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1 Follow us on Project in Progress Concreting Achievements Notable Projects New Product Go Green Projects Go Green Projects Schwing Stetter in Schwing Stetter in Volume : 4 Issue : 12 Q2 2015 3 2 8 10

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Page 1: Project in Progress Notable Projects Concreting Achievements New · PDF file · 2016-12-22Project in Progress Notable Projects Concreting Achievements New Product ... This Expressway

1

Follow us on

Project in Progress Concreting AchievementsNotable Projects New Product

Go Green ProjectsGo Green Projects Schwing Stetter in Schwing Stetter in

Volume : 4

Issue : 12

Q2 2015

32 8 10

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2

Projects in Progress

All the best,

Vice Chairman & Managing Director - SSI

VC & MD’s Message

Machine Model Quantity

Batching Plant CP 30 2 Nos

Concrete Pump BP 350 2 Nos

Transit Mixer AM 6 7 Nos

Shotcrete Machine TSM 30.14 2 Nos

Agra - Lucknow Expressway - India’s Longest - 302KMsThis 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.

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 [email protected].

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.

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.

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Notable Projects

3

Cloud Kisser of The EastChristened ‘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.

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.

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

CP 30

SPB 32

SP 3000 D

Quantity

1

1

1

Unity Group - Residential ProjectThe 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.

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 332,499 M and Schwing Stetter team has

3produced 20,175.5 M so far.

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 3monthly is approx. 2000M .

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Customer Interview

Mr. Kalpesh Panchal - Managing director, Mr. Chirag Patel - Managing director, Mr. Ravi Prajapati - Managing director

About Customer

Landmark Projects

Schwing Equipments

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.

Adani Township- Ahmedabad

Metro Rail Project - Gandhinagar

Central Vista – R & B Department, Gandhinagar

Mukhya Mantri Avas Yojana – Sabarmati & Ambavadi

Gala Eternia & Gala Empire - Ahmedabad

Batching Plant – CP 30 - 1 No

Concrete pumps – SP 1400- 2 Nos

Transit mixers – 6 Nos

An Interview with Shashvat Infrastructure Private Limited

4

Why Schwing Stetter India?

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.

An Interview with Adani Corporate House, Shantigram

About Customer

Landmark Projects

Shantigram, developed by the Adani Group, is Gujarat's largest integrated township spread over more than 600 acres, where state-of-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.

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.

Why Schwing Stetter India?

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.

Mr.Debabrata Chakrabarty - Project Manager- Adani Corporate House, Mr. Kailash Chandra Kalapahad - Cluster Plant Manager- Ahmedabad-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

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Hottest in Concrete Pumping

SP 3000SP 3000SP 3000

ON THE HORIZON 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.

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.

The list of some of the challenges SP 3000 involved in are,

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.

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,

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.

An uncompetable pump in its segment.

SP 1800SP 1800SP 1800A LIMITLESS POSSIBILITY A LIMITLESS POSSIBILITY a

Customer Training Calendar for the year 2015 at SSI Training Centre, Chennai

July

Aug

ust

Sep

tem

ber

Sl Course Code Course Title Products Covered from To Level Days Fees

1 SSI/Che/38/Batching plant/15 Operation and Maintenance of Batching Plant CP30, M1 13.07.15 15.07.15 Basic 3 9000

2 SSI/Che/39/Batching Plant/15 Operation and Maintenance of Batching Plant CP18 16.07.15 17.07.15 Basic 2 6000

3 SSI/Che/40/Con. Pump & TM/15 Operation and Maintenance of Con. pumps & TM BP350, AM6SHN 20.07.15 22.07.15 Basic 3 9000

4 SSI/Che/41/Adv/Batching plant/15 Operation and Maintenance of Batching Plant CP30, M1 27.07.15 30.07.15 Adv 4 12000

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

11 SSI/Che/48/Adv/Batching plant/15 Operation and Maintenance of Batching Plant CP30, M1 01.09.15 04.09.15 Adv 4 12000

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

14 SSI/Che/51/Batching plant/15 Operation and Maintenance of Batching Plant CP30, M1 14.09.15 16.09.15 Basic 3 9000

15 SSI/Che/52/Shotcrete/15 Operation and Maintenance on Shotcrete machine TSM 30 21.09.15 22.09.15 Basic 2 6000

16 SSI/Che/53/Adv/Concrete pump/15 Operation and Maintenance of Concrete pumps BP350, SP1800 23.09.15 26.09.15 Adv 4 12000

Dates

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!

NEW STARNEW STAR

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Cover Story

ConcretingGREEN EnergyConcretingGREEN 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).

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.

Schwing at Windmill ProjectsSchwing 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.

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.

The Construction work in these projects consists of precast concrete towers, which are made using specially developed pre-stressed steel

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.

The tower sections are manufactured in a pre-casting plant. The pre-casted 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.

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.

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 pre-compress 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.

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.

Concreting the Windmill

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7

Schwing Stetter Projects around the world

India - Algeria RelationshipThe 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.

Shapoorji Pallonji at Algeria

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.

Machine Model Quantity

Boom Pumps S 43 3 Nos

Batching Plant CP 30 4 Nos

Transit Mixer AM10FHC 13 Nos

Boom Pumps S 36 2 Nos

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.

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

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

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.

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

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.

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Concreting Achievements3

616m in 24 hrs using Stetter CP30

M/s Ultra Readymix Concrete Pvt. Ltd., Coimbatore achieved a 3record by producing 616 M of M35 Grade Readymix Concrete in 24

3hours & Producing 34 M 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 CP30M/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.

