Concrete Block Making Machines – All about Output and Efficiency

Compared to manual production of concrete blocks, the block making machine has a replaceable gang mould system that produce several blocks per cycle of casting. The concrete block making machines have inbuilt mechanisms that ensure greater strength and performance of the concrete is achieved.

Concrete Block Making Machines

Indigenous block making machines were used in manufacture of larger concrete blocks of both solid and hollow blocks. It was later shown that the size of the aggregate particles affected the quality and strength of the blocks. Concrete with bigger aggregates (greater than 15mm) exhibited segregation and lack of compaction.

New Generation Block Making Machines

To combat this problem there was need to develop a way to achieve better aggregation and compaction. Instead of use of the normal plate vibrator, a technique of pressure vibration was developed to efficiently handle concrete mixes with a wider range of aggregate size and better consistency. This technique has been one of the major efficiency improving innovations in concrete blocks manufacturing. Thus it has been successfully used in stone casting blocks, large size block making and also in making of the traditional aggregate blocks.

Design parameters that enhance efficiency of the Block making machine

Enhanced production efficiency through process innovations and low maintenance costs has been a guiding principle in development of concrete block making machine. The simplicity of the basic design also allows for easier operation and greater productivity.

Mobility of the Machine

There is improved efficiency when the machine is able to set ready blocks at one point and easily move to another position thus eliminating the need for wooden and steel pallets.

Efficiency in Compression

Compression in the block making machine is achieved using hydraulic cylinders which are able to create a much stronger block which still reducing the usage of cement.

The use of high frequency vibrator system achieves greater compaction and the incorporation of powerful motor systems has contributed to enhanced performance. The equipment is also designed to manufacture hollow blocks which are able to save on materials and create an appealing look.

Automatic Block Making Machine

Automation in the concrete industry has led to development of the automatic block making machine. This is an economical machine that delivers high quality blocks in both industrial quantities and special purpose needs. It is generally accepted that the automatic models have two fixed presses able to compress blocks uniformly and with greater force.

Reduced Electrical Installation Needs

The automatic block machine is made with reduced electrical installation requirements and ease of maintenance.  The operating method is designed in such a way to be power efficient and there for quick return on investment.

Flexibility

The ability to develop blocks of different dimensions enhances the flexibility of these block making machines. Latest machines are also equipped with programmable logic control system where specific block dimensions can be set, including batching times and a continuous production process is achieved.

Bottom Line

Technological developments in the concrete industry have enabled the development of machines with greater productivity and profitability. Advances in the design of the block making machines have meant greater output, flexibility in design and also the production of hollow blocks has been made possible.

The Important Role of Concrete Batching Plants in Sustainable Development

Throughout the world there has been much emphasis on the sustainability of each and every project or activity being undertaken. Sustainability in general terms refers to the endurance of systems and processes. Sustainable approaches to construction and development must be sought at all times in order to efficiently manage the resource base from depletion, environmental degradation and even climate change. In other words, sustainable development meets the needs of the present generation without affecting the ability of future generations to meet their own needs.

Concrete Batching Plants

Global Concrete Consumption

Concrete is consumed in massive quantities in the whole world in various activities of building and construction, roads and railways, residential areas and many more. These are important infrastructural requirements that enable the economy to progress rapidly for people to better their living standards.

The preparation methods of concrete must be in such a ways that the demands to the natural environment are kept at minimum for sustainability to be achieved. The concrete batching plant is an equipment used in concrete preparation that has enhanced sustainability in construction.

Energy Efficiency

For sustainable processes to be achieved, efficiency in energy use must be achieved. The Concrete mixing plant is designed to maximize production with reduced energy usage by having highly efficient engines with minimum maintenance requirements and more durability.

Energy saving is also achieved through lower electricity consumption and use of gravity assisted material feeding system as well as computerized controls that precisely calibrate all ingredients of the mixing plant.

Water Conservation during Operation 

In concrete preparations there is heavy water usage in the operation. The batching plant combines all the required materials in mixing of concrete to create a homogenous mix used in construction. Batching equipment is designed in such as way as to ensure optimum usage of water and other materials to achieve a good mix. This includes the ability of some equipment to recycle wet concrete mix before setting and thus reduce wastage.

