Batching plants for precast

Transcription

1 Batching plants for precast

2 The background 02 The company 04 Horizontal batching plants 06 Vertical batching plants 06 Control systems 18 Pan mixers 22 Overhead concrete distribution 26 Accessories 30 Installations 32

3 Forty years of tradition and innovation at the service of the building industry Over 40 years of experience and know-how in the field of concrete mixing and batching plants have made Le ORU Officine Riunite - Udine S.p.A. a leader with a name known and appreciated all over the world. As Batching Plants Division of the IMER Group, ORU confirms its presence on the market as an important industrial complex, capable of expressing a high level of strategic and industrial synergy. As successful partner for its professionalism and experience in the design, production and sale of concrete batching plants, ORU is dedicated to the development of innovative modern solutions capable of meeting the different requirements of the market. The vast range of products offered for the production of quality concrete includes horizontal and vertical batching plants for prefabricated elements; horizontal and vertical batching plants for truck mixers; overhead concrete distribution systems; planetary pan mixers and twin-shaft mixers; batching plants with radius lift arms. The background The company Horizontal batching plants Vertical batching plants Control systems Pan mixers Overhead concrete distribution Accessories Installations 02

4 Design, service and respect for the environment The design of the batching plants and equipment, tailored to the requirements of individual building yards, prefabrication plants and concrete sale facilities, is the brainchild of the efficient and flexible organization of the ORU engineering department. The rigidly selected staff, its constant dedication to quality, the continuous technological innovations and the application of rigid controls have enabled the company to reach high levels of performance and enabled it, in 1996, to obtain the ISO 9001 certification. ORU s service department, through the experience, responsibility and competence of its personnel and its dense network of service centres, makes it possible to promptly meet the different requirements of individual customers. Over 22,000 customers worldwide have shown their preference for ORU products and have been able to verify the quality and reliability of the company s design and service departments. In addition, with a constant concern for the requirements of the environment and the ecological aspect of its products, ORU designs and builds certified concrete batching plants and equipment with noise and dust emission levels below the limits required by the relative standards. The background The company Horizontal batching plants Vertical batching plants Control systems Pan mixers Overhead concrete distribution Accessories Installations 05

5 Horizontal batching plant for precast facilities The ORU horizontal batching plants are designed and built for long operation even in extreme working conditions, a standard prerogative of every ORU product. Particular design features make these machines easy to install, safe to operate and low in their maintenance requirements. The standardization of some elements common to all versions, the modular construction, the different equipment combinations, and the vast range of accessories make it possible to increase the versatility of the batching plant, thus making it the ideal solution for any concrete batching requirement. To respond to the many requirements of building yards of different types (for clearances, dimensions, etc.), ORU proposes an accurate study capable of resolving the most diverse problems: from the installation of the batching plant to the delivery of the concrete (distribution, etc.), to the process of automation and prearrangement of the safety equipment, in compliance with applicable legislation The background The company Horizontal batching plants Vertical batching plants Control systems Pan mixers Overhead concrete distribution Accessories Installations 06

6 Modular construction and hot galvanizing To simplify construction and handling, and cut down delivery times, ORU has standardized some elements that are common to all versions. These elements include walls, extension walls and partitions, aggregate hoppers, the weighing conveyor belt frame, and the frame of the hopper with two discharge gates. The support structure and the aggregate storage bins are hot galvanized. This type of surface treatment of the metal ensures an excellent protection against corrosion in any environmental condition, and therefore a longer life and better inalterability of the product. On request, the equipment can also be provided with paint coating over the galvanized surfaces. Aggregate storage and covers The dimensions of the compartments are such as to allow a considerable filling capacity, and the modularity of the hoppers simplifies their installation. The aggregate storage bin charging system is made to meet the specific requirements of each building yard. Weighing The aggregate and cement weighing system uses load cells applied directly to the supports of the respective hoppers, thus achieving an accurate and reliable weight measurement. The weighing system with load cells is type approved according to CE standards

