In recent years, a string of high profile mine explosions have exposed the danger posed to those working underground. Explosions are just one of many hazards that come with underground mining — lack of fresh air, confined space, and the reduced visibility are others. Miners bravely go into this environment on a daily basis to fulfill their commitment to a job well done.
Strata Mine Services is one company that helps to ensure the safety of those working underground. A division of Strata Worldwide, Strata Mine Services is a contracting service company. Mining companies, both large and small, count on the expertise and assistance of Strata Mine Services, and will contract with the company to do a variety of projects - everything from general labor to ventilation controls.
"One of our specialties is in the application of shotcrete as underground reinforcements for use with spray panel overcasts," said Jeff Waggett, PE, senior development engineer for Strata Mining Services.
Spray panel overcast systems are often used by miners to ensure proper ventilation underground. Constructed of lightweight panels, overcasts are designed to block a passageway or prevent the mixture of airflow at the intersection of two passageways.
"As one can imagine, ventilation is a crucial element of underground safety so it's a major component of our offerings," Wagget said.
These structures consist of two layers of wire mesh with polystyrene in between each layer. The layout is similar to that of a highway overpass, except in this case, it's air (not vehicles) that is being redirected to avoid collision and the result of mixed air supplies. Before the structures can be deemed complete, they must first be reinforced with wet or dry process shotcrete (gunite).
Wet shotcrete is the process of pumping a low slump concrete material to a discharge nozzle where compressed air is injected allowing the material to be sprayed on to vertical and overhead surfaces. Dry shotcrete (gunite) is the process of introducing a dry or predampened shotcrete material into an air stream that conveys the material to a nozzle where water is injected in to the material. Both processes require special equipment to apply the material.
Specialized construction work such as this is part of Strata's repertoire. As exemplified by the work it does, Strata also has a long-standing commitment to safety, with quality work and customer service key to its core values. In order for the company to provide this elevated level of service to customers, it needs reliable equipment from trusted suppliers. Blastcrete Equipment Company is one such supplier.
Based in Anniston, Ala., Blastcrete Equipment Company provides a variety of wet and dry shotcrete equipment. With more than 60 years of experience in the manufacturing industry, Blastcrete has established itself as a company committed to providing high value equipment for enhancing mine safety. The company offers a variety of mixer and pumps in its product line.
Waggett began working with Blastcrete in June of 2010 when he purchased customized versions of the company's AA020 Piccola gunite machines. At the time, Strata was using the dry gunite process almost exclusively for the overcast systems, and Waggett was looking to add some new machines to the mix.
"As a development engineer, I have a lot of involvement on the product and equipment side of the business," Waggett said. "So I'm always the type of person seeking out new, advanced equipment. Something that's easier to operate, safer and more cost-effective."
What initially drew Strata and Waggett to Blastcrete was the ability to obtain custom equipment. "Unlike other manufacturers we've worked with in the past, we didn't have to purchase the model 'off the shelf'," Waggett said. "Blastcrete was willing to work closely with us to customize the equipment to suit our exact needs. Up to that point, no other company had been willing to do that."
Strata had been using dry process shotcrete, as it had been the industry standard. But gunite certainly comes with its share of drawbacks and Strata was really beginning to notice the negative implications. Because it's a dry-mix process, gunite applications produce a lot of dust, which is a major problem in underground mines, where air ventilates throughout the entire mine. Once that air is laden with dust, it will circulate to the other areas in the mine - a serious health and safety concern.
For Waggett the health and safety issues were a top concern, saying, "In addition to breathing in harmful dust, there's also the safety issue of reduced visibility. You can't see as well when there are dust particles everywhere."
Strata had been exploring the idea of using a wet-mix, or wet shotcrete, process to combat some of the issues posed by the dust. Typically, a wet-mix shotcrete process generates less airborne particles and rebound (waste) than gunite, simply because the material has 100% of the moisture added to it. Another advantage is the speed factor; wet shotcrete can be applied much faster than gunite. The Strata crew had actually even tried to utilize wet shotcrete for overcast installations on a few occasions. But while the process cut down on some of the safety issues associated with gunite, the equipment system wasn't as efficient.
"We didn't have any wet shotcrete equipment that was compact enough to actually go underground, so we had to do it from the surface," Waggett explained.
The lack of compact equipment meant there was a large divide from the surface where shotcrete was being pumped, to where the application was actually taking place underground - resulting in a less efficient process than the traditional gunite method. So in May of 2011, familiar with Blastcrete's willingness to customize solutions to his company's specific needs, Waggett approached Blastcrete's Sales Manager, Tripp Farrell, with another challenge: Solve the problem of inefficiency with a customized machine.
What Waggett ultimately wanted was a machine that could operate underground and allow the crew to mix and pump right inside the mine. This would combat the lack of efficiency with the company's current shotcrete process.
"I was confident the crew at Blastcrete would provide us with what we needed," he asserted. And he was right. Early that summer, Blastcrete met Strata's challenge with the Mine Mate.