The Green Technology Equipments

With the development of green commercial concrete plants, the problem of environmental pollution has been effectively tackled.  This model of the ready mix concrete plant increases the material utilization ratio thus creating an overall material saving. Increased material saving from the concrete batching plant in turn increases the productivity and profitability is the operation.

In the current construction industry the demand for increased efficiency is high and the central equipment in this process is the RMC plant or the Ready Mix concrete plant.

In some cases there has been need for all batching equipment to be easily movable to locations closer to construction site to reduce material movement to the site. Some advanced batching equipments may be fitted with twin shaft mixers that increase the production output to up to 160 m3 /hr. The assembly process of the batching plant is also made faster and easy, and with easy to clean concrete handling piping and conveyance systems.

Bottom Line

The concrete batching plant has been important equipment in the construction industry and when effectively used, it has enabled sustainable development to be achieved. More sustainability will be achieved with enhanced technology, water saving initiatives and enhanced efficiency of the batching plants.

Slip Form Paver – Types & Benefits of SlipForm Paving Technology

Slip Form Paver – Unique Technology Machines

The slipform paving is a concrete molding process where concrete is dispensed into a continuously moving mold to attain the required shape or design. This technology is applied in heavy constructions such as roads, bridges and heavy buildings. The main advantage of this technology is the creation of a continuous, “cast in Place” and almost flawless structure that has superior performance over other methods such as molds and discrete blocks.

Slip Form PaverOther Benefits of Slipform Paving

  • They are fast, reliable and produce a much better looking surface that is equally strong.
  • Precise construction is achieved,
  • Reduction in the cost of construction due to high mechanization

Types of slip form pavers Available

Various types of slip form pavers are available in the market depending on the output specifications of each model. Manufacturers of these equipments also classify their machines based on the individual features unique to the equipment. Some of the different functions of these equipments may include;

  • Pavers able to perform convectional paving, offset paving, and custom applications
  • Able to perform automatic width adjustments withoutunnecessary adjustments
  • Half width pavers designed for construction of busy streets and smaller roads with limited supply of concrete, these are also used where larger machines cannot be used.
  • Heavy duty pavers used to recarpet massive projects such as highways, airports, and other heavy jobs. These are sturdily built to create pavements of up to 50cm thick.
  • The slip form pavers may also be specially designed to manufacture continuous kerbs that are strong and appealing.

Technology Involved In Manufacturing Slip Form Pavers

The slip form paving technology is based on the rapid setting properties of concrete material. The technology works on a balance between the quick settings of the concrete and remains workable enough to be molded into the form. This balance is crucial to ensure the final structure is strong and durable.

How the Slip Form Paver Works

The concrete used in this system of paving is very similar to that used in convectional paving systems. It must have a good and uniform consistency having a slump of approximately two inches. This concrete is deposited into the hopper box from where the machine evenly distributes the material across the paving surface. The paver machine helps in achievement of a homogenousmix and compaction through a system of hydraulic or electric vibrators, while the mold helps in forming the slab to the desired thickness and width.

Demandof Slip Form Pavers

The global demand for slip form paving technology continues to increase as more and more pavement roads are required. The market for concrete paving machines is seen to be growing at a rate of 15-20% every year and industry analysts fore see a more rapid growth by the end of year 2017.This is boosted by increasing road networks in various countries ,time bound projects requiring very high efficiency and expansion projects of airports,and residential areas. In India, the government’s plan to construct over 20 kilometers per day of road has created a sufficient demand-pull for these equipments. Some of the global leaders in slipform paver manufacturing includes Apollo Inffratech.

Concrete Block Making Machines – a Boon for the Construction Industry

Concrete block making technology has come a long way from its invention by the ancient Romans. Concrete blocks were initially made manually where each mason would make blocks through special molds designed with the required dimensions. With the slow pace and enormous energy demand for these blocks, there was need for faster manufacturing which led to development of the concrete block making machines.

Operation Technology

The basic technology of the concrete block machine involves molding the concrete and allowing them to set, and cure to form a concrete block. The production process is therefore in a sequence of 4 processes which are mixing, molding, curing and cubing.

Block Design

The shape and design of the concrete block has a great effect on the manufacturing process of these blocks.  In development of new block design careful consideration must be made to retain the cost of production to a minimum.  Complex molding directly translatesto increased production costs. The block making machines are highly efficient in operation and precision to ensure cost of production remains at optimum level. The current machines arefittedwith accurate instruments and timers for profitable operations.