7 Opening with limit switches The aggregate is fed from the hoppers through electro-pneumatic discharge gates, with double speed in the closing phase. On request, the discharge systems can be of different type (by belt conveyor, by vibrating conveyors, etc.) and tailored to the requirements of the customer. When the aggregate is discharged through electropneumatic gates, the use of an adjustable mechanical limit switch controlling the opening of the discharge gate guarantees greater batching accuracy. Vibrator To facilitate the discharge of particularly cohesive materials, vibrators have been installed on independent plates applied with a particular system to avoid negative stresses to the plant structure. Vibrating extractor The vibrating extractors are machines consisting of a springsupported steel-plate conduit used to discharge the aggregate through the movement generated by electromechanical or electromagnetic vibrators. The machines are suitable for discharging aggregate of any grain size. The distinctive characteristics are metering precision, low noise, and practically maintenance-free operation. Extracting conveyor belt When high metering accuracy is necessary in feeding materials such as sand or crushed stone, the use of the extracting conveyor belt is a sure solution to the problem. The machine is equipped with a device signalling the presence of material, a flow regulator, and a manual cut-off gate for routine maintenance

8 Elevator The vertical bucket elevators are endless drag conveyors used to feed the aggregate storage units. Their use is essential when tight spaces do not allow the installation of conveyor belts. Conveyor belt The conveyor belts are used to carry aggregate materials. They can be installed in a horizontal or inclined position, depending on the height to reach. The equipment provided includes charging and discharge funnels and safety guards. The application of tailor-made safety guards allows an absolutely safe access to every component of the batching plant. Safety-cord limit switch Safety device with manual reset switch

9 Oru precast batching plants Description of equipment 1. TP27 aggregate feeding hopper 2. Auxiliary conveyor belt m 50x0,65 3. Translating and reversible conveyor belt 4. Storage group 5. Aggregate weighing hopper 6. Aggregate weighing conveyor belt 7. Skip mod. 2250/ ORU MS 2250/1500S planetary mixer 9. Cement weighing hopper of 600 l of capacity 10. Cement silo 11. Dust remover 12. Additive unit with impulse metre 13. Screw feeder 8400x Screw feeder 11500x Concrete conveyor belt m 9,6x0,7 16. Concrete conveyor belt 17. Control panel 18. Computer CS90-20P 19. Control cabin 20. Compressor unit 21. Control panels 14 15

10 Vertical batching plants for precast facilities In accordance with the general philosophy underlying ORU s commercial policy, the vertical batching plants for prefabrication operations are designed to provide an answer to specific requirements. The choice of a vertical batching plant presupposes a greater output compared to a horizontal plant and offers an excellent possibility of controlling noise and dust emissions. The vertical system requires in fact the material to be raised, but thereafter the whole process takes place in a closed environment and by gravity, with distinct advantages in terms of energy economy, less wear, and contained external noise levels. The combination of the most modern technologies and of trained personnel makes it possible to obtain a system capable of reconciling productivity and quality of the product and of best meeting operating demands

11 Control systems CS 90 Based on a new control philosophy, the CS 90 is a complex software system that can be integrated with easily accessed commercial software whose architecture, based on the WINDOWS NT operating system, is entirely designed, developed and updated by ORU. The application of a highly specialized staff, with direct building-yard experience and a thorough understanding of the related problems, enables ORU to offer a product of considerable potential and with characteristics that are always tailored to the specific requirements of the customer. Special requests and product types are not, in fact, a problem for the CS 90 which, to better adapt to the different production realities, is available in three configurations: CS 90 - V for batching plants used for the sale of concrete; CS 90 - P for plants used in the prefabrication and/or production of precast products; CS 90 - M for plants used for both the sale of concrete and for prefabrication. These configurations are perfectly compatible with each other and, in case of an enlargement or alteration of the batching plant, they can be easily integrated with the different functions, with obvious economic advantages. With the CS 90 it is also possible to provide for the control of other sections of the batching plant, the customer s own equipment, or even different batching plants. Thus, it is possible to manage the production process and exchange data with the customer s own computer systems. Each CS 90 configuration is supplied in the most suitable language for the user, who can thus operate in the condition of maximum productivity right from the start