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.

3506 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

3duration is 71880 m . 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 . Mr.B.Ramakr i shnan, P&M Manager, L&T, B & F also quoted that this historical record was possible only through our equipment's without any glitches.

3148 m in 7 hrs at 99 mtr Vertical- Sobha Indraprastha, BangaloreSchwing 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.

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 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.

“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

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9

RMC Plant Inauguration

Easy Concrete, Raipur recently inaugurated the RMC plant, 8-year-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.

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.

TechROCK 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)

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.

Attention: Only the water jet is to enter the rock valve opening. Keep the nozzle, and your hands and arms out of the opening.

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10

New Product

PIPELINE & PLACING TECHNOLOGY - A Virgin Technology Increases the efficiency of the concrete pumps up to 40%

ENERGY TRANSFORMATION:

Energy is generated by engine, rotational energy (RPM) is converted to hydraulic energy (LPM) and hydraulic energy (LPM) is converted to mechanical (Pumping strokes). This mechanical energy is applied on the concrete, when all the available energy is applied only on the concrete, we derive maximum benefit. The movement or jerk in the pipeline, movement on the bends is a simple demonstration of energy being lost in such places.

Earlier concrete pumping technology was limited to Concrete Pumps, its power rating, pressure, flow, circuit and one had limited understanding and control over the concrete once it leave the concrete pump. Typically, to convey the impact, let us say SP 1400 can pump 100 meter vertically, with the understanding of pipeline technology, we can use the same pump even up to 140 meters, an increase in 40% of efficiency of the concrete pump with the mere understating of pipeline and placing technology. Meaning, we do not need a bigger capacity pump unless it is truly required.

Schwing Stetter, being a predecessor in providing world class pumping solutions has developed a great understanding with the huge experience it has had in handling complex applications.

Concrete pipeline layout • Simulation of pipeline laying

• Rational technical planning of

pipeline layout

• Minimizing no. of bends

• Accessibility to pipeline

Pipeline Support systems • Concrete made thrust blocks of various

sizes depending on concrete pressure

• Concrete cover blocks for bends both

horizontal and vertical

Pipeline Clamping systems • U-clamps

• Angle supports

• Channel supports

• Strip supports

Cleaning • Zero concrete wastage

• Three types of cleaning

[Air, Water, Air+water]

• Water cleaning with hydraulic system

Pipeline • Thickness depending upon

concrete pressure

• Frequent ultrasonic thickness check

• Special designed long and

shirt radius bends Concrete pipeline Layout

Simulation of pipeline laying

What are the attributes of pipeline technology?

Rational Technical Planning of pipeline layout Accessibility to pipeline

Pipe line Support systems

Concrete made

thrust blocks of

various sizes

depending on

concrete

pressure

Concrete blocks

for bends

Horizontal

Introduction to Introduction to

Asphalt Asphalt Asphalt Batch Mix PlantBatch Mix PlantBatch Mix Plant

What is an asphalt mixing plant?

What are the types of asphalt mixing plant?

What is a hot mix or asphalt mix?

How hot mix is produced in the plant?

What are the raw materials?

How each raw material undergo the 4 processing steps?

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).

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.

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

ohot and the temperature is around 150 C to 160 C.

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)

The main raw materials are

1. Aggregate stones – max 40mm

2. Bitumen

3. Filler - Reclaimed filler (or) Cement, lime, fly ash

Therefore, the asphalt batch mix plant carries out 4 processing steps for the above raw materials to produce a hot mix.

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

o

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.

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

oheated to a temperature of 163 C 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.

The Path of aggregates:

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11

Designing Truck Mixers for Evolving New Trends Designing Truck Mixers for Evolving New Trends

Pipe line Clamping systems

U- Clamps- Angle supports

Channel Supports Strip Supports Cleaning

Zero Concrete Wastage Water cleaning with hydraulic system

Pipe line

Thickness depending upon concrete pressure

Frequent ultrasonic thickness check Special long and short radius bends

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).

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. 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.

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.

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

3the filler vertically above to the filler storage bin of capacity 9m 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:

3a. Storing: The new filler storage container is of 9m 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

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.

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.

The hot mix can either be taken to the project site by a tipper or can be stored in the site.

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.

3Bottom mounted finished storage bin: The bin of capacity 36 m 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.

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.

What happens to the Raw materials after weighing?

What happens to the produced hot mix?

How to store the hot mix?

Process Flow of an Asphalt Batch Mix Plant

New Product

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F 71 - 72, SIPCOT Industrial Park, Irungattukottai, Sriperumpudur Taluk, Kancheepuram District,Tamil Nadu - 602105.

Phone : 044 2715 6780 / 781, 47108100 / 33555588 Fax : 044 27156539 Visit us at www.schwingstetterindia.com

MUMBAI NEW DELHI

HYDERABAD BANGALORE

KOLKATA COCHIN AHMEDABAD

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022 25624863 / 64, 30718300 / 33555588 011 3092 8500 / 33555588

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June 2015Published by Schwing Stetter India in Chennai. All Correspondence to be sent to [email protected]

Designed and Printed by A.L. Senthil Kumar :: For private circulation only, not for sale.

ISO 9001:2008 OHSAS 18001: 2007 :: ISO 14001:2004 ::

The Last WordDear 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-Agra-Yamuna 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,

Managing Director - SSSSPL

[email protected]

V.G. Sakthi Kumar

For any feedback regarding this newsletter, email at [email protected]

Think concrete

Think Schwing Stetter

SP 1800 S 36

37m

CP 18

CP 30M1.25

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