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Author:
Nikulin V, Head of Engineering
Nikulin V, Head of Engineering
The formation of dust—composed of fine particles of cement, sand, and aggregates—is a common byproduct of nearly all mechanical operations involving concrete, from construction and demolition to the manufacturing of the mix itself. Inhalation of these impurities can pose serious health risks, as it is a known irritant and allergen that may lead to chronic respiratory diseases. To protect workers and maintain safe air quality, industrial facilities implement various contaminants control technologies. The choice of concrete dust vacuum systems depends on the specific production process and the unique characteristics of the facility.
Plant Generating High Levels of Particles
Dust Management: Suppression vs. Capture Techniques
A variety of methods exist for concrete dust knock down. They can be broadly categorized into the following groups:
1. Concrete dust collection systems
This approach relies on creating a vacuum (negative pressure) in areas where airborne particles are generated and subsequently cleaning the contaminated air using specialized equipment.
2. Technological methods
These methods focus on reducing particulate matter generation at the source. They include, where technologically feasible, replacing dry materials with paste-like ones, using bulk cement (delivered by pneumatic tankers) instead of bagged cement, enclosing conveyor lines, pre-wetting materials, and utilizing equipment with integrated dust suppression features (e.g., water-cooled rotary hammers).
3. Surface treatment (dust proofing concrete)
This method is applied to existing floors and structures that generate airborne particles during use. Special penetrating strengthening impregnations are applied to the surface, where they seep into the material's pores. Grinding is also used to remove the top damaged layer. Additionally, the floor can be coated with a polymer layer, creating a durable, dust-sealing film.
4. Organizational and technical measures
Effective concrete dust control is also achieved by establishing conditions that minimize the spread of solids throughout the facility. Key measures include sealing equipment, maintaining a clean facility through regular area cleaning, washing vehicle wheels, and, ultimately, using personal protective equipment.
For optimal conditions in production, it is recommended to use all of these concrete dust controls in conjunction.
1. Concrete dust collection systems
This approach relies on creating a vacuum (negative pressure) in areas where airborne particles are generated and subsequently cleaning the contaminated air using specialized equipment.
2. Technological methods
These methods focus on reducing particulate matter generation at the source. They include, where technologically feasible, replacing dry materials with paste-like ones, using bulk cement (delivered by pneumatic tankers) instead of bagged cement, enclosing conveyor lines, pre-wetting materials, and utilizing equipment with integrated dust suppression features (e.g., water-cooled rotary hammers).
3. Surface treatment (dust proofing concrete)
This method is applied to existing floors and structures that generate airborne particles during use. Special penetrating strengthening impregnations are applied to the surface, where they seep into the material's pores. Grinding is also used to remove the top damaged layer. Additionally, the floor can be coated with a polymer layer, creating a durable, dust-sealing film.
4. Organizational and technical measures
Effective concrete dust control is also achieved by establishing conditions that minimize the spread of solids throughout the facility. Key measures include sealing equipment, maintaining a clean facility through regular area cleaning, washing vehicle wheels, and, ultimately, using personal protective equipment.
For optimal conditions in production, it is recommended to use all of these concrete dust controls in conjunction.
Example of a Torch-Air Baghouse Installed at a Concrete Plant
Expert Michael Klepik’s Tips on the Best Dust Collectors
Concrete Dust Collection Systems
In industrial settings, including for concrete batch plant dust control, the following types of concrete dust collectors are commonly used:
- Cyclone – this device utilizes centrifugal force. Air enters the concrete dust chamber and, due to a tangential inlet, acquires a rotating motion, spiraling downward. Particulate matters, being heavier than the air, are flung against the housing walls, lose velocity, and slide down into the conical hopper, finally depositing into the collection bin;
- Cartridge type – here, concrete dust collection occurs on the outer surface of pleated filter elements made from non-woven polyester. Clean air passes through the cartridge and exits through the outlet. As contaminants accumulates, the cartridges are cleaned by automated pulses of compressed air;
- Baghouse (sleeve) type – in this configuration, contaminants-laden air passes through fabric sleeves, which trap particles on their surface while allowing clean air to be released. As the solids cake builds up, the sleeves are cleaned using either pulse-jet air streams or mechanical shaking (pulse-bac concrete dust collection);
- Mobile devices with an exhaust sleeve – this concrete dust separator features a flexible hose positioned directly at the particulate matter source. A built-in fan draws contaminated air through the hose and into the unit, where an integrated filtration system captures the particles, after which the concrete dust bin must be emptied.
