Concrete Recycling System
Concrete Recycling Plant
A Concrete Recycling Plant (also referred to as a Concrete Reclaimer or Sand and Stone Separator) is an essential environmental protection and resource-recovery system for Ready-Mix Concrete (RMC) batching plants and precast concrete manufacturing yards.
Type: 1 parking space and 2 parking spaces.
Capacity: 20 to 30 T/H; 30 to 40 T/H.
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PRODUCT DESCRIPTION
Henan Shengmao Machinery Co., Ltd. manufactures heavy-duty, high-efficiency Concrete Recycling Plants & Sand-Stone Separators (SCRP Series). Engineered to solve the environmental liabilities and raw material waste of concrete producers, Shengmao’s systems automatically intercept transit mixer washouts and residual concrete, converting daily waste into immediate commercial value.
With processing capacities from 20 to 40 Tons/Hour, Shengmao systems combine high-pressure jet washing, heavy-duty continuous spiral separation, and multi-stage water clarification into a compact, turnkey package.
Primary Function: It intercepts wet residual concrete, returned batches, and wash-water from transit mixer trucks, batch mixers, and concrete pumps at the end of daily operations.
Separation Mechanism: Using mechanical washing, spiral screws, and screening trommels, it separates the slurry into clean coarse gravel/stones, clean fine sand, and alkaline slurry water.
Closed-Loop Value: The separated sand and gravel are returned directly to aggregate storage bins for new concrete batches, while the wastewater is routed through multi-stage settling ponds to be reused for truck washing or production, achieving 100% zero waste discharge.
Ready-Mix Concrete (RMC) plants and precast yards face strict environmental regulations regarding the disposal of leftover wet concrete and daily truck washdown water. Dumping alkaline slurry into open pits damages groundwater tables, solidifies into useless rock, and triggers severe regulatory fines.
Shengmao Machinery’s Concrete Recycling Plant (also known as a Sand and Stone Separator or Concrete Reclaimer) is an industrial-grade recovery system installed directly at the batching station. It intercepts wet residual concrete, decomposes the slurry, and separates it into clean coarse stone, clean fine sand, and clarified water, achieving 100% closed-loop zero-discharge recycling.
Working principles of our concrete recycling plant:
1. Slurry Receiving & Washout: Transit mixer trucks back into the designated wash bay and discharge leftover concrete and wash water into the heavy-duty receiving tank. High-pressure water jets rapidly fluidize the mixture.
2. Mechanical Aggregate Separation: The slurry enters the continuous sand and stone separator. Internal manganese spiral flights convey, agitate, and wash the material upward, while an internal trommel screen classifies coarse stones (>5 mm) and fine sand (<5 mm).
3. Independent Material Discharge: Clean gravel and sand are discharged via two dedicated chutes onto separate ground stockpiles, ready to be shoveled back into the plant's aggregate batcher bins.
4. Sedimentation & Water Recycling: Slurry wastewater flows through a series of 1 1 to 3 settling ponds. Heavy cementitious fines settle to the bottom, and clarified water from the final pond is pumped into the clean water tank for batch production or subsequent truck cleanouts.
Desgin drawing of our concrete recycling plant:
1) One parking space:
2) Two parking spaces:
PARAMETERS
|
Specification Parameter |
1 Parking Space (Single Bay) |
2 Parking Spaces (Dual Bay) |
|
Model Designation |
Shengmao SCRP-1B |
Shengmao SCRP-2B |
|
Simultaneous Washing Capacity |
1 Transit Mixer Truck at a time |
2 Transit Mixer Trucks simultaneously |
|
Daily Fleet Washing Capability |
Up to 15 Trucks / Shift (8 hrs) |
Up to 30 Trucks / Shift (8 hrs) |
|
Aggregate Recovery Output |
20−30 Tons / Hour |
30−40 Tons / Hour |
|
Separated Fractions |
Coarse Stone (>5mm) & Fine Sand (<5mm) |
Coarse Stone (>5mm) & Fine Sand (<5mm) |
|
Discharge Design |
Dual independent chutes (separate sand/stone) |
Dual independent chutes (separate sand/ stone) |
|
Water Management System |
1−3 Settling Ponds + Clean Water Tank |
3-Stage Settling Ponds + Clean Water Tank |
|
Water Circulation Mode |
100% Closed-loop closed-circuit pumping |
100% Closed-loop closed-circuit pumping |
|
Control Unit |
Automated Industrial Control Panel |
Automated Industrial Control Panel |
|
Site Installation Location |
Directly adjacent to Batch Plant / Wash Bay |
Directly adjacent to Batch Plant / Wash Bay |
CORE PARAMETERS
Type: 1 parking space and 2 parking spaces.
Capacity: 20 to 30 T/H; 30 to 40 T/H.
