Ready-Mix vs. Precast Concrete: How to Choose the Right Pump System For Your Application

Accurate, consistent, and timely dosing of water and admixtures is critical to the production of high-quality concrete that is workable and durable enough for long-term use. However, the tools and processes necessary to manufacture concrete that meets these benchmarks varies depending on whether you’re a ready-mix or precast concrete producer. 

Understanding the differences between these two manufacturing environments is foundational when choosing a pump system that will optimize concrete batch processes via increased equipment reliability, productivity, and efficiency. Here, we'll look at the differences between ready-mix and precast concrete manufacturing to help you select the ideal pump system for your application. 

What kind of pump system is ideal for ready-mix concrete Production?

Ready-mix concrete is produced, mixed, and poured from a truck or mobile mixer. The concrete arrives at a worksite in a liquid state, and operators pour the exact amount of concrete when and where it’s needed. The concrete then cures and sets in the environment where it will be used without the addition of finishing additives or techniques.  

These characteristics require pump and flow metering systems that can provide non-stop, high-level performance. Ready-mix concrete operators also need pumps and/or meters designed for: 

• Reliability in uncontrolled manufacturing conditions where environmental factors like wind, heat, dust, and moisture can be significant challenges in high-quality concrete pouring or smoothing
• High temperature ranges to help ensure pumps can run uninterrupted for long periods of time without breakdown or failure
• Continuous feed capability to facilitate precise dosing based on the required volume of concrete

Yamada’s batch dosing pumps feature simplified engineering with minimal moving parts to reduce frame vibration and undue wear and tear on the pump itself. A bolted construction design helps eliminate leaks and increases pump efficiency and accuracy. In addition, optimal stroke length helps to maximize the service life and performance of the pump’s diaphragm in order to minimize maintenance and downtime. 

Milton Roy’s continuous metering systems are produced to provide consistent dosing and injection of admixtures and other chemicals necessary for high-quality ready-mix concrete production. Using state-of-the-art industrial drive technology, Milton Roy’s metering systems can handle the processing of hazardous and non-hazardous fluids over 1000 PSI without the risk of contamination from process fluids. 

Plus, Milton Roy’s digital monitoring provides real-time flow data to help operators execute more efficient dosing. This not only increases the quality of your final product, but it also helps you conserve natural resources like water for a more sustainable approach to concrete production. 

What kind of pump system is ideal for precast concrete production?

Precast concrete is produced at an off-site facility using molds that are manufactured and tailored for specific jobs. The concrete is cured and finished at the production facility, and then the final slab is transported to the worksite for installation. Because it’s manufactured in a more controlled environment, precast concrete can be laid in thinner layers, and this results in a more prescriptive curing process that increases the weight limit and pressure tolerance of the slab.

The thinner layers of concrete and specialized molds necessary to produce individual slabs means plant operators need pumps and metering systems that prioritize precision and scale — most precast concrete applications include large commercial jobs like boundary and building walls, high-rises, or parking structures.

As a result, precast plant operators need pumps and meters that can provide: 

• Accurate dosing and flow management to pour multiple thin layers of concrete that form to the specific shapes of the individualized molds
• Optimized operational efficiency via the ability to stop and start the batch process multiple times in order to facilitate concrete that is thoroughly cured — this is critical to ensure the ideal weight and stress loads for applications like load-bearing walls
• Real-time monitoring to help reduce the likelihood of wasted resources, which is especially important for large-scale jobs

Yamada’s batch dosing pumps can provide the same level of reliability, accuracy, and flexibility for precast concrete manufacturing as they can for ready-mix work. Plus, Yamada’s simplified design and engineering provide the optimized operational efficiency necessary to facilitate concrete that is properly cured regardless of the size or scale of the job. 

Badger Meter’s line of metering and batch dosing systems incorporate real-time, digital monitoring, diagnostic alerts, and programmable parameters to help plant operators leverage smarter, data-driven dosing strategies. This not only helps reduce instances of unplanned maintenance and loss of productivity, but detailed performance data also helps plant operators adjust their processes mid-job in order to provide a higher-quality product on time and on budget.

IPEC has a field-proven history of helping ready-mix and precast concrete manufacturers unlock unparalleled efficiency and productivity by designing pump and metering systems for their specific needs. 

IPEC partners with manufacturers like Yamada, Milton Roy, and Badger Meter, and our team of experienced technicians and maintenance specialists can help plant operators in the ready-mix and precast space integrate cost-effective pumps and batch meters that are designed for reliable, long-term use. 

In addition, our IPEC Meter Exchange Program can help plant operators exchange their aging meter — from Badger Meter or any other manufacturer — for a new or refurbished meter quickly and easily. Our expanded warehouse and service footprint also help concrete manufacturers deploy the solution they need to operate on a 24/7, 365 basis to meet customer demand. 

Ready to partner with IPEC on the ideal pump system for your ready-mix or precast concrete manufacturing needs? Contact us to get started today!