New state-of-the-art batch plant with heating and curing system at Huffcutt Concrete facilities

Polarmatic has offered state-of-the-art products and system solutions specifically designed for the concrete industry since 1968. The mission is to deliver sustainable and reliable options for clients, such as Huffcutt Concrete located in Chippewa Falls, Wisconsin, USA. 

Huffcutt Concrete has decided to rely on the Polarmatic curing system in order to control the two current forced hot air curing chambers in the carousel plant and also to allow room for expansion in the future.

According to Operations Manager, Chuck Kroll, he believes that the most challenging aspect of producing concrete is consistency. Consistency not only as a measure of workability, but the ability to repeat the same finish ability and hardened concrete results time after time. Huffcutt has just commissioned a new state-of-the-art batch plant in which they are producing architectural wall panels utilizing a carousel system.

The batch plant consists of two 3 cubic yard output mixers, which are fed from ten aggregate bins. The aggregate bins have a capacity of 50 (US tons) each and are loaded from a single receiving hopper. All of the bins and the receiving hopper have single heating register inside them where the Polarmatic heating media is introduced. This allows the thawing of the frozen material in the receiving hopper and the heating of the material in the aggregate bins prior to batching, all independently from each other.

Huffcutt chose the non-boiler Polarmatic thermal energy unit because of the capacity, fuel savings and streamline packaging. With most everything being fully enclosed within the shipping container, it is not necessary to accommodate any extra floor space under our roof. The way the unit is set up, it is neatly positioned just outside of the plant. The ability to provide aggregate heating, heated water for batching and curing in one piece of equipment was also very attractive. It very easily combines two or three separate units into one.

Kroll states that they are using the Polarmatic heating and curing system. Both systems are very easy to operate which is great for everyone involved. There isn’t anything overly complicated to learn on how to operate it. The Polarmatic heating system handles the main operation of the unit including aggregate and water heating. The use of the Polarmatic curing system is to control the two current forced hot air curing chambers in the carousel plant and also allows room for expansion in the future.

In Huffcutt’s previous production operation, the process was much different. They had a very small dry batch plant with only two bins and very small capacity. There was reliance on the heat inside the batch plant to thaw frozen material and it used a large water heater for water. They could produce in the winter, but with very limited quantities before the concrete temperature was too low. Not having heated aggregates was also a chore as frozen rock/sand or snow would block the discharge gates on the bins. When the gates would get blocked, someone would have to poke and rake the gate opening to get the material to flow again. This is a very labor-intensive and counter-productive process, not to mention very unsafe and expensive.

“To be honest, the people that never had to get frozen aggregate out of a bin will never know how great a Polarmatic unit actually is, Kroll claims. The days of busting chunks of ice and snow are gone.” They also did not have much for means of curing. The curing consisted of turning up the radiant heaters that heated the building as everyone left for the day.

“With the Polarmatic, we are able to produce quality concrete throughout the frigid Wisconsin winter.” Kroll states that he would recommend Polarmatic to others because it truly does combine multiple systems into one.