POLYGON MACHINE

Concrete Batching Plant Solutions From Polygon Machine for All Your Project Needs

Concrete batch plants are mobile or stationary plants that are employed to measure and mix the concrete ingredients uniformly in the construction industry. Their basic purpose is to yield a high-quality and uniform mix in each batch in the shortest possible time, and with reduced cost.

A concrete batching plant is a specialized structure that is utilized to precisely weigh and blend the components of concrete, which includes cement, aggregate (sand, gravel, crushed stone), water, and chemical admixtures. The basic use of such plants is to prepare a uniform and quality mix of concrete in each batch with optimized cost and production time for various building constructions.

Bolted Segment Kitset Cement and Mineral Silos

Polygon Machine Bolted Segment Kitset Silos are distinguished by their modular design, comprising pre-fabricated steel segments that are manufactured with exceptional precision. These segments are transported to the installation site and then systematically bolted together, typically commencing from the base rings and progressing upwards. This assembly method represents a significant departure from traditional welded silos, which are either fabricated as single, bulky units in a shop or field-welded piece by piece on-site, a process that can be cumbersome and time-consuming.

The manufacturing process for Polygon Machine’s bolted silos employs sensitive laser cutting and drilling methods, ensuring that each component fits with high precision during assembly. This meticulous approach to fabrication contributes directly to the structural integrity of the assembled silo. Furthermore, the structural soundness of these silos is rigorously verified through advanced Computational Aided Engineering (CAE) software, such as ANSYS Workbench.

This analytical rigor ensures that the silo can safely stock large quantities of cement or similar materials without any deformation, even under demanding conditions. The design also incorporates robust features like high-strength steel ladder systems, safety handrails, and maintenance platforms, enhancing operational safety and ease of access. Polygon Machine’s bolted silos are available in a wide range of capacities, with modern large bolted silos capable of reaching up to 40 meters in diameter and storing up to 50,000 cubic meters of material.

Horizontal Low Level Cement Silos

Polygon Machine Horizontal Low Level Cement Silos are characterized by their compact, elongated horizontal structure, which results in a low-profile footprint. This design makes them particularly suitable for environments with height restrictions. A key feature of these silos is their high mobility, often achieved by mounting the silo body on a trailer equipped with double axles and tires, facilitating easy transport between sites.

Internally, these silos are engineered for efficient material flow. They are equipped with vibrators, pneumatic elements, and fluidization nozzles that work in concert to ensure proper and continuous discharge of cement, preventing material clumping or blockages. Material transfer from the silo is efficiently managed by an integrated V-type horizontal screw conveyor positioned beneath the silo body. For operational convenience and maintenance, these silos typically include maintenance doors on both sides and on the roof, allowing for easy access and inspection. Polygonmachine offers horizontal silos with capacities such as 39 tonnes (equivalent to 30 m³), with general horizontal silo capacities ranging from 15 m³ to 100 m³.

Monoblock Welded Cement and Mineral Silos

Polygon Machine Monoblock Welded Cement and Mineral Silos are distinguished as factory-welded, single-piece units, designed for maximum structural rigidity and stability. These silos are constructed from heavy-duty steel, with specifications typically including ST-37 grade steel, with body sheets ranging from 4-5 mm and conical parts at 5 mm thickness. The manufacturing process emphasizes high weldment integrity, often utilizing submerged arc welding of carbon steel cylinders to ensure 100% penetration with no slag or porosity.

Standard features integrated into these silos include a skirted design, hinged louvered access doors, a center dome with cover, and a bottom discharge opening. For operational safety and accessibility, they are equipped with deck perimeter guardrails, ladders, platforms, and cages that adhere to OSHA guidelines. Additional components include manholes/vents, air pad holes, sight glasses, silo inventory measuring head openings, safety valves, and level indicators. Polygon Machine offers these welded silos in various capacities, commonly ranging from 50 to 100 tons, with specific models like a 50-ton (39 m³), 75-ton (58 m³), and 100-ton (85 m³) capacity.

Mobile Cement Silos on Wheels

Polygon Machine Mobile Cement Silos on Wheels are engineered for ultimate portability, integrating a robust wheeled chassis, often with double axles and tires, to facilitate rapid transport. These units typically feature a low-profile design, similar to horizontal silos, which further enhances their ease of transport and maneuverability on various job sites.

