teka maschinenbau gmbh, 67480 edenkoben, germany one of

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CPI – Concrete Plant International – 6 | 2014 www.cpi-worldwide.com68

CONCRETE TECHNOLOGY

DSK Grad is located very favourably on aplot of land with an area of 25 hectares inthe Kotowo Industrial Estate in the district ofNaro-Fominsk in the Greater Moscow area,only 2.5 km from the new planned centralring motorway. This allows the precast ele-ments to be delivered quickly and at lowtransport costs to the building sites.

The new precast plant has a productioncapacity of 525,000 m2, of which450,000 m2 are to be allotted to housingconstruction and 75,000 m2 to the con-struction of public buildings. The large area

of the property will allow an extension ofthe production capacities later on.

The production plants were put into opera-tion in several stages; the first productionline was started up in spring 2014, fullcapacity being reached in the third quarterof 2014.

DSK Grad differs from most other Russianprecast plants in that all of its processes areautomated to a very high degree. All pro-duction plants are located under one roof.This method of organising the production

flow leads to a reduction in costs and to anincrease in the production performance.Through this flexible approach to produc-tion organisation it is possible to react veryquickly to the changes on the market aswell as to customer requests. The entire pro-duction plant is controlled by the integral,computer-assisted CAD/CAM system,wherein this system unites the functions ofCAD technologies and those of the specialsoftware.

An automated system for warehouse man-agement as well as sophisticated logistics

One of the world’s largest dosing and mixing plantsfor state-of-the-art precast plant in Russia

Teka Maschinenbau GmbH, 67480 Edenkoben, Germany

The Russian construction and property group Morton of Moscow was established in 1994. Morton specialises in the construction of largesettlements and housing complexes and has constructed buildings with a total area of around 7.5 million m² since its establishment. Theprecast concrete elements and ready-mix concretes are manufactured in the company’s own plants. Morton is one of the three largest com-panies in Russia in terms of the construction of living space. In the context of the strategy for the expansion of its own production, Mortonhas erected the DSK Grad precast plant in the Greater Moscow area. The latest developments, modern machines from leading suppliers andinnovative solutions in the new DSK Grad precast plant will contribute to it occupying a top position in the Russian building market. The build-ing of its own precast plant will also help strategic goals to be attained. This means that having its own precast plant makes GK Morton afull-range supplier, from the development and design to the construction, commissioning and operation of the housing complexes. As a result,the product quality is increased and the costs are minimised. The German company Prilhofer Consulting was hired as the project consult-ant. The equipment in the DSK Grad plant encompasses three circulation plants, a plant for the manufacture of special structural elementsand a further plant for the manufacture of structural elements such as columns and beams. A high-performance, state-of-the-art concretecentre was installed by Teka of Germany for the supply of all production lines with concrete. Teka Maschinenbau GmbH has set a high stan-dard on the market with the delivery and installation of the concrete mixing plant, whose dimensions make it one of the largest in the world.A further Teka dosing and mixing plant with even larger dimensions is currently at the planning stage and will be built in 2015.

Teka binding agent silo installation Teka mixing stations

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At TEKA, everything revolves around mixing and about the requirements of our customers. That’s

why we put the customer in front and advise with custom-designed and highly effi cient solutions –

with machines that perform exactly how our customers expect them to.

>> each mixer designed and confi gured individually in order to meet the customer‘s mixing requirements

>> the right mixer from TEKA (planetary, pan-type, turbine and twin-shaft mixers) for each specifi c application

>> experienced and reliable partner from planning to commissioning

>> fast and reliable spare parts supply, over 15,000 spare parts in stock

TEKA High-Performance MixersYour specialist for the most demanding concrete mixing requirements

The TEKA-Principle: maximum adaptability for your project

TEKA Maschinenbau GmbHIn den Seewiesen 2 >> D-67480 EdenkobenTel. +49 6323 809–0 >> Fax +49 6323 809–[email protected] >> www.teka.de

At TEKA everything revolves around mixing.

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CONCRETE TECHNOLOGY

for the delivery of the elements from theworks to the building site is used for the opti-misation of the business procedures. Precastconcrete elements are assembled into spe-cial transport packages and these pack-ages are stored in the works on pallets. Thedelivery of the complete transport pack-ages from the works will then take place onlow loaders. Inloaders have been acquiredfor this, with which the precast concrete ele-ments can be transported to the buildingsite without further reloading.

State-of-the-art dosing and mixing plant from Teka

The complete concrete mixing plant at DSKGrad consists of five completely autono -mous and independent mixing stations situ-ated next to one another. Four mixing sta-tions are equipped with the proven TekaTPZ 3750 high-performance planetarymixer (with an output of 2.5 m3 per batch),while the Teka THT 1500 high-performanceturbine mixer (with an output of 1.0 m3 per

batch) produces the concrete in the fifthmixing station.