The Mine Mate, a new machine featuring Blastcrete's X-10 high-pressure swing tube pump, can apply up to 12 cubic yards per hour. The machine also includes a high-shear continuous mixer. Perhaps most importantly, the Mine Mate is designed to be compact enough to work underground.
"I've still never found another piece of equipment, other than Blastcrete equipment, that can operate in the mine," Waggett said. "This was exactly what we needed."
Since using Blastcrete's Mine Mate, Waggett and his crew have seen a significant reduction in the amount of dust emissions underground. In fact, Waggett estimates the crew is seeing "about 40 to 50 percent less dust. That's a huge reduction."
Waggett was also very pleased with how easy the Mine Mate was to clean. One of the misconceptions and deterring factors about using wet shotcrete equipment is that it needs more attention than gunite machinery. While wet shotcrete equipment does require more immediate attention after operation, both types of machines require frequent cleaning and maintenance. But Waggett noted that cleaning and maintaining the Mine Mate has been quick and easy every time, particularly thanks to Blastcrete's innovative continuous feed mixer. The mixer is easily cleaned by removing the mixer housing and flushing. The pump is simply engaged in reverse and flushed with water until the swing tube and material cylinders are clean.
Beyond customized and user-friendly equipment, Blastcrete also provides excellent customer service. The domestic nature of Blastcrete's operation allows Waggett's crew to reduce downtime. Replacement parts can be overnighted from Blastcrete's facility in Anniston, Alabama. And the significance of reducing downtime can't be overstated, especially with safety and lives at stake.
The Mine Mate continues to help Strata provide safe and efficient overcast installation, but Waggett and his crew have kept the machine busy with other tasks as well. The crew often detaches the wet shotcrete nozzle in order to simply mix and pump concrete for various underground applications. It sounds simple, but according to Waggett, "It's very convenient and provides us with the versatility we need for several applications." This convenient and versatile nature has allowed the Mine Mate to benefit crews in various tasks.
With a commitment to safety a core value of the company, Strata Mine Services has found the key to meeting that goal is a combination of finding the right equipment to ensure productivity and refusing to settle for anything less than the ideal solution. In both cases, Waggett credits Blastcrete with being an essential element in the mix, providing Strata with concrete results and a safer environment in the mine.
]]>The X-10 is a 3-inch swing tube pump capable of pumping up to 12 cubic yards per hour, and can handle aggregate up to ¾-inch diameter. Offering the highest piston face pressure in the industry at 2,200 PSI, it can pump material in excess of 500 feet, horizontally and vertically.
To allow simplified cleaning and maintenance, Blastcrete has designed its swing tube pump for easy access to crucial areas. Thanks to a heavy-duty hinge mounting, the 2,500-pound capacity-receiving hopper features easy swing-out capabilities. The flat pack is held in place by four heavy-duty bolts, allowing the spare flat pack to be quickly and easily replaced, virtually eliminating downtime. An optional 2,000-PSI hydraulic pressure washer is available for fast and easy cleaning of the mixer and the pump.
A hydraulic agitator is included in the receiving hopper to ensure the mix stays consistent and blended. The agitator's high intensity mixing action assures that the aggregate materials remain in suspension as the material is loaded into the pump.
Power options on the X-10 are a V3600, 66-horsepower Kubota water-cooled diesel engine or 40-horsepower electric motor with starter and disconnect, and the machine comes standard mounted on a 6,000-pound single capacity axle trailer. The X-10 is CE Certified, meeting European Union safety standards for equipment operation, and backed worldwide by Blastcrete's unmatched customer service and support.
For 60 years, Blastcrete Equipment Company has been manufacturing safe, reliable and user-friendly solutions for a variety of industries worldwide. With a complete product line consisting of concrete mixers, pumps and related products, Blastcrete Equipment Company is poised to meet the needs of the commercial and residential construction, ICF and SCIP building systems, refractory and underground markets. For more information, contact Blastcrete Equipment Company, 2000 Cobb Ave, Anniston, AL 36202, call 800-235-4867, fax 256-236-9824, e-mail, or visit the Web site at www.blastcrete.com.
]]>Created at the request of several customers seeking a machine to apply shotcrete in underground coal applications, the Mine Mate was developed, and utilizes the wet-mix shotcrete process. In contrast to the dry shotcrete (gunite), the wet shotcrete process minimizes dust emissions and improves visibility making it much safer, particularly for underground use. Featuring a compact and extremely low-profile configuration, the Mine Mate is designed for operation within a 4-foot ceiling.
The Mine Mate includes Blastcrete's X-10 3-inch, high-pressure swing tube pump, and a high-shear continuous mixer. The unit is capable of mixing and pumping 12 cubic yards per hour, and can handle aggregate up to 3/8" diameter. Offering the highest piston face pressure in the industry at 2,200 PSI, it can pump material in excess of 500 feet, horizontally and vertically. Additionally, the hydraulic pump can run in reverse to eliminate line pressure from the delivery line should a hose plug. This is a very important safety feature in any pumping operation.