CORE SELLING POINT
100% Closed-Loop Zero Environmental Discharge
The Problem: Discharging alkaline residual concrete slurry and wash water violates EPA/local environmental regulations, leading to steep fines or plant shutdowns. Shengmao Advantage: Intercepts the entire waste stream. The slurry water passes through 1–3 settling ponds and is pumped directly back to batch mixing or truck washdown, achieving complete compliance with zero wastewater discharge.
Fast Truck Turnaround with Dual Parking Bays
The Problem: When multiple mixer trucks return simultaneously after daily concrete pours, long washing wait times cause driver overtime and truck congestion. Shengmao Advantage: The 2-bay system supports simultaneous washout of two mixer trucks with an aggregate output of 30−40 tons/hour, washing out each truck in just 5–8 minutes.
Clean Aggregate Separation for Immediate Batching Reuse
The Problem: Inadequately washed sand and stone retain high cement slurry content, making them unfit for quality concrete production. Shengmao Advantage: High-pressure internal spray bars vigorously scrub the aggregates while spiral flights lift and dewater them. Sand (<5mm) and coarse stone (>5mm) are classified cleanly and meet fresh concrete production standards.
Fast Economic Payback & Direct Cost Reduction
Quarry Material Savings: Every ton of recovered aggregate directly substitutes newly purchased sand and gravel. Water Bill Savings: Recirculates up to 80% of daily wash water. Zero Disposal / Hauling Fees: Eliminates third-party sludge hauling and tipping fees.
RECOMMENDED USAGE SCENARIOS
Commercial Ready-Mix Concrete (RMC) Batching Plants
Operational Need: Commercial batching plants operate fleets of 10 to 50+ transit mixer trucks. At the end of daily pours or between different concrete mix designs, mixer drums must be washed out immediately. Surplus or returned concrete must also be handled without creating unsightly waste heaps.
Shengmao Solution: Installed directly in the plant's wash bay, trucks back up and discharge leftover concrete and wash water directly into the hopper. In 5–8 minutes, the truck is clean, and the slurry is separated into clean reusable sand, gravel, and water.
Recommended Configuration:
Up to 15 trucks/shift: 1 Parking Space (SCRP-1B, 20−30 t/h)
15–30+ trucks/shift: 2 Parking Spaces (SCRP-2B, 30−40 t/h)
Precast Concrete & Structural Component Factories
Precast Concrete & Structural Component Factories
Operational Need: Precast yards manufacturing concrete pipes, utility culverts, wall panels, railway sleepers, and prestressed beams generate continuous residual concrete from stationary pan/planetary mixers, crane transport buckets, and casting molds.
Shengmao Solution: Leftover high-grade concrete and equipment wash water are immediately processed. Clean aggregates are fed straight back into high-strength concrete mixes, significantly reducing virgin aggregate purchases.
Recommended Configuration: 1 Parking Space (SCRP-1B, 20−30 t/h).
Concrete Pumping Fleet Washout & Maintenance Depots
Operational Need: Contractors and equipment rental depots operating concrete boom pumps, truck-mounted line pumps, and trailer pumps must flush pumping cylinders, hoppers, and pipelines with large volumes of water after every job.
Shengmao Solution: The deep receiving tank easily absorbs high-flow pump discharges, intercepting heavy rocks and gravel before they can settle, harden, or clog yard drainage networks.
Recommended Configuration: 1 Parking Space (SCRP-1B) with heavy-duty splash guards.
Large Infrastructure, Highway, Dam & Tunnel Projects
Operational Need: Remote civil engineering sites (hydropower dams, mountain tunnels, highway bridges, airport runways) are often located in ecologically protected zones subject to strict zero environmental discharge mandates. Hauling aggregates to remote locations also carries high freight costs.
Shengmao Solution: Establishes an on-site closed loop at dedicated jobsite batching plants, eliminating slurry hauling expenses and maximizing on-site aggregate conservation.
Recommended Configuration: 2 Parking Spaces (SCRP-2B, 30−40 t/h) with 3-stage sedimentation ponds.
Existing Batching Plant Environmental Compliance Retrofits
Operational Need: Established concrete plants facing tighter municipal environmental regulations, EPA inspections, or community complaints regarding wastewater runoff and slurry dumping pits.
Shengmao Solution: Compact modular footprint allows straightforward retrofitting into existing batching yards with minimal civil modifications, immediately upgrading the plant to "Green Eco-Friendly Concrete" certification.
Recommended Configuration: 1 or 2 Parking Spaces tailored to available plant yard space.
Dry-Mix Mortar & Specialty Concrete Lines
Operational Need: Plaster, screed, and specialty mortar manufacturing plants that wash mixing units between color, additive, or formulation switches.
Shengmao Solution: Classification trommel screen cleans and recovers fine sand gradations for reuse in appropriate dry-mix recipes.
Recommended Configuration: 1 Parking Space (SCRP-1B) with customized fine-mesh screen.
FAQ
Q1:What is the primary function of Shengmao’s Sand and Stone Separator (Concrete Recycling Plant)?