These mobile silos are equipped with a suite of advanced features designed to ensure efficient and safe operation. This includes a powerful 60HP blower package for high-volume material transfer, an automated vane feeder system, and integrated dust control mechanisms, such as a silo top dust collector and overfill protection systems. A smart control panel provides automated and manual switches for major components, alarm lights for level indicators, and overpressure safeguards, ensuring precise control and operational safety. An aeration system, complete with a pre-wired air compressor and aeration pads, is integrated into the silo cone to ensure consistent material flow and prevent blockages. Polygon Machine offers mobile silos with capacities ranging from 20 to 192 tons, with specific models capable of holding up to 192 tons (174 metric tons) or 3760 cubic feet.

EXPLORE CONCRETE BATCHING PLANT

Automation of the general in modern plants is a wonderful transformation in the construction sector. There is a widespread shift from labor to managerial positions. The ability of a single operator to operate the entire plant and of a few workers to load materials validates the diminished need for extensive quantities of skilled labor staff required for hand mixing but simultaneously increasing the need for technical sufficient operators of software and control systems. All this carries significant implications for workforce development, training requirements, and labor expense within the construction industry. In addition, the value of a plant today is no longer solely on the strength of its mechanics but also the sophistication and reliability of its integrated control electronics and software. This places makers such as Polygonmachine that specialize in leading-edge automation at the forefront of this movement.

Key Components of a Concrete Batching Plant

Stationary Concrete Batching Plants

Stationary batch plants are powerful, high-production plants for long-term, high-volume concrete production in one location. They form the backbone of big construction projects and commercial-ready mix concrete companies requiring constant, high-volume production of concrete.

They have stationary installation, large footprint, and large production rates. They are typically installed on concrete foundations in the site and are designed for continuous and stable working for extended periods.

These plants are intended for use in applications where the plant remains stationary at one location for a long time, such as ultra-high capacity ready-mix concrete projects, dams, mass housing development projects, highways, and bridge construction. They are used for commercial production of concrete and precast concrete members.

Parameter	Specification
Production Capacity	60 – 240 m³/h
Mixer Type	Twin Shaft, Pan, Planetary, Single Shaft
Mixer Capacity	1.0 – 5.0 m³ per cycle
Mixer Motor Power	37 – 2×90 kW
Aggregate Hopper Volume	4×10 – 4×40 m³
Aggregate Weighing Hopper	1.5 – 6.0 m³
Cement Weighing Hopper	600 – 2,400 kg
Water Weighing Hopper	300 – 1,200 liters
Additive Weighing Hopper	20 – 100 liters
Air Compressor	300 – 1,200 liters, 4 – 15 kW
Cement Silo Capacity	50 – 500 tonnes (optional)
Control System	Full Automatic (PLC-based)
Total Motor Power	125 – 420 kW
Required Area to Operate	700 – 2,000 m²
Aggregate Feeding System	Ramp or Pre-Feeding System
Aggregate Transfer Conveyor	Belt conveyors or skip hoist systems
Weighing Accuracy	±1% for aggregates, ±0.5% for cement and water
Automation Components	Siemens & Schneider brand electronic components and PLC

Mobile / Portable Concrete Batching Plants

Mobile or portable concrete batching plants are designed for flexibility and quick installation. They enable the on-site manufacturing of concrete at various construction sites, thereby conserving logistics and transport costs of ready-mix concrete.

A mobile batching plant is a self-sufficient efficient system of concrete making that integrates the storage, weighing, conveying, mixing, and control of raw material systems into one mobile frame. They are more space-saving than conventional fixed plants of identical capacity.

The challenge of attaining high performance (e.g., 100 m³/hour rate) and portability (on a single truck tractor) and easy installation (pre-wired systems) is a significant engineering challenge. It requires optimization of component size, weight, and integration without compromise in mixing quality, accuracy of weighing, or life. Utilizing robust mixers (e.g., twin-shaft) and automation at a high level in a compact design produces highly sophisticated design trade-offs and innovations to deliver a powerful but versatile solution. This indicates the ongoing evolution of technology in the field of concrete batching plants, driven by clients’ need for efficient, versatile building solutions that test the limits of combining seemingly contradicting traits such as mobility and power.

Parameter	Specification
Production Capacity	60 – 150 m³/h
Mixer Type	Twin Shaft, Pan, Planetary, Single Shaft
Mixer Capacity	1.0 – 4.5 m³ per cycle
Mixer Motor Power	37 – 2×55 kW
Aggregate Hopper Volume	4×10 – 4×30 m³
Aggregate Weighing Hopper	1.5 – 6.0 m³
Cement Weighing Hopper	600 – 2,000 kg
Water Weighing Hopper	300 – 1,200 liters
Additive Weighing Hopper	20 – 100 liters
Air Compressor	300 – 1,200 liters, 4 – 15 kW
Cement Silo Capacity	50 – 500 tonnes (optional)
Control System	Fully Automatic (PLC-based)
Total Motor Power	125 – 420 kW
Required Area to Operate	700 – 2,000 m²
Aggregate Feeding System	Ramp or Pre-Feeding System
Aggregate Transfer Conveyor	Belt conveyors or skip hoist systems
Weighing Accuracy	±1% for aggregates, ±0.5% for cement and water
Automation Components	Siemens & Schneider brand electronic components and PLC

Container-Type / Compact Concrete Batching Plants

Container-type or compact concrete batching plants offer a hybrid solution that combines the modularity and fast setup of mobile plants with the performance and capacity of smaller stationary units. These plants are designed for high-efficiency concrete production in confined or challenging environments.

