Schwing Stetter in

Volume : 4
Issue : 12
Q2 2015
2
3
Project in Progress
8
Notable Projects
Concreting Achievements
10
New Product
Schwing Stetter in
Go Green Projects
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1
VC & MD’s Message
Dear Customers,
A very warm greeting to all the readers of Concreting Times.
Unlike the previous six months, the last six months have seen some positive moments in the infrastructure projects. Several road contracts have
been awarded which have brought some cheer in the construction industry and among the construction equipment manufacturers, especially the
road equipment manufacturers.
The concreting equipment manufacturers have also been benefitted, as many of these contracts are road contracts, thereby bringing concrete
demand for bigger capacity batching plants, concrete pavers and the like. The asphalt road equipment manufacturers are also benefitted due to
the spike in demand for asphalt plants, vibratory compactors, motor graders and similar equipment.
The delegation of construction equipment manufacturers ICEMA is in constant interaction with the Ministry of Road Transport and Highways
(MORTH) who have repeatedly assured of flow of new contracts for road
building in the coming months. MORTH is conducting a two day seminar
coinciding with the AGM of ICEMA on the 9th and 10th of July 2015. This
event is likely to be attended by all the stake holders from the Central
Ministry, State Government, Equipment Manufacturers and Construction
Companies specializing in roads and highways construction. Productivity
improvement, safety, skill development, equipment finance, etc. are some of
the topics which will be presented during this event. There will also be a
panel discussion among experts including policy makers, end-users and
equipment manufacturers with a view to understand the challenges and
nuances of speed, scale and skill development.
Since there is a major thrust from the Government to increase the number of
concrete roads, I would urge upon all the readers of Concreting Times to
attend this seminar and get benefitted. Further details on this can be had
from the secretary of ICEMA Mr. S.G.Roy whose email id is s.g.roy@cii.in.
We, Schwing Stetter India are very eagerly looking forward to the success of
this event, which will earmark the restart of our equipment business in the
road sector.
I finally wish the readers of Concreting Times lot of peace, happiness and
faith on Ramadan. “Eid Mubarak” to all of you.
All the best,
Vice Chairman & Managing Director - SSI
Projects in Progress
Agra - Lucknow Expressway - India’s Longest - 302KMs
This Expressway will be India's longest access-controlled
Expressway, construction for which has already begun at five
different locations. The 302-km, 110 meter wide, six-lane road will
cut Lucknow-Agra travel time to four hours. The cost of the project is
around ₹105 billion (US$1.7 billion). It will be financed by the
Government of Uttar Pradesh.
The project is built under the EPC (Engineering, Procurement, and
Construction) model which has been divided into five parts. While
L&T would build the 63 km long Lucknow-Unnao stretch, Afcons
Infrastructure would develop the 64 km long Unnao - Kannauj portion
along with the 62-km Etawah - Ferozabad stretch. NCC Ltd would
construct the 57-km Etawah - Kannauj leg and PNC Infratech would
develop Agra-Ferozabad, a 56-km long stretch.
PNC Infratech has employed 4 numbers of CP 30 compartment batcher with skid, 25 numbers of transit mixers and 1 S36 boom pump. Its significant
to note that every player has trusted Schwing Stetter for years for their concreting equipment needs and even in this project, concreting needs are
being fulfilled by Schwing Stetter.
2
Notable Projects
Cloud Kisser of The East
Unity Group - Residential Project
Christened ‘The 42 Chowringhee', the
245-metre-tall building on 42 B,
Chowringhee road that once belonged
to the Maharaja of Darbhanga is a
super-luxury residential project.
According to Mani Group CEO Sanjay
Jhunjhunwala, who is leading a
consortium of four groups to develop
the landmark, "The 42, like Dubai's
Burj Khalifa, will be the conversation maker for Kolkata". Alcove and
Diamond groups, Kolkata, and Sattva
group, Bangalore, make the quartet.
The Residential Project by Unity Group is coming up in the central part
of Delhi. The project has a team of some of the best consultants from
across the Globe working on it including Benoy (London); HBA
(Singapore); Meinhardt (Singapore); e.Construct (Dubai); UHA
(London); M. Paul Friedberg and Partners (USA). The Project is
spread over approx. 40 acres and has approx. 2400 Apartments being
built in 18 towers. This project would be having all major facilities /
amenities including a state of the art Club House and some of the best
features in a Residential Project in Delhi. The construction of the
project has commenced and is being done by Shapoorji Pallonji & Co.
Ltd. The project has a total concrete requirement of approx. Five Lakh
cubic meter.