12 Control systems CS 90 Control systems IU Main performance features and characteristics - WINDOWS NT / 2000 Operating System - Dynamic synoptic panels with indication of the different active functions - Any number of components, depending on the configuration of the plant - Management of archives for the sale of concrete and/or prefabrication: batching recipes, work orders, customers, building yards, vehicles, drivers, transportation documents, surcharges, manufactured products and batching - Management of production orders with optimization and rationalization of concrete distribution - Automatic or manual moisture compensation (simultaneously or in advance) - Use of different types of moisture detection probes - Control of mixture directly in the pan mixer (consistence, moisture, water/cement ratio) through the interfacing with hygrometers in the pan mixer - Weighing algorithm with control of free-fall learning and dispensing of each component to obtain the required batching accuracy - Batching tolerance test - Zero test and automatic tare determination for the weighing units - Stock of material on hand and consumption of batching plant with possibility of automatic and manual control - Printing of transportation documents in compliance with the legal provisions of different countries - Selective printing of all stored information and production statistics - Alarm messages for all the functions of the batching plant - Modification of parameters through keyboard and mouse - Possibility of data protection through password - Handling of production orders coming from other systems * - Connection with business computer for automatic invoicing and accounting * - Connection through modem with remote assistance * The IU programmable logic unit is the ideal means to automate the operation of the concrete batching plants for prefabrication facilities or for sale. The pan mixer charging sequence can be completely configured so as to allow the addition of various components according to their physical-chemical behaviour to obtain a homogeneous mixture. The system is prearranged for the automatic moisture detection through hygrometric probes placed inside the aggregate hoppers. Compensation involves the automatic increase of the quantity of aggregate corresponding to the moisture content in the aggregate and the consequent subtraction of the water metered out. The characteristics of each batching component (slow-down preset, free-fall learning, discharge time, upper-lower tolerance) can be completely configured from the relative menu. The operator can decide the batching sequence of each aggregate and each cement; he can set up to 3 work orders and 100 recipes (setting of quantities of components to batch, the number of cycles and relative fractions to make, mixing times and batching priorities); and he can suspend or restart, or cancel, all the activities in progress on the batching plant, all at the same time or one by one. *Optional 20 21

13 ORU MS pan mixers The ORU MS planetary pan mixer with vertical shafts and coaxial motor allows the rapid mixing of all types of quality concrete: dry, semi-dry and plastic. The ORU MS, born of a intensive and systematic study of the problems inherent in the mixing of materials of different grain sizes, shape, consistency and specific weight, is an extremely sturdy and reliable machine. The MS is characterized by the high quality and uniformity of the materials, the possibility of achieving any type of mix design, the mixing speed, the wide range of products and the various solutions and combinations of wear-resistant lining. The epicyclic reduction unit The epicyclic reduction unit rotates on a large disk gear that ensures a low-noise rotation without backlash even under severe working conditions. The mechanism is contained in a single cast-iron gearcase, and all the gears work in an oil bath. The large diameter of the gearcase allows the oil level to be lowered without compromising the excellent operation of the machine. The mixing pan is made of thick steel plate. On request, the wear-resistant lining of the mixing pan is available in different types of materials to suit specific customer requirements. The bottom and wall lining of the mixing pan are made up of interchangeable sectors. The bottom and wall plates are made of Hardox steel in the standard version or, optionally, they are made of cast iron or sintered hard metal. The scraping and mixing blades can be made of cast iron or, on request, elastomers, or they may be tipped with widia. The angles of incidence and the profiles of all the blades are carefully studied to draw the best advantage from the power available and to achieve the shortest possible mixing and discharge times. The whirling and rotation speeds of the blades have been extensively studied and tested to give the ORU MS a high output without causing the segregation of materials of different grain size and weight. The movement of the material inside the mixing pan is smooth, progressive and continuous

