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One of the main advantages of our Ligtweight Concrete batching Plant (LCP) system is that the dry components (cement-CEM, sand, etc.) can be loaded into the feed hopper of MS_1000 unit by all possible ways. To assess advantages of investing in these SIRCONTEC’s  highly modular LCP, we have prepared various examples / configurations of them depending on different criteria coming from the construction practice – see the examples of LCP Configurations in the attached Configurator (Annex B):

 

Alt.1) – Cement or Cement and Sand are loaded into the unit manually or from truck mixers or from silo.
 
Alt.2) – Cement loaded manually or from a silo into a hopper of 1 conveyor.
 
Alt.3) – Cement or Cement and Sand are loaded by 2 conveyors.
 
Alt.4) – The MS_1000(S) unit filled from a truck-mixer using a pump.
 
Alt.5) – 2 dry components are fed into the unit feed hopper simultaneously using External el. Scale.
 
Alt.6) – Cement or Cement and Slag are fed from one or two silos using fast conveyors.
 
 
Description of operation of MS_1000 LCP configurations:
 
Alt.1) – Cement or Cement and Sand are loaded into the unit manually or from truck mixers or from silo.
  
A - Each MS_1000(S) unit is ready to be loaded with dry components manually:
Cement or Cement and Sand are manually loaded into the unit feed hopper.  Mixing water and preformed foam are dosed automatically by the unit CC. In this semi-automatic working mode, just a very good personal discipline can control quality & costs properly. The lightweight concrete mixing and pumping plant (LCP) works only as fast as dry components are loaded quickly into the unit. Its production capacity with 2 operators can be up to 8 for Cement-only foam concrete (FC) or up to 5  m³/hour for Cement&Sand FC without fibre.
 
Pros: - Very easily moveable from place to place. – Good availability and price of cement in bags on any construction site. – Very good ability to work indoors, i.e. in all weather conditions.
 
Cons: - Low production capacity. – Quality & costs control depends on human factor, personal control of loaded dry components quantity. - Need to protect the bags and workers from rain. - For  large projects, a forklift or a crane for handling pallets with cement and/or sand ought to be available on site.
 
B - Each MS_1000(S) unit can be filled from a truck-mixer:
The MS_1000 unit is designed to be operated batch-wise, with approximately 1m³ of foamed concrete produced per batch. The wet-mix grout shall be delivered from the chute of a standard mixer truck into the unit feed hopper. Once the unit is filled, the supply of wet-mix is manually stopped. This is normally a 2 person activity between the mixer truck driver and the MS_1000 operator. The unit automatically measures the exact quantity of wet-mix (weigh cells) and automatically adds the appropriate quantity of foam and possible also water. Once mixed the discharge pump can be started to deliver the FC. The pump automatically stops after the entire batch is discharged. Operating as above, the unit can produce and pump 5 to 10 m³/hour of foam concrete (FC) regardless whether with or without fibre.
 
Pros: - Easily moveable from place to place. – Effective solution for FC with higher densities.
 
Cons: - Applicable only there where is a concrete batching plant available near the site.– The performance and quality control depends partially on human factor, mainly on the skill of the workers. - Depending also on FC density, the truck-mixer will need to be on site for 1 to 2 hours.
 
C - Each MS_1000(S) unit is ready to be filled with dry components from silo:
CEM is automatically fed from a silo into the unit feed hopper using a conveyor controlled by the unit CC. The  silo is typically provided together with the conveyor and CEM by a cement supplier.
With only 1 operator, depending on the speed of the conveyor the LCP  can operate with permanent performance up to 15 m3/hour of Cement-only foam concrete (FC) without fibre.
 
Pros: - High production capacity. – Maximum possible quality & costs control.  - This solution is also rainproof and windproof and it can also be frost-proof, if the MS_1000 unit is placed inside a building and the silo equipped with a long conveyor beside it.
 
Alt.2) – Cement loaded manually or from a silo into a hopper of 1 conveyor.
 
A - Cement is manually loaded into a hopper of the conveyor which is controlled from the unit control centre (CC) and is automatically fed into the unit feed hopper. In order not to prolong the shortest possible production cycle with one conveyor, loading cement into the hopper should be as fast as possible. During foaming and pumping a fresh foam concrete (FC), there is enough time to prepare a supply of about 100 kg of cement into the hopper of the conveyor for a next production cycle. This manual loading of cement into the hopper should continue intensively also after emptying the unit when the new production cycle starts again dosing components.
 
B - Cement automatically falls from a silo into a hopper of the conveyor and is automatically fed into the unit feed hopper. The conveyor together with a silo vibrator are controlled (switched on and off) from the CC. After emptying the unit, when a new production cycle again starts dosing components, the cement again falls from the silo down into the hopper of the conveyor, etc.
 
In both cases the MS_1000 LCP can operate at a maximum quality & costs control  with highest possible performance – production of FC  without fibre  with one conveyor:
 
- Cement loaded manually: up to 11 m³/hour of FC  with 1 operator or up to 13 m³/hour with 2-3  operators
 
 
- Working with silo: up to 13 m³/hour of FC with 1 operator.
 