It is almost twice the height of the
South City towers (36 floors).This
height is comparable to Mumbai's
tallest buildings, Imperial Towers 1
&2, which are 61 floors each. The
construction construct was awarded
to ITD for piling 55mtrs and ACC India
Limited for the superstructure. The
capacity of this building are 58
number of flats each with a built up
area of 7,780 to 7,851 sq.ft, about the
size of half a dozen flats of standard
type. There will be a triplex at the top.
The strenuous journey of producing the massive Five lakh cubic
meter of concrete has been instigated by 2 Numbers of CP 30
batching plants, and the produced concrete is being placed by SP
1800 concrete pump, while 6 Numbers of 7 cubic meter transit mixers
are employed to assist in the process. The complete picture is yet to
unfold and Schwing Stetter is thrilled to support the customer in their
huge project.
Supernova Project-Noida, UP
This Residential project is developed by
Supertech and construction is by ACC
(Arabian Construction Company). It
consists of six towers and has 80 floors.
Schwing Stetter India’s equipment in this
project are M1.25 T, SP2800 HD, SP3000,
TM – 4 Numbers. The total concrete
produced and poured in this project is
32,499 M3 and Schwing Stetter team has
produced 20,175.5 M3 so far.
This Residential project was started in 2012 and is expected to be
completed by end of 2016. Unique facilities of this superstructure is
that the ground floor lobby will be 13 metres high, more than the
height of a standard three- storey building. The first four storeys will
make up the lobby and three service floors. There will be a six-level
car park for 350 cars and each apartment will get six parking slots.
Total concrete for this building is 34691 M3 with M40, M50, M60 and
M70 grade of concrete.
Model
Quantity
CP 30
1
SPB 32
1
SP 3000 D
1
The concrete grades used are M80, M60,
M50, M40. The pressure at which our
pump is operated to pump the concrete is
SP3000- 180 Bar. The present height of
the building is 118 meter + SPB 33. The
average amount of concrete produced
monthly is approx. 2000M3.
3
Customer Interview
An Interview with Shashvat Infrastructure Private Limited
Mr. Kalpesh Panchal - Managing director, Mr. Chirag Patel - Managing director, Mr. Ravi Prajapati - Managing director
About Customer
Why Schwing Stetter India?
After completion of Civil Engineering and MBA from USA, they started
a readymix concrete venture in Ahmedabad. They registered their
firm in February 2012 and commissioned Schwing Stetter batching
plant on 20th July 2012. Till date, they have produced nearly one lakh
cubic meter of concrete. Because of their hard work and quality of
service, Shashvat Infrastructure Pvt Ltd is now a renowned name in
ready mix concrete. Their motto is to supply quality concrete to their
customers.
After conducting a market research, we went ahead to purchase
Schwing Stetter machineries through other RMC business partners
referrals. We are very proud and happy to be associated with
Schwing Stetter since 3 years. Schwing Stetter equipments are of low
maintenance, extremely user friendly, high quality products. Thanks
to Schwing Stetter marketing, service and spare parts departments
for their professionalism throughout our project tenure.
Landmark Projects
Adani Township- Ahmedabad
Metro Rail Project - Gandhinagar
Central Vista – R & B Department, Gandhinagar
Mukhya Mantri Avas Yojana – Sabarmati & Ambavadi
Gala Eternia & Gala Empire - Ahmedabad
Schwing Equipments
Batching Plant – CP 30 - 1 No
Concrete pumps – SP 1400- 2 Nos
Transit mixers – 6 Nos
An Interview with Adani Corporate House, Shantigram
Mr.Debabrata Chakrabarty - Project Manager- Adani Corporate House, Mr. Kailash Chandra Kalapahad - Cluster Plant ManagerAhmedabad-B&F IC, Mr. V.Girishkumar - P&M In Charge- Adani Corporate House Project.
Schwing Equipments
Batching Plant – CP 30 - 1 No
Concrete pumps – SP 1800- 1 Nos
Boom Placer - 36 - 1 Nos
Transit mixers – AM6SHN2 - 4 Nos
Why Schwing Stetter India?
About Customer
Shantigram, developed by the Adani Group, is Gujarat's largest
integrated township spread over more than 600 acres, where stateof-the-art commercial complexes compliment luxurious residences.
Be it Water Lily, the beautiful lake view apartments or the Meadows,
premium stadium facing apartments or The North Park, Shantigram's
exclusive golf villa community. Shantigram defines good life.
Landmark Projects
L&T has been constructing Adani Corporate house, Shantigram since
July 2013 and will be completed by September 2015. The total
concrete that will be produced is 80000 Cu.m. The total height of this
building is 86 Mtrs, 3+ 16 Floor building. Currently, 12 floors has been
completed with 70,000Cu.m of concrete.
