Willaert expands concrete batching capacity in Belgium

Belgian construction materials supplier Willaert Bouwmaterialen has commissioned two Liebherr Betomix 3.0 concrete batching plants at its Koekelare facility in West Flanders, providing a combined rated production capacity of 240m³ of compacted fresh concrete per hour.

The installation, supplied by Liebherr, replaces or supplements a previously reported batching arrangement rated at approximately 180m³/h. The new equipment has a nominal combined capacity one-third greater than the previous installation, although the manufacturer has not confirmed whether the older plants have been removed or retained.

Willaert operates across ready-mixed concrete production, structural building materials, precast manufacture, recycling, and associated construction services. The investment is intended to support its concrete supply activities and provide additional flexibility over the mixtures produced at the Koekelare site.

The new installation consists of two Betomix 3.0 A RDW plants, each equipped with a 3m³ twin-shaft mixer and rated to produce 120m³ of concrete per hour. Operating together, the plants provide the stated 240m³/h capacity.

The hourly figure represents the manufacturer’s rated output under specified operating conditions, rather than independently measured sustained production at Willaert. Actual throughput depends on material availability, batching and mixing times, recipe selection, plant maintenance, and the coordination of concrete deliveries.

The installation includes 560m³ of aggregate storage across 16 compartments. Each batching plant has a six-chamber in-line silo providing 210m³, while a separate shared storage arrangement adds another 140m³.

These compartments allow the producer to keep different aggregate grades and materials separated before batching. Particle size distribution and the proportions of fine and coarse aggregates influence the packing characteristics, workability, and mechanical properties of concrete.

Material separation is particularly important where a plant produces several concrete specifications. A structural concrete mixture may require a different aggregate grading or binder proportion from a lean concrete or stabilised material, making accurate storage and controlled selection essential to consistent production.

Aggregate moisture also affects batching accuracy. Water carried into the mixer by wet aggregates contributes to the total water content of the concrete, which must be considered when determining the quantity of additional water required.

Where the effective water-to-cement ratio differs from the intended formulation, the strength and durability characteristics of the hardened concrete may also change. Production control therefore requires the batching arrangement to account for the material properties of the constituents being used.

The Koekelare installation also includes nine cement silos, each providing 100 tonnes of nominal storage. Together, they offer 900 tonnes of capacity for the binder materials used in the production process.

Liebherr describes these units as cement silos and has not identified whether any will be used for supplementary cementitious materials or alternative binders. The additional storage should therefore be described in terms of its confirmed equipment specification rather than assumed changes to cement composition.

Storage arrangements influence the flexibility of a concrete production facility because different cement types and constituent materials must be handled without unintended mixing or contamination. Dedicated silos and controlled material transfer systems can support the production of different recipes, depending on the products selected by the operator.

Both Betomix plants use twin-shaft mixing technology. Two horizontal shafts equipped with mixing tools move the constituent materials through the chamber, promoting the distribution of aggregates, cementitious materials, water, and admixtures during the mixing cycle.

Mixing performance depends on the properties of the materials and the requirements of the concrete formulation. The time needed to obtain a suitable mixture varies with constituent proportions, consistency, and the type of concrete being manufactured.

The nominal hourly output reflects the capacity of the plant equipment, but the completed production cycle also depends on loading, mixing, discharge, and subsequent material handling. A plant capable of producing concrete rapidly may operate at a lower average rate where deliveries are scheduled intermittently or customers require different mixtures.

Willaert produces BENOR-certified ready-mixed concrete alongside lean concrete, stabilised mixtures, and recycled concrete. The company’s wider operation also manufactures precast components, including concrete cisterns and septic tanks.

These products require different production arrangements. Ready-mixed concrete is generally transported to construction sites for placement, while precast components are manufactured and cured at a production facility before delivery or installation.

Manufacturing different products places varying demands on the batching operation. The ability to select appropriate constituents and reproduce specified mixtures is important whether concrete is supplied directly to a construction site or used in the production of factory-made components.

Delivery logistics also affect the use of the new plant capacity. Willaert operates ten Liebherr truck mixers in its daily transport activities, connecting production at Koekelare with construction customers across its service area.

Ready-mixed concrete must be transported and placed within the relevant product and project requirements. The distance to site, traffic conditions, vehicle availability, and the rate of discharge can all influence the production schedule and the practical utilisation of the batching plants.

The construction and installation programme for the new equipment was completed within 13 weeks. Willaert prepared the foundations before plant assembly began, allowing Liebherr’s installation team to work from established support positions.

The preparation of foundations is an important part of batching plant installation because the principal equipment, aggregate storage, silos, and supporting structures must be positioned accurately. Structural loads and equipment alignment need to be accommodated by the completed civil engineering works.

Liebherr attributed the installation period partly to the modular design of its Betomix equipment and factory pre-wiring. Electrical and mechanical assemblies prepared before delivery can reduce the number of installation operations required at the customer’s site, although project-specific connections and commissioning remain necessary.

Prefabricated frame elements were also used for the external cladding, simplifying assembly around the completed processing equipment. The enclosure is intended to protect the installation and support operation during colder weather.

Winter operation presents particular considerations for concrete production, including the condition of stored materials, water systems, and mechanical components. The new cladding provides protection for the equipment, although Liebherr has not published a specific minimum operating temperature for the Koekelare installation.

The plants were installed during a period of high summer temperatures. Liebherr reported that the prepared site and coordinated assembly programme allowed the installation and commissioning work to be completed within the planned 13-week period.

Willaert’s previous two batching plants had a combined stated capacity of approximately 180m³/h. The manufacturer has not specified their current status, so the new installation’s nominal capacity should not be treated as a verified increase in the company’s total available production capacity if the older equipment remains operational.

Nor has Willaert published measured annual output following commissioning. The increase in rated batching capability provides the potential to manufacture more concrete within a given operating period, but actual production will depend on demand, plant utilisation, the mixtures required, and delivery arrangements.

The completed Koekelare installation gives Willaert two modern batching plants supported by substantial aggregate and cement storage. Its operational contribution will become clearer as the company establishes production patterns across its ready-mixed concrete and wider building materials activities.