Two-stage dust collection filter
Dust Control by Application
In terms of applicability, cyclone collectors are most effective at capturing particles larger than 10 µm, so they are typically used as a concrete dust pre separator in conjunction with other, finer filtration systems. Cartridge, for instance, are widely employed in cement, gypsum, and dry mix production plants and are also commonly installed directly on silos.
Baghouse achieve residual contaminants levels of only 5–10 mg/m³, which is considered excellent. Moreover, they can operate at temperatures up to 260°C and beyond. For this reason, they are extensively used as concrete batch plant dust collectors, as well as in asphalt plants, metallurgy, woodworking, and various other industries.
Mobile configurations are recommended for industrial sites where construction, repair, or demolition work is carried out. They do not require connection to a centralized aspiration system, making them particularly convenient for tasks such as localized dust control for drilling concrete. These models can serve as polished concrete dust collectors.
Baghouse achieve residual contaminants levels of only 5–10 mg/m³, which is considered excellent. Moreover, they can operate at temperatures up to 260°C and beyond. For this reason, they are extensively used as concrete batch plant dust collectors, as well as in asphalt plants, metallurgy, woodworking, and various other industries.
Mobile configurations are recommended for industrial sites where construction, repair, or demolition work is carried out. They do not require connection to a centralized aspiration system, making them particularly convenient for tasks such as localized dust control for drilling concrete. These models can serve as polished concrete dust collectors.
GIF Animation of Contaminated Flow Through a Cyclone Baghouse
In other cases, contaminants removal may be needed from conveyor belts, screw and belt conveyors, loading hoppers, transfer points, or bulk material loading areas. In these situations, one can look for a suitable concrete dust collector for sale specifically designed for conveyor belt installations.
Baghouse Dust Collector for Cement Silo
Concrete dust ventilation is essential in workshops where work is carried out using various tools, including saws, welding equipment, drills, wall saws, and similar devices which can generate sparks. These sparks, when combined with high solids concentrations (exceeding 50 g/m³), pose a serious explosion hazard. To mitigate this risk, spark arrestors are installed upstream of the filters.
The table below summarizes typical production processes and provides recommendations for the use of specific collector types.
Table 1 - Concrete dust collector review:
The table below summarizes typical production processes and provides recommendations for the use of specific collector types.
Table 1 - Concrete dust collector review:
Common Mistakes in Concrete Dust Collection
1. Design Mistakes
Mistakes can arise even during the configuration selection stage, and these are often the most expensive to fix. A common mistake, for example, is relying solely on a cyclone for fine particulate removal, or using standard bag collectors without considering the chemical composition of the impurities itself. At the design stage, miscalculations in system capacity or pressure drop within the air ducts can also occur; ducts that are too long, narrow, or have excessive bends create high resistance, compromising performance. These issues can be avoided by consulting with experienced professionals to ensure the right air purifier concrete dust control equipment is chosen for the specific application.
Mistakes can arise even during the configuration selection stage, and these are often the most expensive to fix. A common mistake, for example, is relying solely on a cyclone for fine particulate removal, or using standard bag collectors without considering the chemical composition of the impurities itself. At the design stage, miscalculations in system capacity or pressure drop within the air ducts can also occur; ducts that are too long, narrow, or have excessive bends create high resistance, compromising performance. These issues can be avoided by consulting with experienced professionals to ensure the right air purifier concrete dust control equipment is chosen for the specific application.