4
We totally appreciate the quality and reliability of Schwing Stetter
products. The site construction is being completed without any
issues.In addition, we appreciate the service and spares support of
Schwing Stetter India. We have used Schwing Stetter Hydraulic shut
off valve with water cleaning system. It is very good product and it
has saved us a lot of concrete while cleaning the pipeline. Schwing
Stetter Ahmedabad team also supported the site by providing free
training for the operation and maintenance of Concrete Pump &
Batching Plant.
Hottest in Concrete Pumping
SP 3000
NEW STAR
SP 1800
A LIMITLESS
a
POSSIBILITY
ON THE HORIZON
SP 3000 concrete pump is loaded with
a raw power of 169 KW engine,that
could generate a crude concrete
pressure of 156 bar. Engine power and
concrete pressure plays a very
significant role in a pump's ability to
handle heavy concrete and lengthy
pipelines; SP 3000 has enough of both.
A concrete pump which needs no introduction in the market,probably
around 80 percent of towers that are around 100 meters high in India
was concreted by SP 1800.
Customer's experience with SP 1800 has made Schwing to name SP
1800 as a limitless possibility. We have exploited SP 1800 in various
dimensions, experimented in various challenges, recently in a
challenging application; SP 1800 stood to its name and delivered.
Challenges in the application,
Schwing to cater the needs of the 300
METER CLUB, decided to redefine the
concrete pump SP 3000. So out of
market demand, Schwing redeveloped
the pump in lines with – its ability to get
the work done at ease, keep the
running cost very low, offer world class
technology like twin circuit at
affordable price in the Indian market.
A high strength heavy harsh concrete M 80,
Placing height of 140 meters
A separate placing boom of 30 meter at the top with multiple
bends
Even a 160 KW competitor's pump was not able to handle the load,
whereas Schwing's SP 1800 was pumping at ease. Schwing's
application engineers amended various improvements in the pipeline
technology and got the pumping going.
The list of some of the challenges SP 3000 involved in are,
An uncompetable pump in its segment.
Lodha Blue moon by Capacite in Mumbai [Vertical height - 255
meters]
In The 42 Chowringhee, by Arabian Construction company in
Kolkata [Vertical height - 250 meters]
North Eye by Super Tech, Delhi [Vertical Height – 265 meters]
Delhi metro tunnel [Horizontal distance – 1200 meters]
No other player in the market can offer such variety of choices,
reliability and expertise to customers better than Schwing, when it
comes to concrete pumps.
Customer Training Calendar for the year 2015 at SSI Training Centre, Chennai
Sl
September
August
July
1
Course Code
SSI/Che/38/Batching plant/15
Course Title
Operation and Maintenance of Batching Plant
2
SSI/Che/39/Batching Plant/15
Operation and Maintenance of Batching Plant
3
SSI/Che/40/Con. Pump & TM/15
Operation and Maintenance of Con. pumps & TM
Dates
Products Covered
from
CP30, M1
13.07.15
To
Level
Days
Fees
15.07.15
Basic
3
9000
CP18
16.07.15
17.07.15
Basic
2
6000
BP350, AM6SHN
20.07.15
22.07.15
Basic
3
9000
12000
4
SSI/Che/41/Adv/Batching plant/15
Operation and Maintenance of Batching Plant
CP30, M1
27.07.15
30.07.15
Adv
4
5
SSI/Che/42/Owners Program/15
Prime program on "Know your equipment"
SSI Eqmts
03.08.15
04.08.15
Basic
2
6000
6
SSI/Che/43/Safety/15
"Safety" Program on Schwing Stetter Equipments
Safety
05.08.15
06.08.15
Basic
2
6000
7
SSI/Che/44/Batching plant/15
Operation and Maintenance of Batching Plant
CP30, M1
10.08.15
12.08.15
Basic
3
9000
8
SSI/Che/45/Concrete pump/15
Operation and Maintenance of Concrete pumps
BP350, SP1800
17.08.15
19.08.15
Basic
3
9000
9
SSI/Che/46/Transit mixer/15
Operation and Maintenance of Transit mixer
AM6SHN & SHC
20.08.15
21.08.15
Basic
2
6000
10
SSI/Che/47/Adv/Concrete pump/15
Operation and Maintenance of Concrete pumps
BP350, SP1800
24.08.15
27.08.15
Adv
4
12000
12000
11
SSI/Che/48/Adv/Batching plant/15
Operation and Maintenance of Batching Plant
CP30, M1
01.09.15
04.09.15
Adv
4
12
SSI/Che/49/Boom pump/15
Operation and Maintenance of Boom Pumps
S32, S36
07.09.15
09.09.15
Basic
3
9000
13
SSI/Che/50/Batching plant/15
Operation and Maintenance of Batching Plant
CP18
10.09.15
11.09.15
Basic
2
6000
CP30, M1
14.09.15
16.09.15
Basic
3
9000
TSM 30
21.09.15
22.09.15
Basic
2
6000
BP350, SP1800
23.09.15
26.09.15
Adv
4
12000
14
SSI/Che/51/Batching plant/15
Operation and Maintenance of Batching Plant
15
SSI/Che/52/Shotcrete/15
Operation and Maintenance on Shotcrete machine
16
SSI/Che/53/Adv/Concrete pump/15
Operation and Maintenance of Concrete pumps
Operator Training School, Chennai
2 months Operator course for Batching plant & Concrete Pump
SL
Course Code
Course Title
Commencement Date Completion Date
1
SSI/07/OTS/Pump Oper/Plant Oper/15
Operator Training for Batching Plant / Concrete Pump
06.07.2015
04.09.2015
2
SSI/08/OTS/Pump Oper/Plant Oper/15
Operator Training for Batching Plant / Concrete Pump
10.08.2015
09.10.2015
3
SSI/09/OTS/Pump Oper/Plant Oper/15
Operator Training for Batching Plant / Concrete Pump
07.09.2015
06.11.2015
Come, Learn with Schwing Stetter in the changing Monsoon!
