Automated and software-controlled batching for
concrete pipes
Concrete is the world’s most commonly used building material. In its simplest form, concrete is a mixture of paste, composed of water and cement, with fine and coarse aggregates. Within this process lies the key to the remarkable trait of concrete – it’s plastic and malleable when newly mixed and strong and durable when hardened.
The character of the concrete is determined by the quality of the paste. The strength of the paste, in turn, depends on the ratio of water to cement. The water-cement ratio is the weight of the mixing water divided by the weight of the cement. High-quality concrete is produced by lowering the water-cement ratio as much as possible without sacrificing the workability of fresh concrete. Generally, using less water produces a higher quality concrete provided the concrete is properly placed, compacted, and cured. Typically, a mix is about 10 to 15 percent cement, 60 to 75 percent aggregates and 15 to 20 percent water. Entrained air in many concrete mixes may also take up another 5 to 8 percent.
Precast concrete products like pipes, manholes, boxes and culverts are cast in a dedicated factory setting with very tight quality controls, highly controlled environments under rigid production standards and testing specifications.
Excellent quality concrete pipe produced nowadays is a direct result of the following operations:
computer-aided design and analysis,
advanced concrete mix designs,
automated and software-controlled batching,
precision fabricated wire reinforcement,
quality driven manufacturing techniques,
improved water tight joints and
new installation standards.
MCT Italy: Total control from Australia to Canada
Since 1967 Marcantonini has been managing the complexity of the production cycle, transport and distribution of concrete, developing for our customers integrated and customized technological systems in relation to specific concrete elements.
MCT Italy S.r.l. turnkey solutions include all the components of the system starting from the detailed design of the functional areas of the site, going through to the manufacturing of the plant and completed with the automation of the processes which performances MCT measures and checks.
Years of experience in 5 continents and top-notch connection technologies are what CompuNet, the MCT Italy software for management and control of both batching plant and concrete delivery system, is made of. Batching plants and factories dedicated to concrete pipe production have recently been installed in Canada, Australia, USA, Middle East and Europe. MCT added value includes research in safety, risk prevention and knowledge that translates into total compliance with specific national regulations regarding plants, emissions and environmental impact.
Together with hollow core and block & pavers productions, the concrete used to produce precast concrete pipes has a low water-cement ratio because most manufacturing processes utilize relatively dry mixes.
CompuNet automatically:
detects the moisture content of the aggregates through dedicated sensors mounted on the aggregates extraction gates (or belts),
checks the power absorption of mixer motors,
manages the batching water by determining the amounts to be deducted from the value set in the mix design according to the water content that has been monitored by the sensing probes and
provides final fine water correction through extremely precise flowmeters.
MCT Windows running software automation
MCT Windows running software automation is totally developed and realized inhouse, allowing the customer full control of the plant, giving access to the analysis of the working parameters and the production reports, and plan the management of the production, including all the auxiliary platforms of the concrete batching plant.
With the remote technical support, we provide a 24/7 assistance to help in case of required support, to check or assist the operations of the batching plant: it is possible to modify parameters or processes on-line, while it is running, just by an internet connection.
Environmental considerations
With its long life, use of natural/recycled products and local availability, the concrete pipe is extremely environmentally friendly.
Comprised of the world’s most commonly used building materials, precast concrete infrastructure is quickly integrated into ecosystems. This is clearly demonstrated by the use of three-sided precast boxes used to accommodate the natural channels of streams at road crossings, and precast concrete pipes for storm sewers and outfalls in valleys and shorelines.
Design/Construction flexibility
Some projects have design elements that are a little more complex or intricate than others. Precast concrete pipe provides solutions for these projects, whether they are open-cut, deep burials, tunnels, trenchless, shallow burials, or with vertical structures or complex alignment changes. Concrete pipe design is simple to do; the math is sound and easily definable.
Warum Betonrohre?
Festigkeit: Das Betonfertigteilrohr ist das stärkste verfügbare Rohr: Es kann so ausgelegt und im Werk geprüft werden, dass es jeder erforderlichen Belastung standhält. Im Gegensatz zu flexiblen Rohren hängt die Belastbarkeit nur geringfügig von der Installation ab, sie beruht in erster Linie auf der eigenen Festigkeit, die Betonrohre durch die Herstellung erlangen. Die Druckfestigkeit von Betonrohren liegt in der Regel bei 4.000 bis 8.000 psi.
Widerstandsfähigkeit: Langlebig wird definiert als „lange Zeit ohne nennenswerte Verschlechterung bestehen zu können“. Bei Betonrohren bezieht sich die Dauerhaftigkeit auf die Lebenserwartung und die Beständigkeit ihrer Materialien. Die Fähigkeit von Betonrohren, während der gesamten Lebensdauer eines Projekts die erwartete Leistung zu erbringen, ist eine grundlegende technische Überlegung, insbesondere im heutigen wirtschaftlichen Umfeld, in dem Anforderungen zur Gewährleistung einer nachhaltigen erdverlegten Infrastruktur aufgestellt werden. Die kanadische Corp. of Engineers empfiehlt für Betonfertigteilrohe eine vorgesehene Lebensdauer von 70 bis 100 Jahren und es gibt unzählige Beispiele von verlegten Rohrleitungen, die diesen Zeitraum übertreffen.
Nicht brennbar: Im Gegensatz zu thermoplastischen Rohrleitungen brennen Betonrohre nicht. Dies ist bei der Planung von Landstraßen- und Autobahnabflüssen in städtischen Bereichen und abgelegenen Gebieten, die stark bewaldet sind, von Bedeutung. Betonrohre sind eine kluge Wahl für die Sicherheit auf der Baustelle, die öffentliche Sicherheit (Brandgefahr und Gefahr durch giftige Dämpfe) sowie die innere Sicherheit.