Performance Features

Some importance features to consider in the concrete block making machines can be described as:

  • Machinery capacity, this is the output of the machine per hour. Thisoutput varies depending on the machine size and model with some equipment going up to 40 blocks per cycle.
  • Block making machines are sturdyand rigidly made with minimum vibration to achieve maximum block quality
  • The size of the molding area. This may vary depending on the regulations required from different countries. The size of the molding area can be up to 600 mm *600 mm
  • Depth of block is also variable but can range from 50mm up to 300 mm
  • The power consumption efficiency of the machine.
  • They are fitted with powerful hydraulic drive motor of up to 5 Hp for maximum compression

Concrete Block Making Machines

Advancement in machine technology has led to addition of other features such as vibration motors able to deliver a 0.5 hp, and up to 3000 vibrations per minute. More advanced models are equipped with a travel motor for easier placement of molded blocks.

User Friendliness and Durability

Block making machine is made to be user friendly and easy to operate, this is important for easy training of users on site. The durability is guaranteed through usage of strong steel frame work able to resist the heavy workload on the equipment.

Innovations in the concrete block manufacturing process has led to development of machines that have the ability to manufacture hollow blocks of equal strength characteristics  as the solid blocks. This translates to material efficiency and huge savings to the total cost of materials.

Conclusion

There has been rapid advancement in the concrete block making technology. Block making machines are able to deliver high quality concrete blocks over a short period. The machines are developed to withstand the heavy concrete workload without damage to the equipment. The concrete machines come in various models, and sizes vary depending on the desired throughput.

The Hume Pipe Making Machine Technology – Features & Applications in Infrastructure

The concrete pipe production technology has been fully automated for manufacture of first class quality concrete pipes. The machine has been equipped with advanced control systems that ensure high production efficiency is attained. Products manufactured by the machine include;

  • Concrete pipes compliant with all international standards of piping and construction
  • Production of steel reinforced concrete pipes
  • Prebed pipes
  • Jacking pipes
  • Steel cylinder “core pipes” that can range up to 6 meters length

The equipment can produce pipes from diameters 225mm up to 1600 mm

The equipment has short change over time from one job to another thus ensuring optimum equipment utilization and greater profitability. The compaction of the equipment is computer controlled thus well regulated and structural consistency of the pipes is achieved.

The equipment can be installed with an automatic crane, adjustable floor system and pipe testing capabilities as well as base pallet control system.

Pipe Making Machine

Advanced Features

Current machines are developed with a two directional head system, which enables manufacture of concrete pipe with a good wire and concrete bond as well as great compaction.

The hume pipe making machine is developed with a unique frame design that allows for easier feeding of multiple materials and rapid pipe assembly. This vertical cast process has been found very efficient and with great ability for greater automation.

Ease of Maintenance

The design of the system also enables ease of servicing the equipment as well as access for routine maintenance practices. The total clean up time is effectively reduced since there is less material spillage during production.

Easy Assembly

During construction, the use of the steel pit base shell greatly reduces the total installation time and production starts in shortest time possible.

Various Models

The concrete pipe machine is available in various models based on the desired output capacity, pipe diameter and pipe length.

The cross head drive system and power unit situated on frame at conveyor level for better power transfer and easy service and maintenance. The equipment has also been equipped with noise dampening system to enhance the user friendliness.

Hopper and Conveyor Unit

The capacity of the hopper is based on the size of the machine. It is constructed with innovative rounded corners that help prevent build up of materials during operation. A liner can also be added to enhance flow of material through the equipment.

The conveyor system is driven by rollers, which are completely sealed to prevent ingress of particles and ensure ease of maintenance.

Additional Enhancements

Control system has been developed either as manual or computer aided.  For the automated machine operation, adjustments are made with a touch screen interface in a flexible support system. Innovative video screen monitor have also been added to the control system for monitoring machine performance via installed video cameras.

The oscillating tongue mechanism; this system can also be incorporated, for production of roll- in/ profile jackets. The pipe-making machine can also come with different voltage levels, starter options, and even automatic lubrication system.

 The Hume pipe making technology continues to undergo rapid innovation, which has led to increased range of manufactured products. The machine can produce box culverts, manholes, catch basins and other products requiring this molding technology.