5
Cover Story
Concreting
GREEN Energy
Every developed nation looks up to India; here a windmill was built as
early as 1730 at Horse Tail Point in Cuddalore. Concrete as a material
of construction can play an important role in realising the potential of
wind energy. The trend towards increasing generating capacity of
windmills makes concrete a competitive material. Concrete as
material of construction is durable.
India ranks fifth amongst top ten wind power producers in the world.
As on 31 March 2015,the installed capacity of wind power in India was
23,444 MW, mainly spread across Tamil Nadu (7,253 MW), Gujarat
(3,093 MW), Maharashtra (2,976 MW), Karnataka (2,113 MW),
Rajasthan (2,355 MW), Madhya Pradesh (386 MW), Andhra Pradesh
(916 MW), Kerala (35.1 MW).
reinforcement. The individual tower sections and foundation are
fastened together to form an inseparable unit with stay cables
running through jacket tubes in the core of the concrete tower wall.
Tubular steel tower, Tubular concrete, Lattice tower, Three legged
tower, Guy wired tower, Hybrid tower are the different types of wind
tower.
Out of which, Tamil Nadu continues to maintain No.1 position in the
country in wind power with 42% of total installed capacity in India.
Currently, windmill projects are running in various parts of the
country where Schwing Stetter equipments are in action.
The tower sections are manufactured in a pre-casting plant. The precasted segments of tower sections are prepared by casting concrete
in reusable molds in a controlled environment. Specially constructed
steel moulds assure manufacturing precision for each individual
concrete section. This manufacturing process minimizes dimensional
tolerances, which assures a high degree of fitting accuracy.
Schwing at Windmill Projects
The advantages of pre-stressed concrete towers include stiffness in
case of extreme load capacity, better fatigue properties over steel,
unlike steel tower there is no risk of buckling and lower material cost.
The foundations are circular. The piles, symmetrically arranged, are
slightly inclined so that the imagined extended pile centerlines meet
at a point above the center of the foundation.
Schwing Stetter has always been on the forefront for concreting
Green Energy projects – a place where clean energy is produced with
no emission of hazardous waste and no consumption of fossil fuels.
Wind Energy is the least expensive form of renewable energy.
The company Enercon is a pioneer in the construction of wind power
stations and their integration into the power grid. The focus here is on
considerable higher nominal outputs of generators and thus on
greater heights of rotor hubs. The rated output of the plants has risen
in the last few years from 600 kW to 7,500 kW and the height of the
rotor hubs from 45 m to 136 m. In order to make the foundations fit
for withstanding all the higher static and dynamic loads, their
volumes had to be enlarged accordingly. These heavy - duty
foundations require nowadays up to four times as much concrete as
the foundations 10 years ago.
This provides maximum force/load distribution over the entire
surface. The post-tensioned segmental concrete tower design
consists of a number of arc segments that combine to form circular
sections that are stacked on each other and made to act together in a
monolithic manner by post-tensioned high strength tendons that precompress the concrete so that it is nearly always in compression to
applied loads.
The Towers are made from M55 grade concrete. Schwing Stetter's
batching plants like HN2.25 with Stetter pan mixer and wirvler along
with two discharges are used for precasting the tower and the circular
foundation.
Concreting the Windmill
Concreting is the major work in the windmill tower construction.
Schwing Stetter equipments are used for concreting their windmills
across India. The windmill projects consist of various concrete
structures and types, which are considered to be a very challenging
task. Depending upon the site conditions both in-situ and pre-cast
construction methods have been used for the wind tower
construction.