14 ORU MS pan mixers: The Skip ORU MB mixers The pan mixers can be charged by means of a conveyor belt or a skip. The skip, available in two different upward/downward speed versions, consists of a double-wound drum which, thanks to its large size, allows a high peripheral speed with a low power input. The skip has a truncated pyramid shape and is equipped with a gravity discharge gate supported by two sturdy bearings. The skip moves between rails on 6 special steel wheels, thus guaranteeing excellent stability of the skip in motion. Mechanical and electrical devices prevent the fall of the skip even in case of breakage of the lifting cable. This, together with the other safety devices on the equipment, guarantees a high degree of safety. On request, the skip can be provided with antiwear lining. The ORU MB, the ideal mixer for the preparation of various types of concrete, is provided with two horizontal counter-rotating mixing shafts with a turning motion synchronized with each other. Moreover, the particular configuration of the mixing devices makes it possible to use coarse aggregates (with grain sizes >150 mm). The blades are made of special hardened and tempered steel (on request, of cast iron) and installed on mixing arms, which are also made of steel and have a profile designed to enhance their strength and shorten mixing times. The angle of inclination of the blades and arms imparts a counter-rotating, partially overlapping, spiral movement on the mixture, so as to obtain a complete forced mixing, both horizontally and vertically. This avoids problems of centrifugal separation or flotation of the lighter materials. The pan is lined with small bolted and interchangeable elements of special wear-resistant steel (on request, they can be made of hardened and tempered steel or cast iron). Technical characteristics Model ORU MS Mixing pan dimensions/mm Fresh concrete/litres x x x x x S 2.0x x Model ORU MB Technical characteristics Loading capacity/litres Compacted concrete/litres/kg 330/ / / / / / /4.800 Fresh concrete/litres Average time per cycle/sec Compacted concrete/litres Stars and mixing blades/number 1x2 1x2 1x3 2x2 2x2 2x2 2x2 Average time per cycle/sec. Scraping blades/number Mixing blades/number Gear train/rpm ,7 12,4 10,4 12,4 10,4 Pan motor/kw 18,5 22 2x18,5 2x22 2x30 2x37 2x45 2x55 2x Star/rpm , , ,4 Hyd. unit power supply/kw 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5 Mixer power supply/kw 15 18, Max. aggregate grain size/mm Hyd. unit power supply/kw 2,2 2, Weight (without skip)/kg

15 Overhead concrete distribution The ORU overhead concrete transportation system is the outcome of an engineering effort aimed at achieving maximum functionality and safety. The choice of the ORU concrete distribution system enables the prefabrication operator to draw the greatest advantage from the production capacities of his plant and, at the same time, to achieve a significant reduction of the labour and costs involved in the transportation of the concrete. The ORU transportation system makes it possible to maintain intact the characteristics of the concrete up to the casting phase. Each phase of operation takes place in full compliance with applicable safety standards. VARIABLE SPEED HYDRAULIC TRANSLATION The overhead skip is provided with a variable delivery hydraulic system. This system makes it possible to vary the maximum speeds, the speed on a curve or an incline, the approach speed, and the hopper rotation speed, based on the actual operating conditions. MAXIMUM COMPACTNESS The shape of the hopper makes it possible to carry all types of concrete without any wasted space. The compact length and height of the skip also favour the use of the overhead travelling skip in existing plants. Twin-rail overhead skip with discharge and rotation The discharge with rotating skip is particularly suitable for fluid concrete, as this type of hopper guarantees maximum tightness, and the discharge system is particularly versatile. The skip can rotate to the right or left and can be stopped at any angle. This type of rotation allows a thorough washing of the hopper. Twin valve The discharge with a twin-valve hopper is particularly suitable for semi-dry and, especially, dry concrete. With this type of hopper it is possible to supply paired hoppers. Monorail For long travelling distances, with many curves, in the presence of more or less sharp grades and switching points, the monorail version is more suitable

