CONCRETE BATCHING PLANT

Configured to Your Requirements

No One-Size-Fits-All Approach

Every concrete production operation has different requirements. GPE therefore does not limit clients to a standard plant configuration. Our concrete batching plants can be engineered and manufactured to suit the specific production, site, concrete mix and operational requirements of each project.

The mixing system is an important part of this approach. GPE can integrate different mixer technologies and capacities depending on the application, including:

• Twin Shaft Mixers — suited to high-output production and demanding concrete applications.
• Pan Mixers — a proven solution for a wide range of concrete production requirements.
• Planetary Mixers — particularly suited to applications requiring intensive and homogeneous mixing, including many precast concrete applications.

For twin shaft mixers, GPE can integrate BHS-Sonthofen, Germany mixers, while Teka, Germany mixers are available for pan and planetary mixer applications. Other recognised mixer technologies can also be integrated where specifically required by the client.

The Mixer Is Selected Around the Application

Mixer capacity is not selected simply from a standard catalogue. GPE considers factors including required hourly production, batch size, concrete mix design, aggregate characteristics, cycle time, concrete quality and the intended application.

Mixer capacities can therefore be selected to suit the overall plant configuration and production requirements.

Your Plant. Your Specification.

Whether the requirement is for a ready-mix concrete plant, precast concrete production line, infrastructure project or a specialised concrete application, GPE can engineer the batching plant around the client’s requirements.

This flexibility allows GPE to combine different mixer technologies, capacities, automation systems, aggregate configurations, cement storage arrangements and ancillary equipment to create a complete concrete production solution rather than forcing the project into a predetermined standard design.

Mixer Tower

Engineered Around Your Production Process

The mixer tower is designed to suit the specific production requirements and site configuration of each GPE concrete batching plant. Clients can select the mixer technology, mixer brand, capacity, discharge arrangement and construction options that best suit their application.

GPE can integrate Planetary, Pan and Twin Shaft Mixers, with mixer capacities selected according to the required production rate and application. Twin Shaft Mixers up to 4.5 m³ compacted concrete output per batch can be accommodated, with other mixer capacities available to suit the overall plant configuration.

Flexible Mixer Selection

GPE can supply its standard mixer configuration or integrate a client-specified mixer brand. Depending on the application, GPE plants can accommodate mixers from recognised manufacturers such as BHS, SICOMA, IME and TEKA, as well as other suitable technologies requested by the client.

For demanding applications, high-wear and abrasion-resistant mixer linings can be specified to extend component life and reduce maintenance requirements.

Discharge Designed for the Application

The mixer tower structure and discharge height are engineered around the way concrete will leave the plant. The discharge chute can be configured for:

• Mixer trucks — for ready-mix concrete production
• Forklifts — for egglayer and other concrete-product applications
• Flying buckets — for precast concrete production
• Custom discharge arrangements — for specialised applications

The mixer tower can also be supplied with a hot-dip galvanised finish where additional corrosion protection is required, particularly for demanding environments.

Waiting Hopper for Higher Ready-Mix Output

For ready-mix applications, GPE can provide a waiting hopper beneath the mixer as a standard plant feature.

The waiting hopper allows a completed batch to be held while the mixer prepares the next batch. This creates a more efficient batching cycle, with up to three batches simultaneously moving through different stages of production, depending on the plant configuration and operating cycle.

The result is higher effective plant output without simply increasing mixer size.

Aggregate Storage

Designed for Capacity, Durability and Efficient Transport

GPE designs aggregate storage systems around the production capacity, operating hours, aggregate requirements and site conditions of each concrete batching plant.

Aggregate bins and hoppers can be configured in different capacities and numbers to provide the storage volume required for the application. The system can be scaled for compact installations as well as high-utilisation plants serving demanding construction and infrastructure projects.

Built for Demanding Outdoor Conditions

Aggregate storage equipment is exposed to continuous loading, impact and abrasion from coarse aggregates, sand and other raw materials. GPE therefore designs the storage system for robust, long-term operation in demanding outdoor environments.

Structural components, mechanical equipment and electrical systems are selected with the operating environment in mind. Appropriate weatherproof enclosures and protection are incorporated where required.

Optimised for International Transport

For projects requiring equipment to be shipped internationally, GPE can provide collapsible aggregate storage systems designed for efficient containerised transportation.

This reduces shipping volume and can simplify logistics, particularly for projects in remote locations or markets where plant equipment must be transported over long distances.

Capacity Matched to Your Production

Aggregate storage capacity is determined in consultation with the client. Key considerations include:

• Required concrete production capacity
• Hours of plant operation per day
• Aggregate types and number of aggregate fractions
• Delivery frequency and availability of aggregates
• Site constraints and available footprint
• Required production autonomy

For high-utilisation projects, larger multi-bin configurations can be engineered to provide sufficient aggregate reserves and minimise interruptions to concrete production.

Hot-Dip Galvanised Options

Where required, aggregate storage structures can be supplied with a hot-dip galvanised finish for enhanced corrosion protection and extended service life, particularly in harsh or corrosive environments.