Windmill towers are constructed using massive amounts of concrete
in which our Schwing Stetter batching plants, truck mounted boom
pumps contributions are enormous. The prolonged service life of
concrete and its ability to cope with increased loading allows possible
retrofitting of turbines after their initial 20 year design life. Therefore,
longevity from the concrete avoids the
financial and environmental costs of
construction.
The Construction work in these projects consists of precast concrete
towers, which are made using specially developed pre-stressed steel
6
Schwing Stetter Projects around the world
India - Algeria Relationship
The important ongoing projects are at
various cities of Oran namely
Moughon, Misserghine, Gdyel and
Bousfer sites along with the landmark
project of City Abdullah University at
Algiers, which is one of the biggest
projects of SPCL in Algeria. Apart from
these projects, Shapoorji has bagged
multiple small projects in the city of
Oran.
The diplomatic relationship between India and
Algeria was established in 1962, the year
Algeria gained independence from colonial
rule.
Since the beginning, the relations
between the two countries have been warm
and cordial. Both countries have been
consistently supporting each other on vital
issues at bilateral and multilateral levels.
Algerian Democratic Republic and
popular ministry of Habitat is
urbanizing and promoting the city
office and real estate management of
the City of Oran through these
multiple projects as seen below
Moughon Project
1300 public rental dwellings at
Moughon
Master of book I - OPGI of Oran
BET load Followed: - MHT Oran
Enterprise - Shapoorji Pallonji & Co ltd
Control Organization: - CTC Quest
Date of completion: - 27 Months
Bousfer Project
500 public rental dwellings at Bousfer
Master of book I - OPGI of Oran
BET load Followed: - MHT Oran
Enterprise - Shapoorji Pallonji & Co ltd
Control Organization: - CTC Quest
Date of completion: - 27 Months
India-Algeria Parliamentary Friendship Group was established in
2008. Two Young Algerian Parliamentarians visited India in March,
2013 under the “Leaders of Future” programme. Hon'ble Mr. Ali
Melaghsou, MP from the ruling party FLN, visited India from 8-15
March, 2014 under this programme.
Gdyel Project
500 public rental dwellings at Gdyel
Master of book I - OPGI of Oran
BET load Followed: - MHT Oran
Enterprise - ShapoorjiPallonji& Co ltd
Control Organization: - CTC Quest
Date of completion: - 27 Months
Shapoorji Pallonji at Algeria
Misserghine Project
1500 public rental dwellings at Gdyel
Master of book I - OPGI of OranBET load Followed: - MHT Oran
Enterprise - Shapoorji Pallonji & Co ltd
Control Organization: - CTC Quest
Date of Completion: - 27 Months
Master of book 1 and BET load are methods and rules followed for
construction as per MHT of Oran.
Shapoorji Pallonji provides contracting services for Residential,
Commercial, Industrial, Healthcare, Hospitality, Institutional, Power
through various contracting and pricing offerings customized based
on customer's expectations. Shapoorji Pallonji has bagged the orders
from Algerian Government for construction of residential buildings as
per details given.
City Abdullah University, Algiers
One of the biggest projects of Shapoorji Pallonji in Algeria, One CP 30
batching plant has been erected and concrete of around 2 lakhs cu. m
is planned. These projects are in its initial stages.
Schwing Equipments Used
7
Machine
Model
Quantity
Boom Pumps
S 43
3 Nos
Boom Pumps
S 36
2 Nos
Batching Plant
CP 30
4 Nos
Transit Mixer
AM10FHC
13 Nos
“We are proud to be a SCHWING customer. With their excellent service support, quality products – we have achieved our concreting target of 1.5 Lakhs well within time.”
- Mr. Rajendra Deore, Director – Shirpur Construction pvt. Ltd, Shirpur, Dhule.
Concreting Achievements
3
616m in 24 hrs using Stetter CP30
75 meter vertical pumping
using SP1200
M/s Ashtech India recently succeeded in
achieving the 75 meter vertical pumping
through our SP 1200 Concrete pump. This
project has 22 floors and is at Nanded City,
Mumbai and the customer is satisfied with
the achievement of Schwing Stetter
Equipments.
The building has a horizontal length of 45
Mtrs and a vertical length of 74 Mtrs.
3
148 m in 7 hrs at 99 mtr VerticalSobha Indraprastha, Bangalore
M/s Ultra Readymix Concrete Pvt. Ltd., Coimbatore achieved a
record by producing 616 M3 of M35 Grade Readymix Concrete in 24
hours & Producing 34 M3 of concrete per hour using Stetter CP30
Batching Plant exceeding its capacity at its Pollachi Plant.