Important Concrete Production Equipments – The Foundation of Concrete Technology

The construction equipment industry has rapidly developed in innovation over the last few years. The turn of the millennium marked the crossroad where existing technology appeared to have reached the climax, and newer operational concepts had started taking shape. The advances in technologies have also been prompted by the need to enhance efficiency and reduction in environmental emissions, which impacted heavily on the engine designs. New and more well engineered designs have achieved much more performance and functions than would have been conceived a decade ago.

Some of the greatest developments discussed here include-

Slip form Paver

Slip form paving is among the recent and now widely accepted technologies in infrastructure development. The slip form paver is an equipment that can perform several tasks such as;

  • finish grading
  • disperse concrete on the sub grade
  • Vibration
  • Concrete shaping
  • Trim surface to the desired thickness
  • Create surface uniformity

Slip form paving

The equipment uses concrete of a similar grade to that used in convectional paving systems. It must have the same consistency and uniform slump of approximately two inches. The prepared mix is fed into the hopper box or deposited in front of the machine. The material goes through the vibrators, tampers and oscillators after which it is extruded through a metering system extending the width of the surface to achieve a uniform surface conformation.

The slip form paver is equipped with a modern control system that has increased the machine efficiency of operation. The equipment has intelligent electronic controls for precise driving and concrete processing system to achieve high precision in paving.

Concrete Batching Plant

This machine is one of the most important equipments in the construction industry. The final strength, consistency and durability of concrete is dependent on the efficiency of the batching plant. The machine is equipped with an advanced and computer aided operation system which regulates the weights of aggregate, sand, cement, additives and water. The machine also regulates the mixing time for each recipe depending on the requirements of the concrete.

concrete batching plant

The concrete batching plants operate in two categories, which are the ready mix concretes and the central mix batching plant.

The introduction of computer aided batching processes has been one of the greatest advancements in concrete processing. It means that material mixing can easily be altered to changing requirements, and modified to achieve greater throughput, while reducing the operation cost.

Block Making Machine

These equipments come in various models depending on the type of blocks desired. The machine lays blocks with high efficiency and low on maintenance, therefore delivers quick and easy blocks production.

Block Making Machine

It has eliminated the need for wooden and steel pallets, the mould and the Ram mechanism are hydraulic operated and achieves stronger blocks with less cement usage. These modifications have enables consistent in quality and size of blocks. The block making machine is able to achieve pressures of up to 2000 Psi for maximum compaction. The equipment has advanced vibrators that also enhance the compaction of the equipment.

All about the Batching Plant

The batching plant is an equipment that efficiently combines the various ingredients to make up concrete. The ingredients are sand, aggregate, water, air, cement, fly ash, and silica fume. These ingredients are mixed at different ratios depending on the final type of desired concrete.  There are two main types of batching plants, which are the dry mix and the wet mix plants.

Main Components of the Batching Plant

Important components of the plant include the cement batchers, aggregate batchers, conveyors, aggregate bins, heaters, chillers, cement silos, batch control panels and dust collectors. At the center of the batching plant is the mixer, which is a key component of the equipment. The mixer can be; tilt drum, Planetary, pan, single shaft and the twin shaft mixers. Each type of mixer orientation has its special advantages.

Concrete Batching Plant

Features of the Dry Mix Concrete Plant

For efficient and effective operation, the modern batching plant has been highly automated and utilizes computer aided controls to precisely deliver and mix each ingredient according to the preset ratio.

The exact proportion of aggregate, cement, water and admixture are fed into the drum by selecting the preferred mixing code from the control panel.

Weighing of each constituent is done by sensitive load cells attached to the hopper, therefore accurate mixing is achieved.

Operation of the Concrete Batching Plant

In operation, the concrete batching plant has 4 key components. These are the gravel feed; Powder feed component (cement, fly ash, bulking agents), water and feed additives, transmission and storage. The basic operation procedure of the machine can be defined as,

  • System Activation; the mixing formula is input through the control panel, this also includes the concrete slump, grade and productivity. This is the calibration that will be used for the individual components of the mix.
  • The hoppers are tested and calibrated for accuracy before the operation begins
  • The belt conveyor is initiated to transmit the aggregate to the weighing hopper.
  • The control valve of the water sump and admixtures are opened to allow water and admixtures to flow into weighing hopper.
  • Once all weights have met the required volumes the doors of the weighing hoppers is opened automatically.
  • The materials are released into the mixer where mixing continues until the setting time is over. The loading doors are then opened and the mix flows into a concrete mixer truck.
  • This process is done very carefully to ensure the concrete does not segregate , and it must be used before the preliminary setting time of 30 – 45 minutes is reached.

