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Liebherr mixing tower supplies quality concrete for crane ballast weights

An aerial shot of a concrete batching plant
Liebherr Betomat 3 mixing plant with ring-pan mixer supplies sophisticated concrete types.

Betonwerk Högerle has modernised its precast concrete production with significant investment in a new Betomat 3-235 concrete mixing tower from Liebherr. 

Högerle, based in Dietenheim, Germany, is known for producing high-quality solid concrete components, including prefabricated staircases, basement systems, filigree elements, and ballast weights for Liebherr tower cranes.

The company’s new Betomat 3-235 replaces a 36-year-old Liebherr mixing tower bought in 1987 when Högerle previously modernised its production facilities and installed a Betomat mixing tower.

Sophisticated concrete types and qualities are one of the most important features in the precast industry, which is why the Betomat 3-235 uses a Liebherr RIM 1.5-D ring-pan mixer. 

The RIM 1.5-D works with a double agitator system, homogenising all materials and additives quickly and efficiently. In addition, the mixer is controlled by a frequency converter, which means that the speed of the mixer can be infinitely varied during the mixing process and thus optimally adapted to concrete recipes.

In addition to precast concrete parts for construction, Högerle also manufactures ballast weights for cranes. Manufacturing crane counterweights comes with several challenges. 

The weight per unit must fit perfectly, the tolerances are tight. Durability for decades must be guaranteed. The appearance of the visible surfaces should be smooth, without inclusions or other defects. 

A picture of a tower crane's concrete ballast system

As ballast weights are repeatedly put on and taken off the crane or loaded, high fatigue strength is particularly important. The casting moulds are complex, with weights or logos cast in relief. 

The focus in concrete production is primarily on quality rather than quantity, so the Betomat 3-235’s throughput capacity in hardened concrete of around 75m3 per hour is more than sufficient for Högerle.

With a diameter of 6.75m the tower has a storage volume of 235m³ for aggregates in seven chambers arranged in a star shape. The system is fed with a galvanised bucket elevator. Four types of cement, with a total capacity of up to 160 tonnes can be stored in the cement section. The cement screw conveyors are controlled by frequency inverters and ensure greater dosing accuracy, resulting in considerable cost savings.

High-quality components and an almost completely galvanised steel construction make the system particularly durable. To ensure smooth operation during the cold winter months, the entire system is insulated, clad with plastic-coated façade sheeting and equipped with a heating system.

The mixing plant was equipped with many additional options at the customer's request: For example, high-pressure mixer cleaning, Litronic-MPS III plant control system, camera monitoring system, Liebherr Litronic-WMS sand moisture measurement system, silo filling signalling systems, swivel hopper for lorry loading, dry material outlet (mixer bypass), demand signalling point in the production hall. The intensive mixer is equipped with the "Cleaning mode with creep speed" function, which makes cleaning the mixer more convenient.