One Lakh Cu.m. of Concrete in 1 year
& 650 Cu.m. of Concrete in 22 hrs
using Stetter CP30
Schwing Stetter equipment’s total amount of concrete produced has
been mentioned above. Sobha Indraprastha, Central Bangalore's
tallest, ritziest residential tower boasts of an infinity pool on the 37th
floor, inspired by the famed infinity pool at Marina Bay Sands,
Singapore. A Sky Lounge at 433 feet height, giving the perfect view of
the city's skyline. It also houses one of the finest retail spaces offering
the best of global brands, right within the premises.
M/s SSM Builders & Promoters achieved a record by producing
“1 Lakh Cubic Meter of concrete in 1 year and a record of 650 Cubic
Meter of Concrete production in 22hrs using Schwing Stetter CP30
Batching Plant in Chennai.
3
506 m in 11 hours at 350 mtr
Horizontal-ITC project, Bangalore
Yes, that's the record of our
Schwing Stetter equipment's M1
and 3 numbers of SP 1800 in the
ITC project constructed by
Larsen & Toubro, Buildings &
Factories. The total concrete
poured in the 18 months
duration is 71880 m3. The
pressure at which our pump is
operated to pump the concrete
i s a t m a x 1 8 0 b a r.
M r. B . R a m a k r i s h n a n , P & M
Manager, L&T, B & F also quoted
that this historical record was
possible only through our
equipment's without any
glitches.
Indraprastha, a super luxury residential address 'Fit for Kings' is all set
to amaze your discerning taste. Set in a sprawling 9.37 acre
landscape with just 40% built-up, Sobha Indraprastha has limited
356 Super Luxury Apartments & Duplex Penthouses, spacious
enough to house your king size living aspirations. The total concrete
poured is 47,000 m3 with grades of M25, M40. The pressure at which
our pump is operated to pump the concrete is at the Max 120 bar
(piston side).
“We are satisfied with the product performance, after sales support and committed team of SCHWING Stetter for the past 8-10 years.They are the one stop solution for concreting machines.”
- Mr. Ganesh Sonawane. HOD- P&M, ABL Infra, Nashik
8
RMC Plant Inauguration
CT News
SLM Road Show
Builders Association of India,
Trichy chapter along with
Schwing Stetter conducted a
road show on our new range of
product, Self-Loading Mixer
4000 with 4 Cu.m capacity. It is a
prototype mixer with great
advantages. The event was
concluded with presentations on
SLM and the concrete industry.
Easy Concrete, Raipur recently
inaugurated the RMC plant, 8year-old CP30 Star Batching
Plant. It has been shifted 6 times
from its commissioning month
since March 2008. Total concrete
poured and produced is 90,000
Cu.m using the plant.
Tech
ROCK VALVE CLEANING PROCEDURE
The cleaning procedure described below has proven tobe the best in
practice.
1. Clean out the pipeline using either water cleaning or sucking out
method.
2. Knock out wedge (pos. 1, fig. 1), remove clamp (pos. 3, fig. 1)
and swing away the pipe bend. (pos. 2,fig. 1)
3. Put the pump in forward, and adjust the stroke limiter to the
lowest possible strokes per minute.
4. Pump the remaining concrete out of the rock housing, then direct
a water Jet into the hopper, as shown in figure 2. The concrete
pump will suck the water and flush the material cylinders.
5. Stop the concrete pump, then open the clean out door (fig3).
Do not open the clean out door while the Concrete Pump is
engaged.
6. Switch the rock back and forth, each time flushing the inside and
outside. Direct the waterjet through the rock valve into the
material cylinders, and continue this procedure until the water
running out is clear and clean. (figure 4)
Attention: Only the water jet is to enter the rock valve opening. Keep
the nozzle, and your hands and arms out of the opening.
For further cleaning details, see the operation manual. By following these instructions, it is possible to thoroughly clean the rock
valve without any additional tools or procedures.
9
New Product
Introduction to
Asphalt
Batch Mix Plant
belt conveyor with a variable frequency drive, called a batching
conveyor attached to it, for discharging the material. So for four
bins we have four separate batching conveyors attached to it. We
have another belt conveyor called gathering conveyor below the
batching conveyor running along the length of cold feeder bin,
which collects the different sized aggregates from each bin via
the batching conveyor. From gathering conveyor the material is
transferred to an inclined conveyor and this inclined conveyor
feeds the material to dryer drum for heating the aggregates. In
this stage no weighing of aggregates takes place.
What is an asphalt mixing plant?
Asphalt mixing plant is an equipment for producing hot mix or asphalt
mix used for laying roads. Asphalt mix have different gradation
depending on the strength. SDBC (Semi Dense Bituminous
Concrete), DBM (Dense Bituminous Macadam), BM (Bituminous
Macadam) and SMA (Stone Mastic Asphalt).
