Design efficiency of concrete equipment is more than just substance

 Much before the construction boom happened in early 2000’s, buildings were small in size. The boom in construction and demand for housing led to changes. Similarly, there was a growth in infrastructure with an increasing number of roads, bridges and highways being built across the country. The rise in construction activity led to a demand for better concrete equipment. This called for concrete equipment to be more efficient, long lasting and economical. Also, as better concrete equipment is being called for with augmented set of needs, it led to a change in the equipment. Concrete equipment now require an increased output along with several constraints like increased productivity, reduced downtime, cost efficiency, and fuel efficiency .

The inclusion of design in concrete equipment was initially seen as being able to give an aesthetic sense to the equipment. However, this perception is changed and design became an important determinant given the type of constraints faced by concrete equipment. Today, design of concrete equipment speaks of its capacity and several other features. Design is not limited to individual components but encompasses the entire equipment. This enables concrete equipment to perform more complex tasks. Manufacturers today focus on design of the equipment even though their primary focus remains on the application of the equipment.

Putzmeister’s new generation equipment: designed for optimum performance
Several developments have happened on the front of R&D at the Putzmeister centres at both India and Germany.  Putzmeister introduced a new range of eSmart concrete pumps . The new range of eSmart pumps comprises of four pumps, BSA 1404HD, BSA 1405HD, BSA 1405D, and BSA 1407.

The latest eSmart machines come with HMI (Human Machine Interface) control panel have Ergonic Graphic Display (EGD) which allows the operator to determine operating status and diagnosing faults of the machine in real time. The EGD performance displays various parameters like pumping hours, concrete output, hydraulic oil temperature, fault diagnosis matrix, stroke counter, engine speed etc., which makes it possible to monitor the pump continuously. This system reduces the restrictions in hydraulic oil flow; and as a result, the heat generation in this hydraulic system is minimised and thus saves recurring maintenance cost. The machines are designed for safety and safe operation. The RSA or the grill safety switch keeps the pump and agitator from working if the hopper grill is open, thus ensuring safety and avoiding accidents.

The new Open Pump system (OPS) design will drastically reduce the operational costs. The eSmart machines are very efficient and have a high output besides being ecological and environmental friendly. The system reduces the restrictions in hydraulic oil flow, thereby minimising the generation of heat. This saves recurring maintenance cost.

The Putzmeister stationary concrete pump BSA 1408HD is a very popular and reliable concrete pump for high rise projects. The stationary concrete pump has some phenomenal capabilities. The Putzmeister BSA 1408HD set a record with a 601M vertical pumping with single stage pumping for Burj Khalifa. This is a reflection of Putzmeister’s expertise in high rise pumping. Putzmeister’s stationary pumps are a specialised equipment to get the job done. In India, where high rise buildings are becoming commonplace in several cities, Putzmeister pumps offer single stage pumps that are most suitable.

BSA 1408HD has some remarkable features which make it stand out. Some advantages which are attributable to the pump are as follows: The reduction in S-valve gives BSA 1408HD a longer life. It requires less maintenance, given environmental and climatic conditions in India. The Putzmeister pumps use Chrome cylinders which increases the life of the machine by 50 per cent. The S- valve has only 4 wear parts. It has better energy utilisation and no losses in pressure. The mixture is kept equally homogenous by an agitator motor. The safety switch is well protected.

Schwing Stetter’s new generation pumps: made for the ultimate experience
Schwing Stetter has pioneered with India’s largest boom on a 4-axle Truck. Schwing Stetter redefines standards in the 40-metre class with its S43SX truck-mounted concrete pump. Schwing RZ boom design combines the “Roll and Fold” boom with a Z-fold boom at the tip to offer 270 degree flexibility at the last boom section. The boom folding system also enables concreting work right up to the vehicle bumper. With an overall length of less than 12-metre on a standard chassis this compact boom package does not extend beyond the machines outlet.

With the 270-degree Z-fold section at the tip of the boom, operators have a myriad of options for placement while shooting concrete up to 42.3 metres vertically, and 38.1 metres horizontally. The S 43 SX has an unfolding height of 8.7 metres for those low overhead situations and a slewing range of 740 degrees to suit many job site requirements. Its pipeline is a full DN-125 mm diameter. The S43 SX front outriggers extend along an arc, do not have to be swivelled or telescoped and can fit into even the smallest gaps at the construction site thanks to their low height that saves space and time. S43 SX outriggers are designed to be compact, with a fast set-up time. It requires an 8.3 metres outrigger spread (the spread is the same, front and rear) for maximum stability.

The “Generation 3” concrete pump is a low-maintenance, 164 metre/hr unit that provides long, slow-stroking action. The all-hydraulic design utilises Schwing Big Rock Valve, promoting maximum filling efficiency of the material cylinders even with harsh mixes. An open circuit design provides continuous hydraulic oil flow for fuel efficiency, filtration and cooling. The S 43 SX can do infrastructure work, light commercial projects and bridges. In conjunction with the DN-125 pipeline, contractors can perform high-volume pours or provide a slow delivery with infinite volume control. A 600 litres water tank on the unit helps with clean-up at the yard or on the job site. Consistently lightweight design makes this machine a universal and flexible long-boom pump – both for medium-sized operations in downtown urban areas and on large construction sites.

