Instacrete Concrete Plant is an industrial facility producing ready-mix concrete and concrete products. Devpan supplied MCCs feeding the mixer, conveyor and crusher motors, along with main distribution and power factor correction panels.
Electrical Profile of the Project
- Location
- Building typeIndustrial facility
- Installed power≈ 5,000 kVA
- Transformer configuration2 × 2,500 kVA
- Main busbar rated current2 × 4,000 A
- Short-time withstand current (Icw)80 kA / 1 s
- Devpan scopeLow voltage switchboards, engineering and site coordination
- Verification standardIEC 61439-1, IEC 61439-2
About the Project
Concrete plants are a harsh environment for electrical equipment. Cement and aggregate dust finds its way into enclosures and settles on contacts and cooling paths, while mixers, screens and conveyors generate constant vibration. High-power mixer and crusher motors start under load, and their inrush currents cause voltage dips across the plant. Supply continuity is critical: if power is lost mid-production, concrete can begin to set inside the mixer and damage the equipment.
For a facility of this scale, distribution is typically built on two 2,500 kVA transformers fed from the medium-voltage network and two coupled 4,000 A main busbars. Motor loads are concentrated in IP54 DevControl MCCs, with large motors started via soft starters or VSDs. Generators of approximately 2 × 1,250 kVA pick up mixer discharge and critical process loads during an outage. Form 4b segregation allows safe maintenance even in a dusty environment.
Devpan Scope and Switchboard Architecture
Devpan’s scope extends from the transformer secondaries to production-line motors, silos and auxiliary supplies.
- Main distribution boards (DevPanel): typically 2 × 4,000 A, 80 kA / 1 s, Form 4b, IP54, with coupler and generator changeover.
- Motor control centres (DevControl): VSD and soft-starter feeders for mixers, crushers, screens, conveyors and compressors.
- Power factor correction (DevComp): detuned stepped compensation sized for the motor load.
- Sub-distribution boards (DevBox): dust-protected local distribution for silos, laboratory, workshop and offices.
- Standby power: approximately 2 × 1,250 kVA of generation for mixer discharge and critical process continuity.
Technical Configuration
| Installed power | ≈ 5,000 kVA |
|---|---|
| Transformer configuration | 2 × 2,500 kVA |
| Medium voltage level | 10 – 34.5 kV |
| Low voltage / frequency | 400 / 230 V, 50 Hz |
| Main busbar rated current | 2 × 4,000 A |
| Short-time withstand current (Icw) | 80 kA / 1 s |
| Form of internal separation | Form 4b |
| Degree of protection (IP) | IP54 |
| Generator back-up | 2 × 1,250 kVA |
| Verification standard | IEC 61439-1, IEC 61439-2 |
Devpan Products Used in This Project
Project-Specific Engineering Topics
Dust and vibration protection
IP54 enclosures, filtered ventilation and vibration-resistant fixings extend the life of internal equipment.
Motor starting under load
Starting methods for loaded mixers and crushers are chosen by weighing starting torque against network voltage dip.
Process continuity
On an outage, the generators first serve mixer discharge and critical conveyors.
Automation integration
Communicating motor protection relays in the MCCs pass status and fault data to the batching control system.
Frequently Asked Questions
What is the installed power at Instacrete Concrete Plant?
For an industrial facility of this scale the installed power is approximately 5,000 kVA, with a typical transformer configuration of 2 × 2,500 kVA. The main busbars are typically planned at 2 × 4,000 A and 80 kA / 1 s, the medium voltage lies in the 10 – 34.5 kV range, and around 2 × 1,250 kVA of standby generation is provided.
Why is a power cut critical in a concrete plant?
Concrete left in a stopped mixer starts to harden quickly, so mixer discharge loads are generator-backed.
How is maintenance made easier in a dusty plant?
Form 4b segregation and withdrawable MCC units let one feeder be serviced while others keep running, with minimal dust ingress.
Similar Reference Projects
Kotok Facility ProjectIndustrial facility · Russia
Oxagon, Saudi ArabiaIndustrial facility · NEOM, Saudi Arabia
Nizhny Novgorod IT CampusTechnology campus · Nizhny Novgorod, RussiaDo you have a project of a similar scale?
Send us your single-line diagram, your transformer rating or simply your load list. Our engineering team runs the short-circuit and discrimination study and defines the form of separation and busbar cross-section with you.
Request a quotation