Pumping innovations into concrete mixing

Featuring the advanced concrete pumping and concrete mixing plant technologies

The illustration demonstrates the homogenous mix of planetary mixers.

Previously in the construction work cranes were engaged to lift large buckets of concrete to the desired places which was a very time consuming process. Over a period, to reduce this painful and time consuming task, the development of concrete pumps started taking place. Today the construction realm uses advanced concrete pumping technology by which transferring liquid concrete at desired heights at construction work has become easier. It is no more a strenuous task and has many advantages than lifting large buckets and cranes. On this note, experts will share some of the latest pumping innovations into concrete mixing.

Latest concrete mixing plant technology
Ajax Fiori is always striving to bring to the market innovative, modern technology, superior quality, versatile, highly maneuverable, yet simple and cost effective solutions through its world class construction equipment, to cater particularly to the concreting sector.

Ajax Fiori has also established itself in the batching plant arena, offering its customers in various technologies and capacities yet compact in design, apart from the dominance in self loading mobile concrete mixer.

While sharing on the latest concrete mixing plant technology Debasis Bhattacharya –Head Sales, Marketing & Product Support, Ajax Fiori Engineering (I) Pvt. Ltd informs, “The compact reduced bin batching plant with planetary mixer – capacity of 30 cu.m/hr is the latest addition to or product portfolio.”

The USP of reduced compact batching plant are that, they are supplied standard with planetary mixers and customised PLC based control system. More so, these planetary mixers are manufactured in-house under strict quality control procedures, in technical collaboration with Eurostar, Italy. World over, the planetary mixers have replaced the turbo mixers for most applications, owing to its capability of producing high quality concrete of different types. The key benefits of planetary mixers over conventional turbo mixers are:
• The planetary mixer mixing tools rotate in a synchronised manner and are able to turn the material distributing all of the material uniformly in the pan without favouring the different nature of the materials creating a homogeneous mix; each revolution changes the flow pattern.
• The intensity of the mixing action, appropriate speeds combined with design of the mixing tools provide a complete homogenisation and an efficient flow pattern.
• The pan of the planetary mixer is completely empty thus allowing the material to cover the complete area in a minimum time.
• Planetary mixers have a single type of mixing tool with a geometry that together with a combination of movements distributes evenly the material.

Briefing on concrete mixing plant technology and the customers demand for the same V.G.Sakthikumar, Managing Director, Schwing Stetter Sales and Services Pvt Ltd, Chairman of Mechanization committee, Builders Association of India says, “Customer expectation is the driver for our new product line. The customers are expecting the batching plant to produce high quality concrete consistently without any breakdown. So, the technologies should be meeting these primary criteria in addressing the customer expectation. Once the plant is designed to give maximum output per batch and also uses minimum power to give a homogenous mix in a short time, it helps us to save so much on the power. So, our Stetter plants are designed to meet these standards whereas many plants available in the market do not consider the cost of production as the main criteria.”

Customers are looking for newer innovations to help them to cut costs. Schwing Stetter India offer the customer, an innovative 30 cu.m batching plant that will save them 15 per cent on the total installation cost in comparison to a typical 30 m3 batching plant, and further these are the advantages customers receive, due to the modular system of the Stetter mobile mixing plant that are:
• Fast assembly and disassembly
• Easily accessible
• Economical, reliable
• Compact and easy to maintain.
• No foundation required.

Schwing Stetter India’s brand new M30Z batching plant is designed from the ground at its Irungattukottai plant, the new model is equipped with a pan mixer and can produce a concrete output of 30 cu.m/hr. The concrete discharge height is 4 metres and can be operated at a voltage of 415V.Control unit for this batching plant is MCI 70 version 3.1.

Besides this, it also does not require a ramp or conveyor to feed the concrete into the bins. The total installation altogether requires batching plant, civilwork, conveyor, loader, and the power and water connection. Disruptive innovation is what Schwing Stetter India has done here. The company is giving the customer, the choice of eliminating the foundation and offering one and only complete concreting solution.

Optional mounting of additional weighers like water and ice weighers are also provided. The ice weigher is used for the weighing of flake ice. At the bottom, the side walls are sloped outwards which ensures the complete discharge of the container.

The plant is delivered to the construction site on a semitrailer. Only a mobile crane is sufficient for the erection. It’s easy to erect, dismantle and transport because it’s a one unit on the whole.
“In the innovative M30Z batching plant, there is no foundation required. Aggregate feeding can be done without a ramp or feeding belt conveyor. Since, the plant comes with a low feeding height and skid (no foundation required).The customers are able to save 15 per cent from the total installation costs that will be incurred making the plant cost effective,” Sakthikumar.

