Concrete is one of the main products used in the construction industry. It is used to build residential buildings, commercial properties, roads, for repairs, and several construction purposes. A batching plant manufactures concrete through a combination of several ingredients. A mixer is the most important part of this plant with several other parts like conveyors, cement bins and silos, heaters, chillers, aggregate batchers and bins and mixers among others. For its smooth functioning, periodical and preventive maintenance are necessary. The maintenance may cost a little bit but repays many times by increasing the output and the lifespan of the plant. It also raises the safety level for the workers and reduces the chances of a machinery breakdown. The below article provides pointers on how to go about the maintenance of the plant.
Maintenance of Batching Plant
Maintenance of batching plant consists of preventive maintenance and periodic maintenance. These are explained in detail below.
1. Preventive Maintenance
Preventive maintenance means the inspection of the plant’s parts and doing the required repairs and maintenance. It requires the following batching plant inspection checklist.
a. Cleanliness
The plant should be kept clean at all times to improve its lifespan. The mixer should be cleaned every day by running it with stones and water. The weighing unit should be cleaned regularly to maintain correct calibration.
b. Safety Measures
Batching plant safety checklist should be followed diligently ensuring the safety of the workers as well as the machinery. This checklist includes the following.
1. Every worker should wear protective gear all the time during operation hours. These include safety helmets, aprons, and gloves among others.
2. Ladders, stairs, and upper floor levels should have mandatory handrails installed.
3. Batching plant should necessarily have emergency shutdown switches and safety disconnects on turn head motors and conveyor.
4. Only permitted personnel to be provided access to manholes of cement and aggregate compartments.
5. Regular inspection of electrical wiring or any other dangerous or inflammable installations.
6. Before starting the maintenance of the concrete mixer the operator should cut off the power supply and lock the power distribution cabinet. A warning sign should be placed on the operation console before the maintenance starts.
7. Before starting the maintenance of the belt conveyor system, cut the power supply, lock the power distribution cabinet with keys in proper custody. This is the job of two people and never be done by a single worker alone.
8. Working on upper levels should always be done with a belt and a fastener. Welding equipment should not be dissembled and a welder should wear protective gear and glasses while performing his work.
9. During repair and maintenance of vehicles and loaders of the plant, lay the wheel rafters. Also, take suitable measures to prevent the jacks from collapsing and vehicles from slipping.
So, these are some important safety measures that batching plant operation procedure requires.
c. Overmixing Control
1. The ingredients required for manufacturing concrete should be mixed and discharged to the mixing compartment at optimum speed.
2. Check and lubricate the conveyor belts carrying ingredients or mix regularly.
3. Avoid stopping the batching plant while mixing and discharging the mix.
4. Update and check the batching software periodically if used.
d. Transportation Control
Transportation should always be on time to receive the product or concrete mix. Delivery at the right time is necessary. Mix trucks should be properly serviced and function well for mixed transport. The delay has adverse effects on the mix.
So, this is the batching plant inspection checklist for preventive measures. Now we move on to the periodic maintenance of the plant.
2. Periodical Maintenance of Batching Plant
Batch plant parts and all areas should be regularly inspected for their proper maintenance. Periodical checklists should be maintained which include checking on a daily, weekly, monthly, and quarterly basis. These are as follows.
a. Checklist for Daily Maintenance
1. Inspect conveyor belts for alignment and excessive wear issues.
2. Inspect cylinders, gates, and air valves. Check for loss of air pressure or air leaks.
3. Inspect oil levels of all parts of batching plant. Inspect for excessive wear also.
4. Apply lubricants on parts where required.
5. Empty and clean the water traps, air tanks, and manifolds.
b. Checklist for Weekly Maintenance
1. Inspect nuts, bolts, and screws of all parts of the plant and tighten any loose parts.
2. Inspect and adjust belt wipers.
3. Clean or replace air filters on aeration blowers.
4. Bearings of all machinery parts should be lubricated. Inspect the aggregate-gate pivot points and lubricate them too if required.
c. Checklist for Monthly Maintenance
Batching plant operation procedure requires the following monthly maintenance checklist.
1. Inspect conveyor skirt boards and sealers and replace if required.
2. Tighten and adjust the conveyor belts to their correct position.
3. Inspect the oil levels of all gear reducers.
4. Examine the silo filter vents and dust collectors.
5. Examine the working of pinch valves, light bars, and level indicators of storage compartments.
d. Checklist for Quarterly Maintenance
Batching plant safety checklist requires the following periodical inspections.
1. Inspect bin aeration pads and replace them if necessary.
2. Inspect and tighten the V-belts. Replace if damaged.
3. Clean the storage compartments.
4. Replace dust collectors and silo vents.
5. Check scale and water meter accuracy.
6. Inspect hanger bearing and feeder screws. Replace them with new bearings and screws if damaged.
Conclusion
Maintenance of Batching Plant requires all these considerations and preventive measures. Performing these checklists will benefit you in the long run by better productivity, the increased life span of the plant, employee retention, and low absenteeism due to increased safety features for workers and the plant alike.