What are the types of asphalt mixing plant?
It is broadly divided into two types namely drum mix plant and batch
mix plant. The major difference between these two are weighing
quantity and quality of mix. In batch type plant, weighing of raw
materials takes place and hence the quality of mix will be good where
as in drum mix plant, weighing of raw materials does not take place
and hence the quality will be low. The output from a batch type plant
is in batches whereas from a drum mix plant it is continuous. Schwing
Stetter focuses on the batch type hot mix plant.
b.
Heating: Aggregates from inclined conveyor is fed to the drying
drum. Drying drum is inclined at an angle to the ground, the
material feeding will be at the higher side of the drum and
heating, discharge of the material will be on the lower side.
Heating is done by a burner which uses LDO (Light Diesel Oil),
diesel and FO (Furnace Oil) as fuel and are stored in tanks, LDO
and diesel are stored in ordinary tanks, but FO is stored in heat
insulated tank and requires preheating. The aggregates are
heated to a temperature of 163oC and discharged to a vertical hot
aggregate elevator (bucket elevator) via a chute. The chute has a
temperature sensor, which continuously senses the temperature
of aggregates and gives feedback to the control panel. The hot
aggregate elevator has hold back arrangement to prevent the
reverse motion in case of sudden power failure.
c.
Weighing: From the bucket elevator, the aggregates are taken
to the top of the batching tower and fed to the vibrator screening
unit, where it is sieved according to the required sizes and get
stored in a hot aggregate storage bin below the vibrating unit.
Hot aggregate bin has 4 different portions for storing different
sizes of aggregates and each portion has individual pneumatic
gates for discharging the aggregates into the weigher. Each bin
has sampling chute and fines bin has temperature sensor. From
the hot aggregate bins, material is discharged to the aggregate
weighing container. Weighing container has 4 load cells for
weighing.
d.
Mixing: From weighing container the aggregates are discharged
to the mixer through a pneumatic gate. The mixer is a twin shaft
pug mill type mixer which has separate drive for each shaft and
has a revolving gate for discharging the hot mix.
What is a hot mix or asphalt mix?
The asphalt mix comprises of aggregates, bitumen and filler (filler
generally will be cement, lime, mineral powder, fly ash) heated and
mixed at definite temperature. As the name indicates the mix will be
o
hot and the temperature is around 150oC to 160 C.
How hot mix is produced in the plant?
There are four processing steps for converting the raw materials in to
a hot mix using an Asphalt batch mix plant, as listed below;
1. Storing
2. Heating
3. Weighing (plus some means to convey from heating to
weighing container)
4. Mixing (mode of discharge into the mixer)
What are the raw materials?
The main raw materials are
1. Aggregate stones – max 40mm
2. Bitumen
3. Filler - Reclaimed filler (or) Cement, lime, fly ash
The Path of aggregates:
Therefore, the asphalt batch mix plant carries out 4 processing steps
for the above raw materials to produce a hot mix.
How each raw material undergo the 4
processing steps?
1. Aggregate stones (max 40mm) :
a.
Storing: Aggregates are stored in a cold bin feeder (like inline
silo for batching plant) based on the sizes. Each bin has separate
10
New Product
manual feeding hopper. Same filler elevator is used for filling both
new filler and reclaimed filler. The filler elevator has two
discharge chutes.
b. Heating: No heating is done for the new filler material.
c.
Weighing: The new filler is discharged from the new filler bin to
the weigher by a screw conveyor. Same filler weigher is used for
weighing and discharging of both new filler and reclaimed filler.
Note: We have two storage bins each for new filler and reclaimed
filler, but only one weigher for weighing both and only one screw
conveyor for discharging the weighed filler into the mixer.
What happens to the Raw materials after
weighing?
All the raw materials (aggregates, bitumen and filler) after weighing
enters the mixer, the mixer is a twin shaft type mixer with replaceable
wear liners and wear resistant mixing arms. The materials after
mixing are discharged through pneumatic gates.
2. Bitumen
a. Storing: Bitumen is stored in horizontal, circular, heat insulated
tanks on the ground and provided with temperature and level
gauges. While storing CRMB (Crumb Rubber Modified Bitumen)
type of bitumen, the tank shall have a stirrer arrangement on top,
each tank will have two stirrers. Stirrer is an electric motor
coupled with paddle. Heating of bitumen is done by thermic fluid
(indirect heating).
What happens to the produced hot mix?
The hot mix can either be taken to the project site by a tipper or can
be stored in the site.