Dosing of the aggregates from 24 chambersThe complete feeding system, silo installa-tion and mixing stations are very generous-ly sized to allow optimum accessibility forcleaning and maintenance work. Ofcourse, the complete dosing and mixingplant is also equipped with state-of-the-artsafety technology.The aggregates are taken up by two truckcharging hoppers, each with a volume ofapprox. 20 m³. Both charging hoppers arefitted with a cover for protection against theweather. The material is transported to thesilo installation by the 109 metre long con-veyor belt. Both hoppers are kept warmwith hot air so that the aggregates do notfreeze. The long conveyor belt feeds twomobile and reversible belts above the siloinstallation. The silo installation, which wasbuilt on site of concrete, is divided into fourrows of six compartments, making a total of24 compartments. All openings of the silocompartments are fitted with gratings assafety measure. All compartments are heat-ed and monitored by temperature sensors.Similarly, all compartments are equippedwith modern level indicators and a total of12 air-blast devices in the form of shockblowers.

Reversible heads belts are attached at bothends of the mobile belts. All conveyor beltsare equipped with the latest technology,such as speed monitors and skew monitor-ing. Local operating panels are installedboth on the hopper and on the silo platformin order to enable local intervention.

Teka mixing and weighing platforms with bottom-discharge feeder and silo installation in the background

Teka mixing platform with TPZ 3750 high-performance planetary mixer


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CONCRETE TECHNOLOGY

Underneath the silo installation there are 22 shutters on the batch-ing segments in three different sizes, which are precisely matched tothe different grain sizes. Two dosing belts ensure the precise dosageof the sand. Under each silo row is a weighbelt with a post-con-tainer that allows continuous weighing. The four weighbelts are driv-en by soft-start devices. All four post-containers are equipped with awearing lining and a vibrator.

The aggregates are transported from the weighbelts to the mixersvia proven Teka feeders with a bottom discharge design. Four feed-ers supply material to the four Teka high-performance planetarymixers as well as to a Teka high-performance turbine mixer. Thismeans that each feeder supplies material via a two-way distributorto a double unit with one planetary mixer and the turbine mixer.

The Teka high-performance planetary mixers have proven them-selves worldwide and have been the core of every Teka dosing andmixing plant to date. Since the introduction of the Teka turbine mix-ers at the bauma 2013, the new turbine mixer is becoming increas-

Teka TPZ 3750 planetary mixer with countercurrent principle



CONCRETE TECHNOLOGY

ingly popular. Its flexibility and perform-ance, even with very difficult concrete mix-tures, impress an ever growing number ofcustomers.

Teka planetary mixerThe 2.5 m³ planetary mixer is equippedwith three mixing stars, one of which turns inthe opposite direction to the other two mix-ing stars. Furthermore, all three mixing starsrun with different radii, so that the base ofthe mixer trough is covered. This uniquemixing principle results in very intensive mix-ing and makes this mixer a genuine coun-tercurrent mixer, which is also very well suit-ed to all possible special concretes or spe-cial products.

The counterflowing material streams causethe permanent movement and shifting of theaggregates and thus an optimum mixturequality in a very short time. The mixing prin-ciple also makes this planetary mixer verysuitable for small and very small quantities.

This targeted input of energy is extremelyefficient. The countercurrent principle guar-antees fast and clean emptying of the mixervia a large discharge opening. The actua-tion of the discharge unit takes place reli-ably by means of a hydraulically actuatedslew drive with a high breakaway torque.

Teka turbine mixerThe Teka turbine mixer has so far been usedmainly in Germany and Western Europe forthe production of facing concretes, dyedconcretes, self-compacting concretes andultra high performance concretes. It is thusa very good supplement to the Teka plane-tary mixer. The turbine mixer can perfectlymix batches of less than 10%, has a con-siderably lower degree of contamination,an extremely quick discharge time and isgenerally very well suited to frequentlychanging batches.

The central position of the rotor and thus theeven distance between the mixer/scraper

paddles and the mixer trough are ensuredby the dimensionally stable upper mixersection with integrated mounting flange forthe gearbox.

The cast steel mixing stars and mixing armsare functional, robust and lift-proof. Theresults of this are minimal wear of the pad-dles and wearing lining, no unmixed mate-rial at the base of the trough and properwiping of the moisture sensors. Due to thespecial shaping of the paddles and mixingarms an efficient mixing effect is achievedand the ‘accumulation effect’, especially inthe case of small quantities, is avoided.Mixture deposits are avoided, which min-imises cleaning work and simplifies theadjustment of the mixing tools. Furthermore,large self-opening cleaning hatches allowgood accessibility for cleaning and mainte-nance work and sufficient space for inletsand additional devices.