Also referred to as modular concrete mixing plants, container-type plants are specifically engineered for efficient concrete production in space-constrained areas. They are smaller, modular versions of traditional batching plants and combine the mobility advantages with high performance.

These plants consist of modular components including the main mixing module, dosing module, weighing module, and control room module. Each module can be quickly connected using bolts, and each layer can be assembled at ground level prior to being lifted into place. This modularity facilitates rapid transportation and installation.

Parameter	Specification
Production Capacity	30 – 120 m³/h
Mixer Type	Twin Shaft, Pan, Planetary, Single Shaft
Mixer Capacity	0.5 – 3.0 m³ per cycle
Mixer Motor Power	18.5 – 2×55 kW
Aggregate Hopper Volume	4×7 – 4×30 m³
Aggregate Weighing Hopper	1.5 – 4.5 m³
Cement Weighing Hopper	300 – 1,800 kg
Water Weighing Hopper	160 – 1,000 liters
Additive Weighing Hopper	20 – 100 liters
Air Compressor	300 – 1,200 liters, 4 – 15 kW
Cement Silo Capacity	50 – 500 tonnes (optional)
Control System	Fully Automatic (PLC-based)
Total Motor Power	45 – 205 kW
Required Area to Operate	400 – 1,000 m²
Aggregate Feeding System	Ramp or Pre-Feeding System
Aggregate Transfer Conveyor	Belt conveyors or skip hoist systems
Weighing Accuracy	±1% for aggregates, ±0.5% for cement and water
Automation Components	Siemens & Schneider brand electronic components and PLC

Dry Type Concrete Batching Plants

Dry type concrete batching plants represent a different approach in the concrete production where the ingredients are initially mixed without water. The method has clear merits, primarily from a logistic, economic, and environmental perspective, in the case of transporting concrete to the site and mixing during transport.

Dry batching plants are especially preferred where distance from the plant to the point of application is considerable, as the ultimate mixing occurs during transit. They are usually used in mega construction projects such as dams, mass housing, highways, and bridges. Polygonmachine emphasizes their use in quick construction and infrastructure development programs. They can also be used in dry regions, where water supply is scarce, or regions where water usage is controlled.

Parameter	Specification
Production Capacity	60 – 150 m³/h
Aggregate Storage Capacity	90 – 240 m³
Number of Aggregate Bins	4 – 6
Aggregate Weighing Capacity	Up to 9 m³ per batch
Cement Weighing Hopper	1,000 – 5,000 kg
Water Weighing Hopper	500 – 2,500 liters
Additive Weighing Hopper	20 – 100 liters
Air Compressor	300 – 1,200 liters, 4 – 15 kW
Cement Silo Capacity	50 – 500 tonnes (optional)
Control System	Fully Automatic (PLC-based)
Total Motor Power	125 – 420 kW
Required Area to Operate	700 – 2,000 m²
Aggregate Feeding System	Ramp or Pre-Feeding System
Aggregate Transfer Conveyor	Belt conveyors or skip hoist systems
Weighing Accuracy	±1% for aggregates, ±0.5% for cement and water
Automation Components	Siemens & Schneider brand electronic components and PLC

On-Site Mobile and Stationary Concrete Batching Plants

This section provides a comparative analysis of on-site mobile and traditional stationary concrete batching plants. It focuses on their advantages and disadvantages in terms of installation, preparation time, labor requirements, and overall project flexibility. This comparison is critical for strategic decision-making in equipment procurement.

These plants are designed for portability and rapid on-site setup. By dosing concrete directly at the construction site, they reduce delays and manual effort, eliminating the need for external truck deliveries and extensive on-site labor. Polygonmachine emphasizes its mobile and compact solutions for clients needing fast, on-site concrete production.