Pros with conveyor loaded manually: - High production capacity. – Maximum possible quality & costs control.  - Easily moveable from place to place. –Good availability and price of cement in bags on any construction site. – If not working with silo, very good ability to work indoors, i.e. in all weather conditions.
 
Cons with conveyor loaded manually: - Need to protect the cement bags and workers from rain. - For large projects, a forklift or a crane for handling pallets with cement ought to be available on site.
 
Alt.3) - Cement or Cement and Sand are loaded by 2 conveyors
 
A - CEMENT is manually loaded into hoppers of two conveyors which are controlled from the unit control centre (CC) and automatically fed into the unit feed hopper simultaneously. During foaming and pumping a fresh foam concrete (FC), there is enough time to prepare a  supply of about 100 kg of cement into each hopper of the conveyors for a next production cycle.This manual loading of cement into the hoppers should continue intensively also after emptying the unit when a new production cycle again starts dosing components. The manual loading of cement therefore does not prolong a production cycle and thus, the MS_1000 LCP is able to operate with the almost highest possible performance permanently, i.e. 14 m3/hour of FC without fibre at a maximum quality & cost control with 2 to 3 operators.
 
Pros: - Highest production capacity. – Maximum possible quality & costs control.  - Easily moveable from place to place. -Good availability and price of bagged cement on any construction site. – Very good ability to work indoors, i.e. in all weather conditions.
 
Cons: - Need to protect bags and workers from rain. - For large projects, a forklift or a crane for handling pallets with cement ought to be available on site.
 
B - 2 dry components (CEMENT and SAND) are manually loaded into hoppers of two conveyors which are controlled from the Unit CC and automatically fed into the unit feed hopper successively, one by one. During foaming and pumping fresh foam concrete, there is enough time to prepare a  supply of about 100 kg of cement and 100 kg of sand into the hoppers of the conveyors for a next production cycle.This manual loading of dry components into the conveyor hoppers should continue intensively also after emptying the unit when the new production cycle starts again dosing components. The production capacity of FC without fibre can be up to 11 m³/hour at a maximum quality & cost control with 2 to 3 workers.
 
Alt.4) – The MS_1000(S) unit filled from a truck-mixer using a pump.
 
The MS_1000 unit is designed to be operated batch-wise, with precisely adjusted volume from 0.1 to 1m³ of foam concrete (FC) produced per batch. The wet-mix grout shall be delivered from the chute of a standard mixer truck into a hopper of the pump which is controlled (switched on and off) from the unit CC and is automatically fed into the unit feed hopper. The unit continuously measures the quantity of wet-mix (weigh cells) in the unit and once it is filled, the supply of wet-mix is automatically stopped. Then the unit automatically adds the appropriate quantity of foam. Once mixed the discharge pump can be started to deliver the foam concrete. The discharge pump automatically stops after the entire batch is discharged. Operating as above, the unit can produce up to 12 m³/hour of foam concrete regardless whether with or without fibre.
 
Pros: - High production capacity. – Maximum possible quality & costs control. - Easily moveable from place to place. - All weather solution. – Effective solution for lightweight concrete (LC) with higher densities.
 
Cons: - Applicable only there where is a concrete batching plant available near the site.
 
Alt.5) – 2 dry components are fed into the unit feed hopper simultaneously using External el. Scale. 
 
A - Components supplied from one silo and bunker and fed simultaneously with External el. Scale.
2 dry components (CEM and Sand) are automatically supplied via conveyors which are controlled from the MS_1000S CC. While fresh foam concrete (FC), is being pumped into moulds (place of installation), one of the dry components, e.g. cement, is being supplied by the third conveyor into a hopper of the conveyor that is placed on a weighing frame (external electronic scale) and after emptying the unit, both components are automatically fed into the unit feed hopper simultaneously; therefore the MS_1000S LCP is able to operate with almost the highest possible performance permanently, i.e. up to 12 m3/hour (no fibre CLC))  at a maximum quality & cost control with just 1 operator.
 
Pros: - Highest production capacity. – Maximum possible quality & costs control.  - Moveable from place to place. – The LCP can also be installed indoors, e.g. the MS_1000S with the sand feeding system is placed inside and the cement silo with a longer conveyor besides the building. -The third (silo) conveyor may be slow, 2-3 kg/sec.
 
 
B - Components are manually loaded into hoppers of 2 conveyors and fed simultaneously with External el. Scale
 
Alt.6) – Cement or Cement and Slag are fed from one or two silos using fast conveyors.
 
1 or 2 componentsare automatically fed at high speed from one or two silos into the unit feed hopper using fast conveyors controlled by the unit CC. In case of 2CEM silos, cement is fed into the unit mixer simultaneously. With only 1 operator, the LCP can operate with permanent performance 15 m3/hour (no fibre CLC) unless the work speed of each conveyor  is not less than 8.5 kg/sec or not less than 17 kg/sec in case of the LCP with 1 silo.
 
Pros: - High production capacity. – Maximum possible quality & costs control.  - This solution is also rainproof and windproof and it can also be frost-proof, if the MS_1000 unit is placed inside a building and the silo(s) equipped with long conveyor(s) beside it.
 
 
  

 

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