Specifications of the Dry Batching Plants

Dry batching plants typical production capacity of the equipment can range from 25 cubic meters /hr to 100 cubic meters/hr. The discharging capacity can also range from 500lts up to 2000l/hr, aggregate size of 80/60 pebble/macadam. The weighing accuracy of the machine is guaranteed  with an accuracy of + or – 2% of aggregate while that of cement, fly ash, water and additives have an accuracy of + or – 1 %.

Innovative Concrete Machines with Great Returns and Durability

The rapid growth in the construction and infrastructure has meant increased demand in concrete pipes and products in general. Equipment used in manufacture of these products has equally advanced. Some of these machines include:

Cage Welding Machine

This is equipment designed for manufacture of circular cages used in production of precast concrete poles, concrete pipes, culverts, columns and bored piles. Advanced technology has led to manufacture of innovative machines able to produce oval, round with spigot as well as square cages. It is also possible to, manufacture conical as well as cages with flattened sides.

Cage Welding Machine

The Cage Welding Machine dimensions range from 220mm by 1700mm to 900mm by 5200mm and even more. Lengths can also vary widely depending on the usage.

Features of the Cage Welding Machine

The machine is has a winding wire pitch that can handle 80/100 KVA up to 100/125 KVA. It is also equipped with an ultra modern touch panel with a programmable logic control that ensures efficiency and ease of operation.

Design of Cage-Making Machine

With increased variability in the design and models of cages, machine design has also advanced significantly that unique cages can be made, with lower investment amount required. The cage making machines market is also bound to continue expanding as infrastructure developments continue to increase globally.


Block Making Machine

The equipment has a robust construction with very rigid frame that only the synchronized vibration will occur during production and interfere with the quality of the product.

The equipment also has high production capacity while requiring minimal maintenance therefore higher return on investment. The equipment is recommended for production at industrial level as well as manufacture of special pieces.

Block Making Machine

It is equipped with two fixed presses that achieve sufficient compression for high quality blocks.

Traditionally , these block making machine required very heavy wiring and electrical installations, however , the current design requires much less fittings thereby adapting to the needs of business people who are starting out as well as those in continuing production.

In addition, the stationery-synchronized press is rigid and very easy use, as it has been highly automated. Instead of moving the whole machine, only the trays are in motion, therefore will take up lesser space.

Pipe Making Machine

The demand for the concrete pipe globally has grown rapidly and even exceeding the supply level. There is therefore a high likelihood of deterioration in quality as manufacturers compete to fulfill their orders. This must never happen and buying the highest quality pipe-making machine is the only solution.

Pipe Making Machine

While looking for a pipe production machine, some important features and innovations increase the efficiency of the equipment. These include;

  • The design of the hoppers and conveyors; They are manufactured with rounded corners that prevent material build up during production.
  • Incorporation of turntable assembly with tapered support rollers for greater support and centering
  • A self-cleaning top table that has a fully machined bottom surface as well as captive fasteners for accurate attachment of the top centering plates, tongue formers and O-ring groovers,
  • Incorporation of a changeover table that supports the roller head assembly and the top centering ring during change over, maintenance and machine clean up.

The modifications and innovation in these equipments has enabled efficient and high quality production of concrete pipes that are guaranteed in performance and durability.

