Concrete Batching Process: From Aggregates to Concrete

When you place a concrete order, it’s easy to assume that the most important step is when the concrete arrives at your site, ready to be poured.

However, in reality, the concrete will have already gone through numerous critical stages by this point.

Before the concrete is loaded into the truck, every batch we mix goes through a meticulous, carefully controlled production process. This ensures that the material is as predictable as possible, and that it meets all the exact specifications and project requirements.

At our concrete batching plant in Essex, every ingredient is measured and mixed exactly, and each element is thoroughly checked to ensure the highest standards of quality. This all occurs before it’s dispatched to the site.

At iMix Concrete, we are one of the regions leading concrete suppliers, supporting domestic, commercial and industrial projects throughout London, Kent and Essex.

In this article, our expert team have outlined all the steps involved in this process.

1. Feeding the aggregates

Concrete aggregates are most commonly sand, gravel and crushed stone.

First, the chosen aggregates are fed into the batching plant’s aggregate hoppers, using loading shovels.

Conveyor belts then take all the aggregates to a weighing system, so that the exact quantities of aggregates can be measured (depending on the requirements, as per the concrete mixture’s design). This is key to ensuring the concrete achieves the required strength, durability and performance properties.

2. Adding the cement

Then, once the aggregates have been weighed, the cement can be added to the mixture.

Before this point, cement is stored in sealed silos (so that it is protected from moisture).

When ready for use, the cement is carefully transferred, using enclosed screw conveyors, and added to the weighing hopper. It is then added to the mixer, and automated weighing systems are used to ensure the cement is weighed using absolute precision.

3. Adding the water and admixtures

The volume of water that is added can have a major impact on the consequent properties and performance of the final concrete. So, the required volume of water is also measured meticulously, before it is added to the batch.

If needed, any chemical admixtures are also introduced to the batch at this point. These admixtures can be used to enhance the properties of the concrete, e.g. by improving workability or durability.

4. Transferring the materials to the mixer

Next, all of the weighed ingredients are transferred into the mixer.

This occurs in a controlled sequence. In fact, in modern batching plants, this process is highly automated. Computer-controlled systems are used to manage the order at which each ingredient is added, and the timing that is followed. This is designed to completely minimise the risk of any errors or performance unpredictability.

5. Mixing the concrete

Once added to the mixer, all the ingredients – aggregates, cement, water and admixtures – are mixed thoroughly.

The required mixing time varies based on the specific concrete specification and type. Usually, it is around the 1 minute mark.

Inside the mixer, all ingredients are blended together to create a consistent, high‑quality and completely uniform concrete mix with the correct slump and texture.

6. Quality checks

Once mixed, the concrete undergoes thorough quality checks. These confirm that the concrete has successfully achieved the required specifications.

Typically, these can include (but aren’t limited to) a visual inspection to check on the consistency, and a slump test to check the workability.

If the experts are happy with the outcomes of these tests, they will confirm that the concrete has passed their checks.

7. Loading the concrete into the truck

Finally, the concrete mixture is discharged into a ready-mix concrete truck.

These trucks feature a rotating drum, which keeps the concrete continuously agitated throughout its transport. This keeps the concrete workable, and prevents the materials from separating.

Once it’s completed its journey, the concrete is delivered so that it is ready to pour immediately.

Whether you are ordering a batch of concrete for a one-off domestic project, or a major commercial development, the iMix Concrete team are on hand to help.

We are fully accredited ready mix concrete suppliers, renowned for our dependable, efficient, precise and friendly services. To find out more about our offerings, or to receive a quote for your project, don’t hesitate to get in touch.

At iMix Concrete, we provide both ready mix concrete and volumetric concrete, delivering directly to sites throughout London, Kent, Essex and the surrounding areas.

Whatever the nature of your project, our team are on hand to advise and help you identify the solution that ticks all your boxes.

If you are looking for a trusted, fully qualified supplier to support your upcoming project, don’t hesitate to get in touch.

Order Now →

Need Concrete for your Project?

Call for today’s best price:

0808 196 7812

• 800m³+ Daily Concrete Capacity
• Same / Next Day Delivery (by 2pm)
• 2-hour Delivery Windows
• Only Pay For What You Use
• Collections Available
• Out of Hours & Night Delivery

Order Now →