Parameter	Specification
Production Capacity	30 – 150 m³/h
Mixer Type	Pan, Planetary, Twin Shaft
Mixer Capacity	0.5 – 3.33 m³ per cycle
Mixer Motor Power	18.5 – 2×55 kW
Aggregate Hopper Volume	4×2.5 – 4×25 m³
Aggregate Weighing Hopper	0.75 – 4.5 m³
Cement Weighing Hopper	300 – 1,800 kg
Water Weighing Hopper	160 – 1,000 liters
Additive Weighing Hopper	15 – 100 liters
Air Compressor	300 – 1,200 liters, 4 – 15 kW
Cement Silo Capacity	50 – 500 tonnes (optional)
Control System	Fully Automatic (PLC-based)
Total Motor Power	45 – 205 kW
Required Area to Operate	400 – 2,500 m²
Aggregate Feeding System	Ramp or Pre-Feeding System
Aggregate Transfer Conveyor	Belt conveyors or skip hoist systems
Weighing Accuracy	±1% for aggregates, ±0.5% for cement and water
Automation Components	Siemens & Schneider brand electronic components and PLC

3D Concrete Printing Plants

3D concrete printing plants represent a revolutionary advancement in the construction sector. This technology enables the automated, additive manufacturing of concrete structures directly on-site, offering unprecedented design freedom, accelerated construction timelines, and reduced material waste.

3D concrete printing plants are specialized systems designed for additive manufacturing using concrete. Typically, they involve a robotic arm or gantry system that precisely extrudes a specially formulated concrete mix to build structures layer by layer.

The process begins with a digital design (CAD file). The 3D printer, usually integrated with a mobile batching unit, receives a hyper-precise concrete mix. The printer then moves along a predefined path, extruding the concrete at a controlled flow rate and speed to construct the structure layer by layer. Built-in site positioning systems such as laser alignment tools ensure perfect coordination with CAD files. Real-time monitoring via integrated sensors and HD cameras ensures quality assurance and allows for remote operation and adjustments based on environmental conditions.

Parameter	Specification
Printing Technology	Extrusion-based additive manufacturing
Printer Types	Gantry systems, Robotic arms, Mobile crawlers, Track-mounted systems
Build Volume	Up to 40,000 x 1,350 x 3,250 mm (L x W x H)
Print Speed	Up to 500 mm/s (e.g., CyBe G 3DP)
Nozzle Types	Circular (10–40 mm), Rectangular/Square (width: 10–50 mm, thickness: 10–20 mm)
Layer Dimensions	Width: 30–80 mm; Height: 6–15 mm; Maximum unsupported overhang: up to 85.5°
Material Delivery System	Positive displacement pumps with continuous flow
Control System	PLC-based automation with slicing software integration
Reinforcement Options	Fiber reinforcement, Welded wire meshes, Integration of rebar
Concrete Mix Requirements	High buildability and extrudability; may include admixtures like nano-silica, fly ash, superplasticizers
Power Requirements	Varies based on printer size and type; specific power ratings depend on equipment specifications
Operational Footprint	Dependent on printer type; mobile units require less space, while gantry systems need larger areas
Applications	Residential housing, Infrastructure components, Architectural elements, Precast modules, On-site construction

Roller Compacted Concrete Batching Plants (RCC)

Roller Compacted Concrete (RCC) is a special, stiff, and extremely dry concrete mix that is compacted by vibratory rollers. RCC plants are special batching plants that produce this special concrete mix, which is highly suitable for heavy-duty pavements, dams, and other massive infrastructure projects that need durability and quick construction.

American Concrete Institute (ACI) has defined roller compacted concrete (RCC) as: “concrete compacted by roller while in its unhardened state, stiff enough to support a roller.” RCC can also be described as dry, very stiff concrete with consistency similar to damp gravel.

It contains far less water than regular concrete, so the mixture is drier and will not slump. Its consistency is more like wet gravel.

Like asphalt, it is placed by a paver and compacted by rollers. The roller compacted concrete is externally consolidated or compacted by large vibratory rollers. The fully compacted and hardened RCC properties are similar to those of traditionally placed concrete.

RCC even attains higher flexural strength than ordinary concrete, with strength developing quickly in excess of 5.5 MPa. Its high flexural, compressive, and shear strength allows it to withstand repetitive, heavy loading without failure.