How to store the hot mix?
b. Heating: Bitumen is heated indirectly. Each bitumen tank has
coils (layers of metal tubes) at the bottom through which the
thermic fluid is circulated by a pump. Heat from thermic fluid will
transfer to the bitumen. For heating the thermic fluid we have a
unit called thermic fluid heater. Thermic fluid heater has a
separate burner which uses diesel, LDO as fuel. The user can set
the temperature in the dedicated control panel available with the
unit. The circulation of thermic fluid is a closed loop system.
c.
When we store the hot mix we have two options, one is storing in the
bottom mounted finished storage bin or using a separate storage silo.
Bottom mounted finished storage bin: The bin of capacity 36 m3
will be located under the mixer unit. And there will be a trolley
running in between the finished storage bin and mixer for collecting
the hot mix from mixer and filling it in the storage bin. The bins have
electrical coils for heat insulation. The finished storage bin has three
partitions with the middle portion for discharging the waste materials
and other two for storing hot mix. By using this type of storage
options the plant height increases by 5m.
Weighing: The hot bitumen is pumped from ground to the
weighing container located near mixer unit. Pipe line carrying
bitumen from tank to weigher is twin walled or co-axial tubes
(inner tube will have the bitumen flow and outer tube will have
the thermic fluid). The weighing container has 3 load cells and
heat insulated by means of electrical coils and mineral wool.
Separate storage silo: Here we have a silo away from the plant and
we use a skip and track mechanism to store the hot mix. The silo will
be provided with proper heat insulation. And the truck gets the hot
mix from this silo only.
d. Mixing: The discharge of bitumen from weigher to the mixer is a
forced type, which means we use a pump located near the
weighing container to discharge the bitumen to mixer. Inside the
mixer we have spray bar (pipe with holes) located on top of
mixing arms through which the bitumen is sprayed inside the
mixer.
Process Flow of an Asphalt Batch Mix Plant
Note: Thermic fluid circulation is a closed loop system which heats
the bitumen, jackets the bitumen pipe line and even the bitumen
pumps for maintaining the temperature and fluidity of bitumen.
3. Filler (Cement, fly ash, lime)
The filler material is of two types namely the reclaimed filler (the dust
particles collected from the plant by using the dust collection system)
and new filler.
Reclaimed filler (Filler collected in the bag filter system):
a. Storing: The filler collected at the bottom of bag house system is
transferred to the filler elevator (bucket elevator with hold back
arrangement) via screw conveyor. The filler elevator then takes
the filler vertically above to the filler storage bin of capacity 9m3
located near the vibrating unit on top of the batching tower.
b. Heating: No heating is done for the filler material.
c.
Weighing: Filler from storage bin discharges to the weighing
container by a screw conveyor. The weighing container has 3 load
cells.
d. Mixing: Filler from the weighing unit is discharged to the mixer
by a screw conveyor.
New filler:
a. Storing: The new filler storage container is of 9m3 capacity and
shares a common partition with the reclaimed filler bin. Feeding
this new filler bin has two options like one is we can
pneumatically load it from the bunker and second is by using a
11
The Last Word
Dear Customers,
Greetings to all “Concreting Times” Readers.
It's a great pleasure to meet you again through “Concreting Times” 12th Edition. In this issue, the progress of Agra-Lucknow Expressway, where
Schwing Stetter have supplied many Pumps, Plants and Truck Mixers for speeding the construction, reminds earlier implemented Noida-AgraYamuna Expressways where our Machines have demonstrated record breaking concrete production.
We have brought some of our record breaking performance in our Plants and Pumps under “Achievements” section in this issue. These
achievements, prove that the Customers are becoming increasingly aware of extracting maximum output from our Machines. These Machines are
built to perform that way. The confidence in our machine is demonstrated further with Easy Concrete, a new RMC Player in Raipur who have
installed an 8 year old Plant to start a new RMC Business where the equipment is expected to perform 24x7 trouble-free.
In line with our series of New Product Launches, we are pleased to bring you “Asphalt Batch Mix Plant”. Our earlier launch of
Stetter Self-Loading Mixer has done extremely well during the field tests and we are pleased to inform that these machines are
available now for the Market with ARAI approval.
We are also pleased to inform the beginning of Tower Crane Production and Assembly in India. SCHWING Stetter India
Customer Training Calendar covering the Training programs for Monsoon period (the idle time of training) are available in Page
5 of this issue.
We hope this Monsoon, brings good fortune to Agriculture and Economy.
Happy reading!!!
With best regards,
V.G. Sakthi Kumar
Managing Director - SSSSPL
sakthikumar.vg@schwingstetterindia.com
For any feedback regarding this newsletter, email at editor.ct@schwingstetterindia.com
Think concrete
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Published by Schwing Stetter India in Chennai. All Correspondence to be sent to editor.ct@schwingstetterindia.com
Designed and Printed by A.L. Senthil Kumar :: For private circulation only, not for sale.
Many more to come...
June 2015