Applications

PowerMix 1500 Stationary Batching Plant - Powering Residential Complex, Vietnam

Project Overview:
The "New Horizon" project is a large-scale residential and commercial development in the outskirts of Ho Chi Minh City, Vietnam. The project required over 250,000 cubic meters of high-quality concrete for foundations, structural frames, and paving. The lead contractor, GlobalBuild Construction, faced significant challenges: stringent deadlines, unpredictable weather, and the logistical complexity of sourcing consistent concrete from multiple external suppliers. To ensure quality control, cost efficiency, and uninterrupted supply, GlobalBuild decided to invest in an on-site concrete batching solution.

The Challenge:
Relying on off-site ready-mix concrete suppliers posed several risks for GlobalBuild:

• Inconsistent Supply: Delays due to traffic congestion jeopardized critical pours, leading to potential structural cold joints and labor idling.

• Quality Variance: Inability to directly control mix designs and water content from different suppliers resulted in occasional non-compliant concrete strengths.

• Escalating Costs: Transportation fees and supplier premiums significantly increased the project's overall concrete expenditure.

• Scheduling Inflexibility: The inability to produce concrete on-demand limited the project's ability to accelerate work during favorable weather windows.

The Solution: Installation of a PowerMix 2000 Stationary Batching Plant
After a thorough evaluation, GlobalBuild selected and installed a fully automated PowerMix 2000 stationary batching plant on a cleared plot within the construction site. Key features of this solution included:

• High Production Capacity: With a theoretical output of 120 m³/h, the plant could easily meet the project's peak daily demand, supporting multiple pouring teams simultaneously.

• Precision and Automation: The computer-controlled system ensured exact adherence to complex mix designs. Each batch's proportions of cement, aggregates (sand, gravel), water, and additives were measured with precision, guaranteeing consistent strength (e.g., C25, C30, C35) and slump for every truckload.

• Integrated Cement Silo: A large 200-ton cement silo allowed for bulk purchasing of cement, reducing material costs and ensuring a buffer stock for continuous operation.

• Dust and Environmental Control: The plant was equipped with a advanced baghouse dust collection system, minimizing particulate emissions and adhering to local environmental regulations, a crucial factor for a project near a developing urban area.

• Flexibility: The plant could quickly switch between different mix designs, producing standard structural concrete, lean concrete for sub-base, and even fiber-reinforced mixes for specific applications, all within minutes.

Results and Benefits:
The decision to install the on-site batching plant proved to be a strategic masterstroke for the New Horizon project:

• Guaranteed Supply & Timely Completion: The project was never delayed due to concrete shortage. Pours happened exactly on schedule, 24/7 if needed, shaving an estimated 8 weeks off the project timeline.

• Superior Quality Control: The consistent, high-quality concrete produced on-site reduced rejection rates and testing failures to near zero, enhancing the structure's overall integrity and safety.

• Significant Cost Reduction: By eliminating transportation costs and leveraging bulk material purchasing, GlobalBuild reported a 15% reduction in overall concrete-related costs.

• Enhanced Operational Efficiency: The automated system required a smaller crew than managing multiple ready-mix trucks, and waste was minimized due to precise batching.

The PowerMix 1500 plant transitioned from being a capital expense to a critical profit center, providing GlobalBuild with complete control over one of their most vital resources and setting a new standard for how large-scale projects are executed efficiently.