Extensive special equipmentAll the mixers at DSK Grad are equippedwith a powerful high-pressure water clean-ing system with mobile three-dimensionalhigh-pressure nozzles made by WalterGerätebau GmbH. The bucket tracks forthe transport of concrete to the machinesare also kept clean by this cleaning system.

A total of five fully automatic dedustingdevices with fan and pneumatic cleaningare used in the works. Each mixing station issupplied with different binding agents byeight binding agent silos, which were man-ufactured on site on the basis of Teka draw-ings. All binding agent silos are equippedwith state-of-the-art environmental and safe-ty technology, such as exhaust air filters,vacuum/overpressure valves and level indi-cators. A total of 19 screw conveyors are inuse. All mixing stations are equipped withindependent binding agent weighers. Allwater weighers are executed as negativeweighers with dosing valves for anadjustable outlet quantity. This allows theuse and exact dosing of both fresh water

Teka THT 1500 turbine mixer

Five 24-inch flat-screen monitors were necessary in order to display the entire plant on the Bikotronic process visualisation.


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CONCRETE TECHNOLOGY

via the water dosing device and process water from the recyclingplant. The system is also equipped with temperature sensors andwater dosing computers with microwave moisture measuring sen-sors from Bikotronic.

Each mixing station is equipped with a separate and independentadmixture unit with a double-chamber design for four differentchemical admixtures supplied by the Würschum company, compris-ing a total of 14 filling pumps.

Control equipment from Bikotronic

The complete automation of the mixing processes, material fillingsand concrete deliveries for one of the largest precast plants in theworld, from the project engineering and the manufacture of the con-trol cabinets to the measuring peripherals and the commissioning,was not an everyday task for Bikotronic. The experienced techni-cians gladly took on this task and designed a system that leavesnothing to be desired for the customer and fulfils the high expecta-tions with regard to quality, robustness, user-friendliness and, last butnot least, sustainability with regard to spare part availability andsupport. Over 40 years of experience and the feedback from over3000 satisfied customers all over the world are an inestimable helpwith projects of such an order of magnitude.

Fully automatic dosing equipment for dyes type TFW fromWürschum during its installation


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CONCRETE TECHNOLOGY

The latest generation of the Bikotronic BWDcombined process control and administra-tion system was used. The modular conceptof this powerful software makes it possible,with both the control and administrativeapplications, to cater especially to the vari-ous requirements of this plant with its exten-sive product range. An SQL server formsthe basis for data storage. It enablesamongst other things a very high function-ality in linking to local ERP/bookkeeping orlaboratory systems, as implemented withthis application.

Due to the extreme expanse of the plant,the installation of the control cabinets was

decentralised; to this end a total of 17 con-trol cabinets are distributed in the plantperiphery and connected via the Profibussystem. The complete plant is operated andcontrolled from the control centre. Five 24-inch flat-screen monitors were necessary inorder to display the entire plant on theprocess visualisation.

The basic control platform is a Siemens S7system with a Profibus or Profinet periphery.Particular importance was attached here tonetworking the plant parts in such a waythat no interferences arise between the indi-vidual modules outside the bus periphery.For example, all controllers that move with

the bucket tracks are equipped with high-performance Profibus data radio modules,which ensure very high functionality in thehandling of the buckets among themselves,as well as an extremely flexible link to theindividual mixing processes and to the vari-ous processing machines. Apart from that,this system structure enables full remotemaintenance with regard to support or pro-duction supervision measures.

Various moisture measuring systems withmicrowave-based sensors from Bikotronic’sown development and production representa further important plant detail. The provencombination of sand moisture measuring

The production workshops are supplied with concrete by six buckettracks from Dudik

The total length of the six bucket tracks is 1,600 m

Bibko recycling system type ComTec Stirrers in the agitator tank of the Bibko recycling system


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www.bibko.com

BIBKO® Umwelt- und Reinigungstechnik GmbHSteinbeisstr. 1 + 2, 71717 Beilstein, GermanyTel.: +49 7062 9264-0, Fax: +49 7062 9264-40E-Mail: [email protected]

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CONCRETE TECHNOLOGY

sensors in the material silos and moisturesensors in the five Teka mixers was adaptedhere. This combination and the latest gen-eration of the process control software withthe fully integrated functionality of theBT7000 module guarantees a very highdegree of continuity and reliability withregard to water management and a con-stant grading curve. The quality standardand the reproducibility of the individual mix-tures are thus very high.