The result is an aggregate storage system that is engineered to your capacity, designed for your operating environment and configured for efficient installation and long-term use.

Aggregate Conveying

Flexible Aggregate Transfer for Every Plant Layout

GPE offers flexible aggregate conveying systems designed around the plant capacity, mixer configuration, site layout and available footprint. Depending on the application, aggregates and sand can be transferred from the storage bins to the mixer using either an inclined belt conveyor or skip hoist system.

Inclined Belt Conveyors

Inclined conveyors are available in different widths and capacities, allowing the conveying system to be matched to the required batching rate. GPE typically sizes the conveyor with sufficient capacity above the mixer requirement to support efficient and uninterrupted aggregate feeding and maximum mixer utilisation.

Where site constraints require a steeper conveying angle or a more compact plant footprint, ribbed belt conveyors can be used. Their increased grip allows aggregates to be conveyed at steeper angles than conventional smooth belts, helping reduce the overall footprint of the batching plant.

Where appropriate, inclined conveyors can be supplied with galvanised covers and housings to protect the conveyor and reduce exposure to rain and weather. Enclosed conveying also helps contain dust during aggregate transfer.

Skip Hoists

Where the plant layout, site conditions or application favour vertical aggregate transfer, GPE can provide a skip hoist system.

Skip sizes and capacities are selected according to the mixer size and required production rate. GPE can supply its standard skip arrangement or integrate equipment from a client-specified manufacturer, subject to suitability for the plant design.

Conveying Designed Around Your Plant

Whether the requirement is for a compact batching plant with restricted space or a high-capacity installation requiring continuous aggregate flow, GPE can configure the conveying system to suit the production requirement, site geometry and operating conditions.

The objective is simple: efficient aggregate transfer without compromising plant capacity, reliability or maintainability.

Control System

Intelligent Control for Accurate and Efficient Concrete Production

GPE’s WEBcon batching and plant control system provides centralised control and monitoring of the concrete production process, combining accurate dosing with clear visualisation and production management.

The system is designed around a client-server architecture and can be configured for networked operation, allowing production data and plant information to be accessed across connected systems and, where required, across multiple plants.

WEBcon provides comprehensive control of the batching process, including recipe management, component dosing, moisture correction, production monitoring and consumption data.

Key Features

• Recipe Database — Manage concrete mix designs and production recipes.
• Customer Database — Maintain customer and delivery information.
• Truck Database — Manage truck and delivery-related information.
• Site Database — Organise production and delivery information by project or site.
• Component Database — Manage aggregates, cement, water, admixtures and other materials.
• Moisture Correction — Automatically account for aggregate moisture to improve batching accuracy.
• Production Visualisation — Monitor the complete batching process through an intuitive graphical interface.
• Production Statistics — Track material consumption and production data for improved operational control.
• Network Connectivity — Link multiple plants and access production information across a network.
• Alarm Notifications — Enable alarm messaging via SMS or email where configured.
• Preventive Maintenance — Support maintenance planning and monitoring to help minimise unplanned downtime.
• System Upgrades — Provide a platform that can be expanded or upgraded as production requirements evolve.

Proven in Demanding Applications

GPE’s control technology has been deployed in demanding concrete-production environments, including projects associated with major infrastructure and high-rise construction.

[If the Burj Dubai reference is documented:]
WEBcon control technology was used in concrete production associated with the construction of Burj Dubai — now Burj Khalifa, demonstrating the system’s capability in one of the world’s most demanding concrete-production projects.

Control More. Produce Better.

The objective of WEBcon is not simply to automate batching. It is to give plant operators greater control over accuracy, production, materials, maintenance and plant performance, helping them operate their concrete batching plant efficiently and consistently.

Ice Flake & Chilled Water Systems

Precise Concrete Temperature Control for Hot-Weather Production

In hot climates, high aggregate and cement temperatures can make it challenging to produce concrete within the required temperature range. GPE integrates ice flake and chilled-water systems into concrete batching plants to provide effective temperature control during concrete production.

Ice Flake Dosing
Ice flakes can be introduced directly into the concrete mix as part of the batching process, replacing a portion of the mixing water and significantly reducing the initial concrete temperature.

Chilled Water Systems
GPE can integrate chilled-water systems designed to supply water at the required temperature for concrete production. The system capacity is selected according to plant output, ambient conditions, mix requirements and the required concrete discharge temperature.

Integrated Plant Control
GPE’s WEBcon control system can integrate the dosing and management of chilled water and ice, allowing the cooling process to be incorporated into the concrete recipe and production cycle.

Engineered for Hot-Weather Concrete Production
The complete system can be configured around the client’s required concrete temperature, production capacity and site conditions — providing a practical solution for demanding hot-climate projects.

By customizing our Concrete Plants to our clients’ specific requirements, we can offer Wet Concrete Batching Plants or Dry Concrete Batching Plants.With our associated offices in Germany, Italy and Middle East, we are able to strike the perfect balance between a Competitive Price and Continuous Upgrades in the Technology for the benefit of our worldwide clients.

By customizing our Concrete Plants to our clients’ specific requirements, we can offer Wet Concrete Batching Plants or Dry Concrete Batching Plants.