Batch plant maintenance
n your efforts to run an efficient and have, manufacturers may recommend differ-
Use this profitable ready mix operation, you
report to are forced to deal with many factors
that contribute to a successful busi-
record ness. Not only are you responsible for turn-
your ing out high-quality concrete, but you must
also juggle such varied managerial tasks as
plant’s dispatching, billing, and customer service.
With all of these activities needing atten-
mainte- tion, it is easy to see how batch plant main-
nance tenance can, at times, be put on hold.
While other matters may require immediate
resolution, maintenance is often viewed as
an activity for slow times, and its impor-
tance is underestimated. This attitude, how-
ever, is a shortsighted one that can cost a
plant money in both repair costs and lost
business due to downtime.
The way to keep your batch plant in good
working condition is to set up and follow a
regular maintenance schedule. Because batch
plants come in many different styles with var-
ious layouts and types of equipment, there is
no one maintenance plan that can be used at
every plant. There are, however, some gener-
al steps that any plant can follow in develop-
ing an effective maintenance schedule.
Carefully examine the operation and
maintenance manuals supplied by the
batch plant manufacturer. Also, take advan-
tage of any training on maintenance of-
fered by that manufacturer. Some manufac-
turers will send a representative out to your
plant to make sure that equipment is prop-
erly used and maintained.
Depending on the specific batch plant you
PUBLICATION #J960046
Copyright © 1996, The Aberdeen Group, All rights reserved
ent schedules for lubrication and inspection
of components. When it comes to the batch-
ing control panel and its related electrical
equipment, having a qualified specialist per-
form the maintenance may be a good idea.
After you have determined the recom-
mended maintenance procedures for your
batch plant, you then must consider what
other items at your plant may not have been
mentioned in the operation manual. Such
components may include gear boxes, bear-
ings, bushings, and an air system. Because
such items and other devices are common at
ready mix operations, manufacturers may
not provide specific maintenance instruc-
tions for them. It is necessary for you, there-
fore, to determine the best schedule for
these components based on your experi-
ence and other recommendations.
Keep in mind that safety is crucial when
maintenance is being performed. Employ-
ees should be instructed to lock out equip-
ment that is being worked on, tag it, and
notify other employees in the work area
that maintenance is under way. Many acci-
dents can be prevented if all employees at
the plant are made aware of maintenance
procedures being done.
Use the following report as a guide to
necessary batch plant maintenance. Consult
with manufacturers’ recommended mainte-
nance and add plant-specific items in the
spaces provided. This checklist was provid-
ed by Monte Stewart of Ash Grove Materi-
als Corp., Overland Park, Kan. ✥
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 PLANT MAINTENANCE REPORT
Plant ________________________________ Date ________________________ Week Ending ______________________

Maintenance Item SUN MON TUE WED THU FRI SAT Remarks or Repairs Made

Daily
1. Inspect oil and filter on air compressor and
drain tank, manifolds, and all water traps.
2. Inspect and fill all oilers on plant.
3. Inspect all air cylinders.
4. Inspect tension on all V-drive belts.
5. Inspect conveyor belts for
alignment and excessive wear.
6. Perform housekeeping items,
such as cleaning up dust and debris.

Weekly
1. Lubricate all bearings (ONE PUMP ONLY).
Included are head and tail pulleys on all
conveyors, snubber roller on loading conveyor,
head and tail bearings on cement feeder screws,
wheel bearing supports on turn head, etc.
2. Lubricate all aggregate gate pivot points.
3. Replace or blow clean all air filters on air
compressor and aeration blowers.
4. Inspect and tighten all bolts and
bearing set screws.
5. Inspect and/or adjust all belt wipers.
6. Lubricate packing at the bottom and top
ends of the cement feeder screws with oil.
7. Inspect all bags in cement bag filters.

Monthly
1. Inspect oil level in all gear reducers.
2. Adjust skirtboards as needed.
3. Adjust and tighten conveyor belts as needed.
4. Change oil in air compressor.

Semiannually
1. Change oil in all conveyor gear reducers.
2. Remove bags in cement bag filters and
blow clean.
3. Tighten or replace all V-belts as needed.
4. Inspect scale and water meter accuracy.
5. Inspect hanger bearings in feeder screws
and replace as needed.
6. Inspect and acidize boiler.
7. Inspect and/or replace bin aeration pads.