Efficient Construction Equipments for Successful Concrete Handling

Concrete Mixture Plant

The concrete mixer plant combines various ingredients to form the final concrete. The mixture components include sand, water, aggregate, cement and fly ash. A good batching plant must be able to produce high quality mixture as well as meet the production capacity requirements. Some of the main considerations in design of the concrete plant include;

  • Ability to fit in with the existing infrastructure
  • Considerations for future expansion and increased capacity
  • Stability and durability of the plant
  • Aesthetic design and workmanship
  • Ability to achieve homogeneous mixture at a shorter time period
  • Ability to have an efficient loading and unloading process
  • Control of dust

construction equipmentsThe mixing plant is central to concrete production. There are the wet mixing plants and the dry batching plant. The wet batching plant has greater advantages than the dry batching plant such as:

  • Ability to deliver consistent quality
  • They have higher production capacity
  • Faster loading and unloading
  • Greater durability and lower maintenance costs
  • Cleaner trucks and environment

Concrete Transit Mixer

The concrete transit mixer is designed in such a way that the mixing operation continues while the concrete is in transit. This allows greater timesavings from mixing to usage. Some important features of design include;

The driving system is highly durable, and is able to withstand long running hours during transit.

User friendliness, easier to operate and maximum discharge of cement is required to avoid wastage of material.

Smooth rotation is critical to operation. All the rotating parts of the machine are well lubricated for efficiency of mixing.

Micro filtration systems are also included for protection of the motor and the hydraulic system to ensure these are adequately protected.

Self-Loading Mixer

The self loading mixer is designed with a special mechanism to load the concrete mix components to the main mixer for batching to occur. The salient features include;

  • it Self loads the required aggregate and sand into the drum
  • Weighs the materials as per the required quantities
  • Continues mixing while proceeding to the site
  • Will easily discharge the mix to the site

Other innovative features include

  • Tight turning circle: This feature enables equipment make small turning radius and can operate in confined places easily.
  • Swivelable operator position; this feature enables the operator have good visibility during driving, turning and pouring.
  • High Gradeability; Enhances the machines ability to work and move in very rough and tough site conditions
  • Hydraulic steering system which allows for easy maneuvering in narrow and constricted places.

Slip Form Paver 

Slip Form Paver is a highly innovative equipment used in paving, to consolidate, shape and finish a mass of concrete. The main features of this equipment include high production ability, versatile, quality material of construction and it has been proven to have high efficiency. The machine has also been developed in consideration of all the important safety features.

Conclusion

Successful construction is dependent on the quality of equipments applied. Technological advancements in the concrete making and construction sector have been the main contributor to efficiency in construction.

What are the Advantages of Doing Slipform Paving

The slip form paving technology is one of the advanced forms of technology that is used for the purpose of paving construction works. The construction materials (PCC) are continuously prepared and poured over the paving surface and the leveling is done simultaneously. The pulling is done constantly to help in the consolidation process. The Slipform Pavers are the machines that are used for this type of topping. There are several advantages achieved by availing this form of paving. Take a look at the major benefits of selecting this type of surfacing.

Best Precision is available: When this machinery is used, the precision levels of the surfacing are very high. The conventional forms of topping cannot be error-free. There may be defects such as undulations. The defects can be minimized the most if this form of surfacing technology is adopted. The Slipform Pavers are used for the surfacing of the best quality roads.

SlipForm Paver in India

Low Slump PCC is used: This type of technology always makes use of low slump PCC. This means that the water content in the PCC mixture is the minimum. The concrete settles down faster than the traditional form of surfacing. The strength of these paving is found to be more. The roads which need to be built very fast always use this technology.

Reduction in Labor Costs: The entire operations are mechanized. The use of manual labor is nearly done away with. This eliminates the high labor costs that are involved in the traditional form of paving. The job is entirely carried out by the machines. Only a single machine can carry out the jobs of many labors at a time. Chances of chaos due to excessive labor are also curtailed.

Slipform Pavers are used for best quality roads

Best for Large area of Paving: Many a time, a large stretch of area needs to be paved or metaled. These machines are the most suitable to use during this period. The conventional method of topping would take longer for the job. There is also an uniformity in the paving process. This is possible only because the entire operation is mechanized. Manual jobs are not involved.

It is a Faster Process: The entire process can be done faster than the traditional surfacing. When roads and pavements are to be constructed, this technology helps in opening up these places for public use at the earliest. You cannot afford to keep these places unusable for long. Otherwise, a huge amount of inconvenience is caused to the common people. The consolidation of the laid materials also takes place faster. If a double layering needs to be done, this is the best option that should be exercised.

It Creates Better Looks: If you want the topping to look good free from defects, this is the method that you must adopt. No other type of surfacing can give a neater appearance. The major roads should always be paved in this manner.

These are the main advantages of implementing this type of surfacing. It may be expensive but is always the best form of paving.