Ajax Fiori: leveraging the advantage of design efficient equipment
In 1992, Ajax Fiori revolutionised the concreting industry in India by introducing Self Loading Mobile Concrete Mixers (SLCM) technology ARGO series product line.

ARGO series SLCM from Ajax-Fiori are unique machines, from self- loading and weigh batching of aggregates to mixing to transporting to placing of concrete to the exacting standards demanded by the critical infrastructure projects, be it in irrigation, roads and building construction.
The salient features of Ajax-Fiori’s ARGO series Self Loading Mobile Concrete Mixers are:
• Four wheel steering: For good manoeuvrability and flexibility.
• Four wheel drive: Ideal to negotiate rough terrain conditions at site.
• Short turning circle: Able to operate in narrow, restricted job sites.
• Weigh batching: To ensure proper quality concrete.
• Ergonomically placed controls: High operator comfort.
• Drum swivel:  Enabling concrete placement on-the-go in select applications
• ARAI certified: Can be registered with RTO for plying on public roads.

These SLCMs are currently available in 3 sizes:
• 4  Cu.M drum version – ARGO 4000
• 2  Cu.M drum version – ARGO 2000.
• 1  Cu.M drum version – ARGO 1000

Similarly in Batching Plant arena Ajax-Fiori pioneered the unique concept of self-loading batching plants through its Radius Lift Arm (RLA) series in the year 1998. These plants eliminate the need for any dedicated loading arrangement of aggregates. RLAs are simple to operate and offer lowest power consumption and operating costs in the industry. The plant has two 180 degree hydraulically actuated swivelling arms which scoop-in the aggregates from the ground, thus reducing the wastages to a large extent. This Batching plant comes with a reversible drum mixer which has unique mixing blades that ensures high homogeneity in the concrete mix. These plants are offered in 2 models, namely RLA 20 and AMBISON at rated output of 20 and 30 cubic metre / hour respectively. A large number of these plants are building the infrastructure for the country in wide range of applications like, irrigation, railways, and roads and building sectors.

In 2004, Ajax-Fiori introduced the high technology planetary Pan Mixers  with most advanced mixing technology which are its standard offerings with its compact and inline bin type Batching plants. The modular design of all the Batching Plants from Ajax Fiori ensures fast and easy erection or dismantling of the plants.

Recently Ajax-Fiori introduced its high performance Stationery Concrete pumps to satisfy its customers’ requirements for high performance in concrete placement.

In a nutshell Ajax-Fiori offers its customers unique solutions for their varied concreting needs through a wide range of high technology products and solutions. These are backed by countrywide efficient after-sales service network to ensure very high equipment up time. 

S. Gopal, Director, Ajax Fiori Engineering (I) Pvt. Ltd. claims, “Revolutionary product concepts with a high technology lineage, providing the customers with high versatility and cost effective solutions to their concreting requirements are the main differentiator for Ajax-Fiori from the rest.”

The efficient and innovative design of all the concreting equipment of Ajax Fiori makes “investment sense”, “productivity sense” and “economic sense” to its customers, Mr Gopal adds. 

KYB Conmat’s new batching plant and transit mixer: powered to perform
KYB Conmat unveiled two new equipment last year in Dec 2014 at the bC India event. The new batching plant and transit mixer were received well by the domestic and international customers at the event.

The mobile batching plant with the latest technology of twin shaft mixer, provides advantages like compactness, direct loading of aggregates, easy relocation etc. The plant requires only a hard surface for installation there by reducing the cost of installation in addition to lesser power consumption.

The transit mixer, combines design patented by the Japanese and the power take off (PTO) technology to bring the company’s customers a machine that will prove to be one of the best of its kind. Instead the truck’s main engine is used to power the mixer as well. This provides a number of advantages such as eco friendliness, low maintenance cost, low operational cost, etc.

Columbia Pakona’s concrete equipment: assure accuracy and uniformity
Columbia Pakona offers four machine models to cater to the need of Indian market. The models are SPM20, SPM26, 1600 and SHP5000C PRO. These models can produce up to 3 lacs fly ash bricks, 1.50 lacs concrete pavers or 50,000 8-inch hollow or solid blocks per day.

Columbia machines work on the principle of patented unique vertical mould vibration. The concrete products made on
these have salient features like high strength, low cement consumption, dimensional accuracy, and uniformity. Steady construction, low maintenance, faster cycle times are some of the features of Columbia concrete products machine.

Conclusion
Today, design is an important and integral part for any equipment because it enables the equipment to perform much better, while executing more complex and sophisticated tasks and functions.  n
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Revolutionary product concepts with a high technology lineage, providing the customers with high versatility and cost effective solutions to their concreting requirements are the main differentiator for Ajax-Fiori from the rest.
S. Gopal,
Director,
Ajax Fiori Engineering (I) Pvt. Ltd.