Maintenance Checklist to Increase the Lifespan of Your Mobile Batching Plant

Mobile batching plants are invaluable assets in the construction industry, offering flexibility and efficiency for on-site concrete production. To maximize the lifespan of your mobile batching plant and ensure it operates at peak performance, regular maintenance is crucial. 

This comprehensive maintenance recommended checklist will guide you through the essential steps to keep your equipment in top shape.  However this is not limited to, as these checklists will depend from site to site.

This recommended checklist is mostly based on mobile batch plants. The same principle is recommended for automated batch plants, however it is important to understand automated plants have a more comprehensive checklist. 

1. Daily Maintenance Tasks

a. Visual Inspection:

• Inspect the entire plant for any visible signs of wear, damage, or leaks.
• Check hoses, connections, and seals for cracks or deterioration.
• Ensure that safety guards and covers are in place and secure.
• Check for any loose wiring on the electronic box and weighing systems.
• Any oil leaks from your gearbox. (Damage seals.)
• Structural damage.
• Damage to the conveyor belt. (Any material wedge under the conveyor system)

b. Cleaning:

• Clean the Aggregate Hopper, Head chute, and other exposed components, to prevent concrete build-up.
• Remove any debris or obstructions from the aggregate bin and conveyor system.
• Free flow of water through the water meter. Cleaning any dirt from the supply line.
• Clean/remove any build up of material on drive & adjustment pulleys.

c. Lubrication:

• Lubricate all moving parts, including bearings, bushes on discharge doors, as per the manufacturer's recommendations.
• Check oil levels on the gearbox and top up if necessary.

2. Weekly Maintenance Tasks

a. Weighing/Measuring systems:

• Check accuracy of the load cell system and water reading/discharge.
• Test and adjust the admixture dosing system to maintain consistent quality in concrete production.
• Any loose wires on the water display, load cell system. (Indicators/Large Scoreboard.) This can prevent accurate readings for each load. 
• Ensure the plant is level  for accurate readings from your weighing system and prevent the conveyor belt drifting.
• If any abnormalities are detected, schedule a calibration of the load cells system. 

b. Electrical Systems:

• Inspect electrical connections, wiring, and control panels for any signs of wear or damage.
• Test emergency stop buttons and other safety devices to ensure they are functioning correctly.
• Ensure that your control box is always sealed properly to avoid any water damage.

c. Belt and Conveyor Maintenance:

• Check the tension and alignment of conveyor belts.
• Adjustment system. (Sliding bearings and threaded rod adjustment bolts)
• Any damage on the sides of the conveyor belt. (Preventing the belt to be ripped)
• Any cuts in the conveyor belt.
• Inspect the rollers and bearings for wear and replace if necessary.
• Discharge doors stoppers. Preventing the doors to open too wide and overloading the conveyor belt. This will cause the belt drifting and damage the belt.
• Free running of the belt.

3. Monthly Maintenance Tasks

a. Structural Integrity:

• Inspect the frame and support structures for any signs of stress or fatigue.
• Check for rust or corrosion and treat affected areas to prevent further damage.
• Plant is level and all safety guards are secured.

b. Aggregate Hopper:

• Examine the hopper for any damage, especially you if you use vibrators. 
• Inspect the discharge doors bushes, ensuring that doors close properly.

c. Pneumatic Systems:

• Check air compressors, hoses, and fittings for leaks or damage.
• Ensure that the air pressure is within the recommended range and adjust if necessary.

4. Quarterly Maintenance Tasks

a. Comprehensive Inspection:

• Conduct a thorough inspection of all components, including the gearbox & motor.
• Review the maintenance logs and address any recurring issues or patterns of wear.

b. Weighing system:

• Test systems to ensure they are functioning correctly and efficiently.
• Ensure weighing mass is correct. If not it is recommended to schedule a calibration of the weighing system. (Most sites require calibration every 12 months, however this will be determined from project to project.)
• Test water discharge quantity with water display. 

c. Component Replacement:

• Replace any components that have reached the end of their service life.
• Ensure that all replacement parts meet the manufacturer's specifications.

5. Annual Maintenance Tasks

a. Professional Servicing:

• Usually this is done during the annual closure of the industry.
• Schedule a professional inspection and servicing of your mobile batching plant by a qualified technician.
• Perform a complete overhaul of the plant or any structural repairs.

b. Documentation and Training:

• Review and update the maintenance logs and service records.
• Provide refresher training for operators and maintenance staff to ensure they are familiar with the latest procedures and safety protocols.

Additional Tips for Prolonging the Lifespan of Your Mobile Batching Plant

a. Operator Training:

• Ensure that all operators are well-trained and understand the importance of regular maintenance.
• Encourage operators to report any issues or abnormalities immediately.

b. Spare Parts Inventory:

• Maintain a stock of critical spare parts to minimize downtime during repairs.
• Source parts from reputable suppliers to ensure quality and compatibility.

c. Environment Considerations:

• Protect the batching plant from extreme weather conditions by making use of good drainage systems around your plant.
• Ensure that the plant is set up on stable, level ground to prevent undue stress on structural components. (Concrete slab is always recommended.)

Conclusion

By following this maintenance checklist, you can significantly increase the lifespan of your mobile batching plant, ensuring reliable and efficient operation for years to come. Regular maintenance not only enhances the performance of your equipment but also reduces the risk of costly breakdowns and downtime, contributing to the overall success of your construction projects.

For more detailed information on mobile batching plant maintenance and expert advice, feel free to contact JA Plant. Our team of specialists is here to support you in achieving optimal performance and longevity for your equipment.