Incorrect Collection Due to Condensate Formation
2. Installation Mistakes
Фото с ошибкой Incorrect Collection Due to Condensate Formation
Mistakes can also occur during system installation, such as poor duct connections or a loose bin seal. Even a small gap on the suction side significantly reduces extraction efficiency in the desired area, while leaks in the bin seal can cause already-collected solids to be blown back out. In such cases, even a top rated concrete dust removal system can malfunction.
When laying out air ducts, installing them in a strictly horizontal layout is a common mistake, as condensation can cause particulate matter to become wet and clog the pipes. Ducts should instead be installed with a slope toward the solids collector or be equipped with access hatches for cleaning.
3. Operational Mistakes
The most common cause of filtration system failure is a violation of the cleaning regime. If cleaning is not performed according to the prescribed maintenance schedule, the solids layer on the elements becomes too thick, resistance increases sharply, and system performance can drop to near zero. However, excessively frequent pulse cleaning is also not recommended, as it accelerates filter wear.
It is important to remember that the cleaning system, particularly in the case of a concrete plant dust collector, must operate in dry conditions. These solids are hygroscopic, meaning that if moist air enters the system, the contaminants on the filters will turn into a cement-like stone that cannot be dislodged by pulse blowing. In such cases, the element will need to be replaced.
Another common mistake is failure to promptly empty the hopper of collected particulate matter. When the impurities level in the hopper reaches the filter inlet or touches the bottom of the bags, solids can become re-entrained into the purified air stream, significantly reducing cleaning efficiency. Additionally, if a non-genuine baghouse for dust control on concrete plant is used, performance may also be compromised, as the replacement material may have a larger pore size or be less resistant to abrasion and high temperatures.
When using mobile configurations, the most common mistake is positioning the hose somewhere near the work area rather than directly in the contaminants-generating zone. For emissions to be drawn into the nozzle, it must be placed within 5–10 cm of the source. If the hose hangs a meter away, its effectiveness is close to zero. It's also important to regularly change the filters on the mobile unit. Compact devices have small filters that clog quickly. If they aren't replaced promptly, suction power drops, and contaminants may start escaping back through gaps (if the filter is torn) or simply fails to be captured.
4. Mistakes in Collected Airborne Particles Disposal
When emptying a bin of collected airborne particles, special adapters, rotary valves, or a spike-tight system (closed bags) must be used. Otherwise, a huge emissions cloud will form during emptying, undoing all collection efforts.
To avoid mistakes, it is important to build in a 20–30% capacity margin during the design phase. Keep in mind that pollutants are heavy and abrasive, so equipment requires an extra safety margin. Operators should be trained never to allow bins to overflow and to initiate cleaning cycles promptly. Hoses should be regularly inspected for wear and tear, replaced as needed, and air ducts must be kept clean.
Фото с ошибкой Incorrect Collection Due to Condensate Formation
Mistakes can also occur during system installation, such as poor duct connections or a loose bin seal. Even a small gap on the suction side significantly reduces extraction efficiency in the desired area, while leaks in the bin seal can cause already-collected solids to be blown back out. In such cases, even a top rated concrete dust removal system can malfunction.
When laying out air ducts, installing them in a strictly horizontal layout is a common mistake, as condensation can cause particulate matter to become wet and clog the pipes. Ducts should instead be installed with a slope toward the solids collector or be equipped with access hatches for cleaning.
3. Operational Mistakes
The most common cause of filtration system failure is a violation of the cleaning regime. If cleaning is not performed according to the prescribed maintenance schedule, the solids layer on the elements becomes too thick, resistance increases sharply, and system performance can drop to near zero. However, excessively frequent pulse cleaning is also not recommended, as it accelerates filter wear.
It is important to remember that the cleaning system, particularly in the case of a concrete plant dust collector, must operate in dry conditions. These solids are hygroscopic, meaning that if moist air enters the system, the contaminants on the filters will turn into a cement-like stone that cannot be dislodged by pulse blowing. In such cases, the element will need to be replaced.