16 Thanks to a PLC-controlled electro-hydraulic system, it is possible to guarantee a complete control of all the parameters of the overhead travelling skip. The software allows an independent operation of the unit and its complete control through the power bus-bar. Washing and maintenance station The automatic washing equipment for the overhead skip consists of a pumping unit with a 1000-litre tank, a washing head with mobile jet, a collecting funnel with discharge, electrical system, timers, tubes, fittings and accessories. Technical characteristics Model ORU FLY Hopper capacity/litres Hopper capacity/kg Driving wheels 2 m/sec/n Driving wheels 3 m/sec/n Power 2 m/sec/kw ,5 Power 3 m/sec/kw 15 18,5 22 Weight/kg IDC average bending radius/mm IMC average bending radius/mm Dimensions in mm Model ORU FLY A B C D E F G H I L The ORU overhead transportation system is generally provided with a casting crane that can be of bridge type, or of semi-portal or portal type, with operator on board and with automation features depending on the specific requirements of every customer. The bucket moving in any direction makes it possible to distribute the concrete in formworks of different shapes and sizes without the need of additional lifting or transportation means. On specific request, the bucket discharge system can be of different types: twin-valve, with rotating chutes, with wider mouths for discharging on extruders, with rotary hopper for discharging the concrete in a longitudinal or transversal direction. ORU can in any case supply special casting cranes to suit the requirements of the customer

17 Accessories Automatic volumetric additive system (ADV) The system consists of: - Motor gear pump of 7.5 l/min capacity kw - Graduated cylinder - Electric control panel - Outflow tube - Inflow tube The quantity to meter is determined by the position of the proximity sensor (adjustable on graduated rod). The cylinder batching and emptying phases are carried out automatically in relation to the batching plant production cycle. Color mix Technological solutions for the color mix. Timed automatic additive system (ADT). The system consists of: - Motor gear pump of 7.5 l/min capacity kw - Electric control panel - Flow meter - Outflow tube - Inflow tube The additive is metered by means of a timer that starts and stops the pump according to the amount of additive required. The system is provided with a flow meter, which stops the pump in case of lack of liquid in the circuit.the delivery of the pump can be adjusted to a proper volume/time ratio. The operation of the equipment is linked to the automatic production cycle of the batching plant. Additive and colour weighing hoppers The system includes metering equipment for both additives and colours in liquid or powder form. Moisture control for aggregate and mixture Resistive or microwave hygrometric instruments interfaced with ORU control units are available to control the moisture in the aggregate as well as in the mixture in the pan. The concrete separator (supplied on request) is an essential item of equipment for recovering the aggregate and washing water from the truck mixers and mixers. The separator puts an end to the problem of formation of concrete stockpiles in the building yard and of free discharge of the water, thus avoiding negative ecological impacts on the environment. Dust suction Ecological systems for smoke and dust abatement in the mixing area

18 References Le Officine Riunite - Udine S.p.A. Concrete Machinery Division Via Santa Caterina, Basaldella di Campoformido (UD) Italy tel fax oru@oru.it - Sales Department Piero Forasassi: Sales Manager Export Michele Sebastiani: area manger Stefano Rodaro: Foreign Sales Department Adele Bianco: Foreign Sales Department Cristina Bianchi: Foreign Sales Department Grillo Helga: Foreign Sales Department Italy Alfonso Sciandra: Area Manager Paolo Berton: Area Manager Massimo Grosso: Area Manager Gianna Pizzutti: Italian Sales Department Pierpaolo Turri: Italian Sales Department Sales processing Valdino Bassi Order Processing - Shipping Nerina Montico Marketing Loredana Viel Operations Manager Luciano Pennati Project Department Nicola Da Riol Project Manager Denis Pitton Spare Parts & Service Department Lorenzo Maestroni: Manager of Spare Parts & Service Department Malvio Leita:Spare Parts & Service Department Alessandro Marchetti: Spare Parts & Service Department Andrea Carta: Spare Parts & Service Department Mario Cristin: Spare Parts & Service Department Administrative Office Gianfranco Lorenzut: Administration Management Mariolina Murianni: Administrative office Susanna Tondolo: Administrative office Le Officine Riunite - Udine S.p.A. reserve the right to change the information contained herein without prior notice when they consider it justified. The data and dimensions are 32 therefore not to be considered as binding. The illustrations may include accessories and therefore they could be slightly different from the standard versions of the equipment.

19 Mod ed. 1/2005 Le Officine Riunite - Udine S.p.A. Concrete Machinery Division Via Santa Caterina, Basaldella di Campoformido (UD) Italy tel fax oru@oru.it - n IT02/0429 c