KYB-CONMAT believes in futuristic technology and also keeping it upgrading. It has a very stringent audit system which not only audits the product quality but the process of manufacturing.

As per Kalpesh R. Soni, GM-Marketing, KYB-Conmat Pvt Ltd some of the unique features of the company’s batching plant are:
• Optimum utilisation of power (lowest in its category)
• Perfect cycle time to achieve the rated output.
• 24X7 service support desk with online fault diagnosis and rectification system.
For transit mixers some of the unique features are:
• Unique press bends shape of blade making filling and discharge of concrete faster.
• 80 mm aggregate with 50 mm slump concrete can be handled by KYB-Conmat transit mixers easily.

USPs of innovative products
Every product has its own uniqueness and USPs that makes it saleable in the market. Players like Swing Stetter India, Ajax Fiori Engineering (I) Pvt Ltd, and KYB-Conmat Pvt Ltd share the USP of their innovative products.

As per Bhattacharya the Compact Reduced Bin Batching Plant (CRB) of 30 cu.m/hr capacity was designed to fulfil the need of its customer in the RMC and infrastructure segments. In today’s competitive world capital and operational cost plays a vital role in the success of the business.
• The CRB 30 eliminates the need of the belt conveyor for handling aggregates and there by reduces the capital cost by 30 per cent compared to other similar plants available in the market.
• Aggregate weighing system is independent of skip transfer system, thereby reducing the cycle time & increases productivity.
• The entire plant can be transported in a single trailer and thereby reducing transportation cost compared to other plants.
• Swivel control cabin fixed to the plant, there by Operator can have a full view of the plant while operation.
• Plug and Play electrical system, thereby fast erection at site
• Compact Layout, hence minimal space required
• Minimal Concrete foundation required for erection
• Skid foundation also available as optional which eliminates the need of a foundation.
As per Sakthikumar the USP of Swing Stetter India’s products are that they are lowest operating cost, lowest in fuel consumption. The company’s products have strong service network. It also has strong design capability and product innovation in India.

“Along with high productivity, the key feature of our equipment is longevity. Our equipment are designed to consume less fuel, operates with low decibel levels, safer to operate, consumes less parts and has a very long service life which makes our equipment, a favourite among our customers,” he adds.

Projects where the equipment are involved
Ajax Fiori’s batching plants are widely used in various prestigious infrastructure projects across construction of roads, bridges, railways, power projects, to name a few. Over 300 batching plants are working successfully in India with most of the construction companies.

On naming few projects where Schwing Stetter India’s equipment is involved Sakthikumar says, “The equipment is involved in many projects like in Chennai, M30Z batching plant is busy working in various projects like residential project for Casa Grande near Alandur, government highways project near Nazarathpet, Chennai – Velachery Bridge, Kalpakkam Nuclear Power Station and in an RMC, SSV foundation. In Bengaluru, it is working in residential projects such as SNN Iprox, Kalyan apartments, Bengaluru Metro, Railway Bridge across Bhima River and road up gradation project of Devangere city.

In Andhra Pradesh, M30Z Batching Plant is used in residential projects such as Legend Harmony, Pacifica, Sumadhura Acropolis and in a Sri Gajanana RMC unit at Kurnool. In Pune, the equipment is employed at Parde flyover. In Gujarat, M30 Z is working at projects like Ahmedabad Metro, road upgradation at Bankura district, river bridge at Bharuch – Gujarat, also in road up gradation of NH76 E: Jetpur Gondel to Rajkot section, and in RMC units at Junagadh and Vapi. In Indore, it is working in a road up gradation project of Kekrakhedi. M30 Z batching plants are also working in road over bridge NH76 – Allahabad – UP, road upgradation of NH24 Sarai Kale Khan to UP Border, Tiruvannamalai temple, wind mill project and in Tuticorin bridge project.

KYB-Conmat Pvt Ltd products are involved in concrete road projects under NHAI and state highway projects. Lower Ganga Canal project, under irrigation projects. Subernrekha canal project in Chhattisgarh and Indira Nehar Canal projects in Rajasthan.

May such innovative technologies are expeted to be showcased at the Bauma Conexpo India 2016 – the international trade fair on construction machinery, building material machines, mining machines, construction vehicles and construction machinery to be held in Gurgaon near Delhi between 12th and 15th December. Adoption of such advanced technologies can generate transformative change in the construction industry.

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