Another common mistake is failure to promptly empty the hopper of collected particulate matter. When the impurities level in the hopper reaches the filter inlet or touches the bottom of the bags, solids can become re-entrained into the purified air stream, significantly reducing cleaning efficiency. Additionally, if a non-genuine baghouse for dust control on concrete plant is used, performance may also be compromised, as the replacement material may have a larger pore size or be less resistant to abrasion and high temperatures.
When using mobile configurations, the most common mistake is positioning the hose somewhere near the work area rather than directly in the contaminants-generating zone. For emissions to be drawn into the nozzle, it must be placed within 5–10 cm of the source. If the hose hangs a meter away, its effectiveness is close to zero. It's also important to regularly change the filters on the mobile unit. Compact devices have small filters that clog quickly. If they aren't replaced promptly, suction power drops, and contaminants may start escaping back through gaps (if the filter is torn) or simply fails to be captured.
4. Mistakes in Collected Airborne Particles Disposal
When emptying a bin of collected airborne particles, special adapters, rotary valves, or a spike-tight system (closed bags) must be used. Otherwise, a huge emissions cloud will form during emptying, undoing all collection efforts.
To avoid mistakes, it is important to build in a 20–30% capacity margin during the design phase. Keep in mind that pollutants are heavy and abrasive, so equipment requires an extra safety margin. Operators should be trained never to allow bins to overflow and to initiate cleaning cycles promptly. Hoses should be regularly inspected for wear and tear, replaced as needed, and air ducts must be kept clean.
View the cheat sheet for engineers
Selecting the Best Dust Collector for Cement Dust Management
We’ve created a useful cheat sheet and a comprehensive brochure to guide you through the various filter types, their key features, and applications for cement dust.
Download the resources and learn how to enhance the efficiency of your cement dust collection system!
Download the resources and learn how to enhance the efficiency of your cement dust collection system!
Price Ranges
The cost for each configuration is ranked as shown in Table 2.
Table 2 - Average Price Range
Table 2 - Average Price Range
The following factors influence cost:
- Performance—a key factor directly tied to motor power requirements;
- Required air purity—systems capturing submicron particles and meeting strict standards need higher-grade media like HEPA filters or advanced cartridges, increasing cost;
- Construction materials—standard carbon steel is affordable, but stainless steel or special coatings for corrosive/high-temperature solids add significant expense;
- Modern technology integration—optional but costly; IoT sensors, predictive analytics, and automated controls enable remote monitoring and optimization but raise upfront investment.
FAQ
- 1. Can I save money and install only a cyclone, without a second filtration stage?Not recommended if you're discharging air into a workshop or within city limits. A cyclone only captures coarse solids (80–95%), while dangerous fine particles are released into the air.
- 2. How often should filters be replaced?Bag filters typically last 2–5 years; cartridges last 1–3 years, depending on the particulate matter load.
- 3. What happens if the filter gets clogged and we don't notice?Draft drops sharply, impurities blow back into the workshop, and the fan motor may overheat and burn out due to increased strain.
- 4. Should the filter and ducts be insulated if the workshop is unheated?Yes. Otherwise, condensation forms inside, wet cement pollutants harden on walls and filters, and the system will fail.
- 5. Do I need a spark arrestor if I'm cutting material with an angle grinder?Yes. Sparks from rebar can enter the filter and cause the hoses to smolder or catch fire.
- 6. If I buy a mobile unit with a hose, can it replace my workshop's contaminants collection system?No. A mobile unit only works for a single workstation. For multiple emissions points, you need a permanent ducted system.
- 6. What type of equipment is best for solids collection during diamond cutting and drilling?Local exhaust ventilation—specifically a Class M or H industrial vacuum with an antistatic hose and automatic element cleaning, positioned directly at the cutting zone.
- 6. Which collectors should be chosen for a mixing area?For concrete plant dust collectors in a mixing area, baghouse (sleeve) units are recommended—they handle high contaminants concentrations, abrasive loads, and humidity fluctuations better, and last longer in continuous 24/7 operation.
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We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
CALCULATION AND SELECTION
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