Fully automatic dosing equipment for dyes from Würschum

In order to be able to meet all customerrequests, Morton uses fully automatic dosingequipment for dyes from Würschum for theturbine mixer. This system currently operateswith four different powdered dyes, whichare delivered in big bags. A large numberof resulting secondary colours can be man-ufactured from these four basic colours.Small dye components can also be dosedwith high precision by the use of frequencyconverters to control the dosing screws.

The fully automatic TFW equipment for thedosing of dyes operates according to thedry-liquid principle, i.e. the powdered dyeis stored dry and dosed dry. However, thedesired dye batch is then mixed in theweigher with water and pumped as slurryinto the mixer. Due to the transport withwater, the compressed air supply require-ments (quantity, quality) are reduced andthere is also no need for dust extractionfrom the mixer. This reduces the plant costsand also the maintenance work.

Morton plans to expand the four-dye sys-tem by two further colours to make a six-dyesystem, which is simple to do thanks to theflexible plant concept. Expansion to furtherdye components, as well as the supply of asecond mixer is possible, since the majorityof production is implemented with dyedconcrete. The Herocrete company fromMoscow has been commissioned with thedevelopment of this colour concept and isdrawing up a complete concept that willmeet these high demands.

Bucket tracks from Dudik

The production workshops are suppliedwith concrete by six bucket tracks fromDudik. These are implemented as twin-railtracks and the rotating buckets have acapacity of 2.5 m³. The buckets move atspeeds of up to 3.5 m/s along the tracks,which have a total length of 1,600 m. Thebucket tracks are controlled by theBikotronic equipment. The automatic clean-ing system from Walter in each track car-riage takes care of the regular automaticcleaning of the buckets.

Residual concrete recycling system supplied by Bibko

Morton ordered a second residual con-crete recycling system from Bibko. Thedelivery was preceded by a correspondingproject planning phase in which the cus-tomer’s requirements and local conditionswere considered.


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CONCRETE TECHNOLOGY

The ComTec residual concrete recyclingsystem features a 1.5 metre long hopperand was placed at floor level. A 4 metrelong screw conveyor provides for optimaldischarge of the washed-out material. Thedischarge height is 3.2 m.

The ComTec 20 system supplied offers arecycling capacity of 20 m3/h and isequipped with a suitable recycling watertreatment facility. The rinsed material mixgoes directly from the charging hopper intothe machine. Here, solids > 0.2 mm arewashed out and removed appropriately.

In order to maintain the separating layereven at the maximum feeding speed of theresidual concretes, the washing unit wasequipped with a rotary partition. To thisend a plate was fixed to the shaft after thematerial inlet area. The plate has the task ofseparating the inlet area from the residualwater overflow. The plate separates the twoareas – the residual material is forciblyguided around the water overflow. This pre-vents material from entering the outlet areaduring heavy discharges. The separationlayer is kept thus constant.

The water with the fine particles < 0.2 mmmoves from the washout machine into theexisting agitator tank. This is equipped withtwo stirrers which keep the fine particles ofthe residual water in motion by means ofcyclic stirring, thus preventing settling. Thewater containing the fines is fed back to themixing process.

The Bibko ComTec system includes thepatented bearing that has proven itself1,500 times over. It is positioned outsidethe water bath and offers an increased lifespan. All plant components are suppliedhot-dip galvanised with increased life span.

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FURTHER INFORMATION

TEKA Maschinenbau GmbHIn den Seewiesen 267480 Edenkoben, GermanyT +49 6323 8090, F +49 6323 [email protected], www.teka.de

Prilhofer ConsultingMünchener Str. 1, 83395 Freilassing, GermanyT +49 8654 69080, F +49 8654 [email protected], www.prilhofer.com

Bikotronic Industrie Elektronik GmbH Im Hohen Acker 7, 67146 Deidesheim, GermanyT +49 6326 96530, F +49 6326 [email protected], www.bikotronic.de

Würschum GmbHHedelfinger Straße 33, 73760 Ostfildern, GermanyT +49 711 448130, F +49 711 [email protected], www.wuerschum.com

DUDIK International Kübelbahnen- und Transportanlagen GmbH Mackstraße 21, 88348 Bad Saulgau, Germany T +49 7581 8877, F +49 7581 4692 [email protected], www.dudik.de

Bibko Umwelttechnik & Beratung GmbH Steinbeisstraße 1–271717 Beilstein, GermanyT +49 7062 92640F +49 7062 [email protected]

„DSK GRAD“143300 Moskauer Gebiet, Naro-FominskDorf KotovoKalinina-Str. 4, Russia

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teka maschinenbau gmbh, 67480 edenkoben, germany one of

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