating haul unit at a central mix operation. Dump trucks or other non-agitating
units are sometimes be used for low slump and mass concrete pours supplied by
central mix plants.

Horizontal shaft mixers have a stationary shell and rotating central shaft with blades or
paddles. They have either one or two mixing shafts that impart significantly higher
horsepower in mixing than the typical drum mixer. The intensity of the mixing action is
somewhat greater than that of the tilt drum mixer.

3 Installation of Batching Plant

Proposed area for batching plant installation shall be leveled and also there shall be firm
access road for the movement of Transit mixers. The time period required for the
installation and commissioning of batching plant is about 15 to 21 days.

4.1 Machineries for installation:

S.No Description Capacity Quantity Remark

1 Generator 65 KVA 1No
2 Hydra 5 MT 1No
3 Crane(Tyre Mounted) 40MT 1No

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 ORIENTAL STRUCTURAL ENGINEERS PVT LIMITED
( 30 Cum Batching Plant)

4 Welding set 1No

5 Cutting set 1No
6 Tool box with 1no
complete set
7 D- Shackles and 8No
slings

4.2 Manpower During Installation:

1. Civil Engineer 1
2. Mechanical Engineer 1
3. Rigger 4
4. Electrical Foreman 1
5. Sr. Supervisor 1
6. Welder 1
7. Laborers 6

5.0 Operation

5.1 Typical Working of Batching Plant

The four aggregate gates are pneumatically operated and the weighing is done through
electronic load cells. The aggregates are weighed in a skip bucket and then are moved
up to the turbo pan mixer by two units of pole change motors. These pole change
motors operate the skip at two different speeds to reduce the time cycle at each batch
and at the same time protect the important components of the weighing system. The
batching of water and admixture is by weight.

The cement from the cement silos is fed into the combined cement water weighed
through screw conveyors. The water and cement are weighed in a combined weighed
and discharged into the pan mixer. The pan mixer has been designed in such a way
that it can handle various slumps of concrete and achieve a homogenous mix in the
shortest possible time.

Batching plants are usually fully computerized and offers state of the art features .
Batching Plant is installed with an interface in the control system that provides the batch
reports through the printer. The interface also facilitates the transfer of all data from the
control system to a computer where the data can be processed as per the requirements
of users.

Hence, it is an ideal plant for use in RMC operations and for projects where the down
time of the plant is expensive.

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 ORIENTAL STRUCTURAL ENGINEERS PVT LIMITED
( 30 Cum Batching Plant)

6.0 Organization Requirement

The organizational set up required for operation and maintenance of Batching
plant/shift

S.No Organization No
1 QC Engineer 1
2 Lab technician 1
3 Batching Plant operator 1
4 Scrapper operator 1
5 Mechanic 1
6 Electrician 1
7 Store Supervisor 1

7.0 Space Requirement for Installation and Operation

The below mentioned area will be required for the installation and operation of 30
cum batching plant.

S.No Description Capacity Area (Sqm)

1 Batching Plant 30 Cum 450
2 Cement Store 10000 bags 400
3 Material Stock Pile 5000 cum 2000
4 Work shop for machineries 150

8.0 Prices of Equipments & Machineries( Approximate)

S.No Specification Price inclusive of taxes

1 30cum batching plant with four bin Rs. 40,50,000/=
feeder and pan mixer (Type1)
2 30 cum batching plant with scraper Rs.27,02,500/=
( Type 2)
3 Silo & Compressor Rs. 8,50,000/=
4 125 KVA DG set Rs 6,00,000/=
5 JCB for feeding material Rs 20,00,000/=

9.0 Production cost

Monthly Expenses in operation and maintenance of Batching Plant

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 ORIENTAL STRUCTURAL ENGINEERS PVT LIMITED
( 30 Cum Batching Plant)

10.1 Manpower cost

S.No Description unit No Cost/month Amount

1 QC Engineer No. 1 45000 45000
2 Lab Technician No. 1 18000 18000
3 Batching Plant Supervisor No. 1 15000 15000
4 Batching Plant Operator No 1 12000 12000
Batching Plant Scrapper
5 Operator No. 1 10000 10000
6 Batching Plant Loader Operator No. 1 15000 15000
7 Store Keeper No. 1 10000 10000

8 Laborer at batching Plant No. 10 175 17500

Total(Rs) 142500

10.2 Operation cost

Approx
S.No Equipment Unit No cost/month
1 DG 125 KVA No. 1 67200
2 Compressor No. 1 45000
3 Front Loader/JCB No. 1 100000
Total ( Rs) 212200

10.3 Placing and Transportation Cost ( Hire Charges)

Hiring
S.No Description unit No charges Cost/month
1 Transit Mixer No. 4 125000 500000
2 Concrete Pump No. 2 80000 160000
Total(Rs) 660000

11 Contact details of Manufacturers and suppliers

1) SCHWING STETTER (I) Pvt. Ltd.

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 ORIENTAL STRUCTURAL ENGINEERS PVT LIMITED
( 30 Cum Batching Plant)

A/410, B – wing, Galleria,

Hiranandani Gardens, Powai
Mumbai – 400 006
Phone: +91 – 22 – 5797735/5708802
Fax: +91 – 22 – 5705260
E mail: schwing1@vsnl.com

2) MACONS EQUIPMENT

Plot No. 37/C, Phase – I,

G.I.D.C. Estate, Vatva, Ahmedabad – 382445, Gujarat, India

Phone: +91-79-25896184 / 25891510

Fax: +91-79-25892097

3)SHREE CONMIX ENGINEERS PVT. LTD.

7603, G.I.D.C. Estate, Phase – IV, Vatva, Ahmedabad – 382445

Phone : +91 – 79 – 25840917, Fax: +91 – 79 – 25840297

Website : www.conmixcrusher.com

4 )Apollo Infratech Private Limited

Ahmedabad – Mehsana State Highway, Village: Rajpur – 382740

Taluka: Kadi, Dist.: Mehsana, Gujrat, India

Tel: +91 2764232217, FAX : +91 2764 233117,

Website: www.apolloinfratech.com

5)Jayem Manufacturing Co. (Mobile Batching Plant)

Mr. J. L. Dhawan

C – 99, Sector – 4, Noida – 201301 , Uttar Pradesh

Phone: +91 – 120 – 2520242 / 2530163 / 2538136

Mobile: +91 - 9212704664

Fax: +91 – 120 – 4322849

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 ORIENTAL STRUCTURAL ENGINEERS PVT LIMITED
( 30 Cum Batching Plant)

E-mail: jayemmfgco@rediffmail.com

6. Hycon

Mr. R. B. Anand

Akona Engg. Pvt. Ltd.

A – 455, Hycon House, Hidcon Vihar

Meerut Road, Ghaziabad, Uttar Pradesh – 201001

Phone: +91 – 120 – 9891949705, 9810316314 ,

Fax: +91 – 120 – 2854742

7. National Machine Corporation

Mr. Ravinder Kumar Choudhary, Mr. Pushpendra Singh

C – 17/1, Sector – 22, Meerut Road

Ghaziabad – 201001

Phone: +91 – 9818738899/9810768253

12. Photograph

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ORIENTAL STRUCTURAL ENGINEERS PVT LIMITED
( 30 Cum Batching Plant)