A1:
The system is designed to process leftover wet concrete, returned mixes, and wash water from concrete transit mixers, stationary batch mixers, and concrete pumps. It mechanically separates the waste stream into clean reusable sand, coarse gravel/stones, and clarified slurry water, achieving 100% closed-loop material recycling with zero environmental discharge.
Q2:Why is a concrete recycling plant necessary for modern Ready-Mix Concrete (RMC) facilities?
A2:
Discharging untreated concrete slurry into open pits or municipal drains violates environmental protection regulations, damages local groundwater tables, and solidifies into massive heaps of unmanageable solid waste.
A concrete reclaimer eliminates environmental fines, cuts hauling/landfill tipping fees, and recovers valuable aggregates and water for immediate reuse in production.
Q3:What is the processing capacity of Shengmao’s concrete reclaimers?
A3:
Shengmao offers two standardized capacity configurations:
1 Parking Space (Single Bay): Yields Hour20−30 Tons / Hour of clean aggregates, processing up to 15 mixer trucks per 8-hour shift.
2 Parking Spaces (Double Bay): Yields 30−40 Tons / Hour of clean aggregates, processing up to 30 mixer trucks per 8-hour shift with simultaneous dual-truck washout.
Q4:What aggregate sizes and materials does the system separate?
A4:
The internal spiral classifier and rotary trommel screen cleanly classify aggregates into two standard gradations:
Coarse Stone / Gravel: >5 mm
Fine Sand: <5 mm
Both materials are washed and discharged via two independent chutes to prevent cross-contamination.
Q5:Can the recovered sand and stone be reused in concrete production immediately?
A5:
Yes. The reclaimed sand and gravel undergo rigorous high-pressure washing during the spiral conveyance process, effectively stripping away residual cement paste. They meet standard concrete aggregate cleanliness specifications and can be transferred straight back into aggregate batcher hoppers, directly lowering raw material procurement expenses.
Q6:How does the slurry water treatment and settling pond system work?
A6:
Slurry wastewater exiting the separator flows into Settling Pond 1 (heavy cement fines settle out).
Overflow moves into Settling Pond 2 (secondary precipitation) and Settling Pond 3 (clarification).
Clarified water from the final pond is pumped into a Clean Water Reservoir/Tank, from which it is recirculated for concrete mixing or subsequent truck washout.
Q7:How many settling ponds are required on site?
A7:
Standard Recommendation: 3 Settling Ponds + 1 Clean Water Reservoir for optimal water clarity and sediment settling.
Compact / Space-Constrained Yards: If yard space is limited, a 1 to 2-stage settling pond system (with or without a mechanical slurry agitator) can be configured.
Q8:How long does it take to wash out a concrete transit mixer truck?
A8:
A single truck washout cycle takes approximately 5 to 8 minutes. In a 2-bay configuration, two trucks can discharge and wash out simultaneously, completely eliminating traffic congestion in the yard during peak end-of-shift hours.
Q9:How does Shengmao ensure wear resistance against abrasive concrete slurry?
A9:
Spiral conveyance blades are fabricated from high-strength manganese alloy steel.
The receiving hopper and internal screening barrel are lined with heavy-duty replaceable anti-wear plates.
Drive motors and gear reducers are sealed with heavy-duty IP55 dust/moisture protection for long-term continuous operation.
Q10:Where has Shengmao exported its concrete recycling plants?
A10:
Shengmao concrete recycling systems are operating reliably in multiple international markets, including:
Hungary: High-capacity closed-loop recycling installation for an EU-standard ready-mix plant.
Estonia: Integrated sand-stone separator and water recycling configuration.
Philippines: Dual-bay concrete reclaimer serving an urban infrastructure batching facility.
Specification Parameter | 1 Parking Space (Single Bay) | 2 Parking Spaces (Dual Bay)
Model Designation | Shengmao SCRP-1B | Shengmao SCRP-2B
Simultaneous Washing Capacity | 1 Transit Mixer Truck at a time | 2 Transit Mixer Trucks simultaneously
Daily Fleet Washing Capability | Up to 15 Trucks / Shift (8 hrs) | Up to 30 Trucks / Shift (8 hrs)
Aggregate Recovery Output | 20−30 Tons / Hour | 30−40 Tons / Hour
Separated Fractions | Coarse Stone (>5mm) & Fine Sand (<5mm) | Coarse Stone (>5mm) & Fine Sand (<5mm)
Discharge Design | Dual independent chutes (separate sand/stone) | Dual independent chutes (separate sand/ stone)
Water Management System | 1−3 Settling Ponds + Clean Water Tank | 3-Stage Settling Ponds + Clean Water Tank
Water Circulation Mode | 100% Closed-loop closed-circuit pumping | 100% Closed-loop closed-circuit pumping
Control Unit | Automated Industrial Control Panel | Automated Industrial Control Panel
Site Installation Location | Directly adjacent to Batch Plant / Wash Bay | Directly adjacent to Batch Plant / Wash Bay
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