At a glance: Kelude Heavy Industry provides crane configuration solutions for ready-mix concrete batching plants, covering four key zones—aggregate storage, powder silos, the mixing main unit, and transport vehicles. With lifting capacities from 3 to 32 tons and spans from 8 to 30 meters, the total investment in plant-wide lifting equipment ranges from approximately $18,000 to $178,000. The aggregate area is equipped with grab bridge cranes (5–16t), the powder silo area uses electric hoists (3–8t), the mixing area is fitted with LD type single-girder cranes (5–16t), and the transport area utilizes jib cranes (1–3t)—delivering full-workstation hoisting coverage for both equipment installation and routine maintenance.
Crane Configuration for Ready-Mix Concrete Batching Plants
Aggregate Storage | Powder Silo | Mixing Tower | Transport & Dispatch
A crane solution covering all four zones of a ready-mix concrete plant: aggregate storage, powder silos, mixing, and transport.
Zone 1: Aggregate Storage
• Lifting capacity: 5t–16t, MH type / grab bridge crane
• Sand & gravel grab bucket / feeding
• Outdoor wind-resistant / dustproof design
• Integrated water-spray dust suppression
Grab Bucket | Dust Suppression
Zone 2: Powder Silo Area
• Lifting capacity: 2t–5t, explosion-proof electric hoist
• Dust explosion-proof for powder materials
• Silo top cover maintenance access
• Sealed dust-proof motor
Powder Explosion-Proof | Silo Maintenance
Zone 3: Mixing Tower
• Lifting capacity: 5t–16t, LD type / electric hoist
• Mixer / liner plate replacement
• Batching station maintenance
• Compact / multi-level space
Mixer | Multi-Level Access
Zone 4: Transport & Dispatch
• Lifting capacity: 1t–3t, jib crane / electric hoist
• Mixer truck maintenance
• Pump truck component replacement
• Compact / fast operation
Vehicle Maintenance | Compact
Selection Parameters Across All Four Zones
| Parameter Item | Aggregate Silo/Bin Zone | powder Silo/Bin | Batching Plant | Transport Dispatch |
|---|
| recommended model | MH Type/grab bridge crane | Explosion-proof electric hoist | LD Type/Hoist | jib crane/Hoist |
| Lifting Capacity | 5t~16t | 2t~5t | 5t~16t | 1t~3t |
| special requirements | Grab (grab bucket)/Dust Suppression | Powder Material Explosion-proof | Liner Replacement | Vehicle Maintenance |
$178,000–$1,780,000
Total Plant Investment
A4~A5
Work Duty Classification
120–360 m³/h
Batching Plant Capacity
Lifting Challenges Across Key Zones of a Ready-Mix Plant
In the aggregate yard, grab cranes handle sand and gravel while dust-suppression spray systems keep airborne particles in check. At the top of powder silos, explosion-proof equipment is essential due to cement dust. The most critical maintenance task centers on replacing the mixing main unit's liners.
Why Kelude Stands Out for Ready-Mix Plants
Kelude has spent years specializing in crane systems for concrete batching operations. We supply complete lifting solutions for both commercial ready-mix and on-site project plants—from aggregate handling to truck maintenance bays. Our full range covers grab bridge cranes, gantry cranes, and electric hoists, with installations supporting over 200 batching plants nationwide.
Grab Crane Solutions for Aggregate Handling
Stone (5–31.5 mm) and medium-coarse sand in the aggregate yard are unloaded and stockpiled using grab bridge cranes rated from 5 to 16 t. Grab bucket volume is optimized around bulk density—crushed stone at 1.5 t/m³ and sand at 1.6 t/m³. Paired with below-grade receiving hoppers, these cranes keep unloading running around the clock, unaffected by rain or nighttime conditions.
Mixing Unit Maintenance Lifting
Replacing mixing arms and liners on twin-shaft JS mixers demands reliable crane support. Kelude recommends a 5–16 t LD-type single-girder electric overhead crane positioned directly above the mixing unit. With mixing arms weighing 50–150 kg each and liners at 30–80 kg per piece, this crane sees daily use. Given the vibration and dust in the mixing zone, anti-vibration motor mounts and dustproof electrical control boxes are standard recommendations.
Truck Maintenance Bay Lifting
Routine service on concrete mixer trucks and cleaning of their drums require auxiliary lifting. Kelude recommends 3–5 t jib cranes or LD-type single-girder cranes positioned over the drum area. Replacing the hydraulic drum drive motor—typically 150–300 kg—is a common job that demands reliable hoisting. A small electric hoist underslung crane covering 2–3 service bays is an ideal configuration for this zone.
Frequently Asked Questions
Q: What is the daily throughput of a grab crane used for aggregate handling at a batching plant?
A: For an HZS180 batching plant (production capacity of 150 m³/h), the daily aggregate consumption is approximately 2,000–3,000 t. The grab crane must handle unloading of all incoming delivery trucks and stockpiling in the yard. A 5–16 t overhead crane with grab is recommended to operate 8–12 hours per day, achieving an unloading rate of 150–200 t/h. If the plant capacity is expanded to HZS270 (240 m³/h), aggregate consumption rises to 3,000–4,500 t per day, requiring a larger grab capacity or the addition of a second grab crane.
Q: What specialized tools are required for replacing the lining plates of the mixing main unit?
A: Each lining plate of the twin-shaft mixer weighs 30–80 kg, with approximately 80–120 plates per machine. The connection bolts become difficult to remove once the concrete has hardened. Kelude recommends the following: an impact wrench (for bolt removal), a dedicated lining plate fixture (hydraulic clamping that protects the mounting slots), and an electric balancer for assisted handling. The replacement interval is approximately 6–8 hours with a two-person crew. Kelude can supply a specialized lifting spreader kit for mixing main unit maintenance.
Q: What are the safety requirements for a crane on top of a powder silo?
A: Maintenance of the roof-mounted dust collector and safety valve on a powder silo (15–30 m high) requires crane assistance. Kelude recommends installing a fixed jib crane or an electric hoist on a suspension rail at the silo top. Safety requirements: ① Operators must wear a safety belt and attach it to an independent safety rope; ② Hoisting operations on the silo roof are prohibited when wind speed reaches 8 m/s (Beaufort scale 5) or higher; ③ Dust explosion-proof — the silo roof is classified as Zone 22 (Ex tb IIIC T120℃); ④ Guardrails on the silo roof must be at least 1.2 m high, and the maintenance platform must feature anti-slip grating.
Q: How are cranes dismantled and reassembled during a batching plant relocation?
A: The dismantling and reassembly of cranes is a critical factor that directly impacts the project timeline when relocating a ready-mix concrete batching plant. Based on Kelude's field experience, the MH type gantry crane is broken down into structural components—segmented main girders, outriggers, and the travel mechanism—and transported by flatbed trailer, then reassembled on-site. The LD type overhead crane is split into main girder and end carriage sections, with the electric hoist packed separately. A typical crew of 5–7 workers completes the dismantling and reinstallation in 3–5 days. Kelude offers full-process crane support services for batching plant relocations.
