Raw Materials :
Raw Materials Procurement: Time is allocated and extra care is given to choose/source the best available cement, salt free sand, & strong/clean aggregates to use for the concrete mix, no matter the sourcing distance at times.
Water treatment: To control the quality of the salt free supply of water, and to ensure having an abundant water supply for the production without interruption or shortage, a fully automated PLC controlled “RO” water treatment plant is in place. For a most conducive concrete mixing water temperature, treated water is stored underground in buried concrete reservoirs to maintain a stable cool 20°c temperature year round even in the hottest of Basra summer heat.
Batching Plant :
The ample aggregate bunkers, four cement silos, and two concrete mixers of the batching plant are strategically placed to accommodate for any future addition/expansion of the overall production capacity of the plant.
For optimum mixing consistency (segregation free mix), the batching plant is equipped with two “Planetary” mixers made by Sicoma of Italy. Achieving excellent mixing consistency is an essential prerequisite to a successful result at the subsequent block making stage.
With its state-of-the-art/PLC controlled automation system (by Schneider), the Batching plant is fully integrated to work in perfect harmony with the ongoing concrete block making plant to create an uninterrupted manufacturing circle.
Block Making :
Block Making Machine: With its performance and strategic production capacity, the installed cutting edge concrete block making machine has redefined the rules of the game in the block making industry in Iraq.
The Fully Automated/PLC controlled Block production line has a maximum production capacity of up to 50,000 (of 20x40x20cm) blocks/day, or 70,000 (15x50x20cm) blocks/day, or 4,500m2 of paver/day, or 15,000 pieces of 1 m long curbstones/day. Should the need arise, the installed concrete batching plant capacity is capable of supplying enough concrete mix to allow for the addition of another Block Making Machine to double the overall capacity of the plant within a time frame of not more than 3-4 months.
With installed Top and Bottom Vibrators (by Schneider), and using pneumatic bellow on the fixation points of the mould and compaction head of the block machine, vibration & compaction is fairly distributed through the mould allowing the concrete mix to be thoroughly vibrated/compacted thereby optimizing the compressive strength of the product to its highest possible level.
With such advanced block making technology, some block moulds design are optimized to hold a reduced volume of mix needed to achieve the block’s desired/ required compressive strength. The result is a lighter and cost effective block at the required compressive strength. This makes for a logical/optimal overall use of the raw materials.
To save on valuable production time, and to efficiently accommodate simultaneous orders for a variety of blocks to different customers, a “Rapid Mould Changing Unit” is provided with the machine. The Plant operates fully automatic. Controlled via PLC automation software, each unit of the plant communicates to each other in real-time. The entire plant could be operated by one person, As a result, human errors in production are minimal and quality is stable.
Curing & Packaging :
Instantaneous Curing: Immediately after casting the dry concrete mix into blocks, the product is transferred to one of nine (humidity injected) closed curing and cooling chambers allowing the freshly moulded product to cure for its (critically important) initial few hours. This critical step ensures the success in attaining the desired level of cohesiveness and strength of the product even in the hottest of Basra summer heat.
Packaging and Outdoor Curing: An outdoor water spraying system awaits the freshly packaged products to start the several days water dosing journey until tested and approved by the Quality Control unit.