Parameter	Specification
Production Capacity	Up to 800 tons/hour
Mixer Type	Twin-shaft continuous mixer
Mixer Capacity	2×5.0 m³ per cycle
Mixer Motor Power	2×90 kW
Aggregate Bins	4–8 compartments, each with 20–75 m³ capacity
Aggregate Feeding System	Ramp or pre-feeding system
Aggregate Transfer Conveyor	Belt conveyor system
Air Compressor	Included; piston or screw type, 7.5 kW
Cement Weighing Hopper	2×2,500 kg capacity
Water Weighing Hopper	2×1,200 kg capacity
Additive Weighing Hopper	2–6 units, each with 20–60 kg capacity
Cement Screw Conveyor	1–8 units, diameter 323 mm
Control System	Fully automatic, PLC-based system
Operational Features	Intelligent automation, compact design, modular components, cost efficiency
Applications	Highways, airport runways, municipal roads requiring continuous high-volume output

Mortar Concrete Mixers and Mixing Equipment

Concrete and mortar mixers are essential equipment in the field of construction that aids in achieving a well-mixed blend of materials such as cement, water, sand, gravel, and other admixtures. The selection of mixer is of the utmost significance in the quality and strength of the concrete and the general safety of the project.

Polygonmachine offers a wide range of concrete and mortar mixers, including Pan, Planetary, Single Shaft, Twin Shaft, and Cone mixers. Each mixer type is suited for a specific concrete type or end-user application.

Drum Mixers:

These mixers employ a rotating drum for mixing the materials. Blades within the drum lift and fall the material in order to mix. Because of their uncomplicated structure, simplicity in operation, and low price, they are apt for small-scale works. The quality of mixing is inferior, and production capacity is restricted, so they are not suitable for the production of high-standard concrete.

Pan Mixers:

They possess a heavy circular mixing pan, typically with blades or paddles mounted on a vertical shaft. In most modern designs, the pan is stationary and star-shaped blades rotate, often assisted by a scraper arm to mix all materials with high shear force. They mix more quickly and uniformly than drum mixers. Ideal for precision-intensive applications such as precast concrete products, wall mortar, tile adhesives, and colored concrete.

Planetary Mixers:

A unique sub-type of the pan mixer, planetary mixers achieve intense mixing action. One or two central mixing stars (equipped with multiple paddles) not only spin around their own axes but also revolve around the mixer center, creating a counter-current effect with high shear forces for uniform particle coating in a short time. Due to their high shear force and fast mixing cycles, they are used for special mixes like high-performance concrete, fiber-reinforced concrete, and ultra-high-strength concrete. Preferred for small to medium batch sizes where quality is more important than quantity.

Twin Shaft Mixers:

With two horizontal mixing shafts, oppositely rotating intermeshing blades intensely mix the batch. Their final strengths are extremely high mixing intensity and speed. With heavy-duty gearboxes, wear-resistant liners, and strong steel construction, they are built. It is the most popular mixer type for high-capacity ready-mix concrete production. They achieve high homogeneity in very short cycles and are therefore the first choice for ready-mix concrete plants and large infrastructure projects.

Single Shaft Mixers:

These mixers typically have mixing blades on a single horizontal or vertical shaft. They offer flexibility for various concrete and mortar applications. Polygonmachine supplies them with auto lubrication systems and easy maintenance access.

Cone Mixers:

A twin-cone mixing device used to mix dry powders and granules gently and thoroughly. It consists of a pair of cone-shaped containers fused at their widest diameters and a central rotating shaft that is fitted with agitators or mixing blades. As the cones turn in opposite directions, powders or granules are intensively mixed and circulated inside the container. Ideal for gentle and thorough mixing of dry powders and granules without inflicting injury to fragile particles. Variable speed controls for customized mixing.

Mixer Type	Typical Batch Capacity	Energy Efficiency	Suitable Applications	Maintenance Requirements	Wear Parts & Materials	Motor Power Range (kW)	Automation Features
Drum Mixer	0.25 – 1 m³	Low	Basic site mixes, low-grade mortars	Low	Basic steel blades, low wear parts	3 – 7.5	Manual or basic electric control
Pan Mixer (Vertical Shaft)	0.25 – 1.5 m³	Medium	Precast, tile adhesives, colored concrete	Medium	Steel liners, scrapers, replaceable arms	7.5 – 15	Semi-automatic, PLC compatible
Planetary Mixer	0.25 – 2 m³	High	High-performance, fiber-reinforced concrete	High	Hardened paddles, replaceable liners	11 – 30	Full automation, recipe controls
Twin Shaft Mixer	1 – 6 m³	Very High	Ready-mix, infrastructure, highways	High	Heavy-duty arms, Ni-Hard liners, paddles	18 – 90+	Advanced PLC, SCADA integration
Single Shaft Mixer	0.5 – 2 m³	Medium	Versatile concrete and mortar use	Medium	Standard blades, moderate wear items	11 – 22	Programmable, simple automation
Cone Mixer	0.2 – 1 m³	High	Powders, granules, fragile materials	Low	Low-wear paddles, stainless options	5 – 15	Optional sensors, timing systems