Unlike competitive swing tube pumps, the X-10 provides easy access for cleaning and maintenance. The receiving hopper of the pump is mounted with a heavy duty hinge so that it can easily swing away from the swing tube section. The flat pack is held in place by four heavy-duty bolts so that the spare flat pack can quickly and easily be replaced. This assures that downtime will be all but eliminated. An optional hydraulic pressure washer is available for quick and easy cleaning of the mixer and the pump.
Available power options include a V3600, 66-horsepower Kubota water-cooled diesel engine or 50-horsepower electric motor with starter and disconnect. The machine can also be equipped with a material screw conveyor, with bin indicator for charging the continuous mixer.
The Mine Mate's X-10 is CE Certified, meeting European Union safety standards for equipment operation, and the entire unit is backed worldwide by Blastcrete's unmatched customer service and support. To accommodate even the most unique and challenging underground applications, Blastcrete offers the option to customize the machine to suit any end-user's specific needs.
For 60 years, Blastcrete Equipment Company has been manufacturing safe, reliable and user-friendly solutions for the shotcrete industry. With a complete product line consisting of concrete mixers, pumps and related products, Blastcrete Equipment Company is poised to meet the needs of the commercial and residential construction, ICF and SCIP building systems, refractory and underground markets. For more information, contact Blastcrete Equipment Company, 2000 Cobb Ave, Anniston, AL 36202, call 800-235-4867, fax 256-236-9824, e-mail info@blastcrete.com, or visit the Web site at www.blastcrete.com.
]]>THEODORE, Ala. - Downtime - it's an ugly word. Regardless of the business type, downtime is one of the most detrimental and negative things a company can experience. Whether it's unexpected downtime due to equipment failure or labor shortage, or planned downtime for routine practices such as equipment maintenance and repair, the key to minimizing its damaging effects of downtime is simple - limit it as much as possible.
Perhaps no one understands this concept better than Kirby Sternfels. As the owner of K&G Industrial Services, Sternfels' and his company's mission is getting others back in business. Located just outside Mobile, AL in the small town of Theodore, K&G provides refractory demolition and installation to a variety of industries.
Refractory, which is high-temperature, heat-resistant material such as fire-brick, shotcrete or gunite, is essential for operation in facilities including cement production plants, paper mills and chemical plants. Refractory material is used as a lining in furnaces, incinerators, kilns and reactors, and is a necessary component for structures that are exposed to environments above 1,000 degrees Fahrenheit. It's applied to the interior of the surface using a high-pressure pumping machine that sprays on the material. Depending on how much production a plant experiences and how hard its equipment has been worked, clients typically require K&G's services one to three times a year.
K&G is a fairly large company, employing anywhere from 45 to 200 people at a time, depending on how many jobs are ongoing at once. It services clients in 20 states, from as far southwest as Texas, up to the New York area. Although the company was only recently formed in October of 2008, K&G has made quite a name for itself in the industry - much of the success stemming from the fact that Sternfels is an experienced veteran in the refractory industry. Prior to starting his own company, he worked for nearly ten years at a company that provides similar services as K&G. Before that, he was employed by a refractory equipment manufacturer. One could say he's been eating, sleeping and breathing refractory for most of his adult life. And those close to this industry know that experience matters, as refractory installation isn't a common, well-known practice.
K&G has managed to grow and keep current clients coming back with knowledge, professionalism and quality work. But most importantly, what really matters to these companies is urgency. Regardless of the type of facility it's servicing, K&G knows efficiency is the name of the game to all its clients. When Sternfels and his crew are performing their services, they're stopping that plant's work - and money-making opportunity. Again, Sternfels' industry experience is priceless, as he understands the importance of getting these companies back up and running as quickly as possible. And he makes that his number one priority.
"Even though most plants typically only require maintenance to be performed once or twice a year, any amount of downtime is hampering to their productivity and profitability," Sternfels said. "These companies, they can't afford to be held up a long time, waiting for us to finish. After all, time is money!"
For this reason, it's crucial for K&G to be able to get in, perform its service quickly and effectively, and get out. Seems like a simple enough philosophy, but Sternfels needs more than values and a hard-working team to ensure the work gets done quickly. He's found a major key to the success of his company is the equipment his crew utilizes on each job.
Refractory installation equipment isn't something sold off the shelf in a local big box retailer. It's very technologically advanced, sophisticated and powerful equipment. It needs to do just one job, but must do it exceptionally well. So when he first started his company, Sternfels wanted to work with an equipment manufacturer that had reliable, quality equipment and also provided top-notch service and support. After all, in order for his crew to help its customers minimize downtime, his company would need to avoid it altogether - equipment failure was not an option. He knew just the manufacturer to call.
"I had previously worked with a manufacturer out of Anniston [Alabama] called Blastcrete Equipment Company," Sternfels said. The company, which manufactures a variety of shotcrete and gunite mixers and pumps, was already familiar to Sternfels, as was its reputation for providing remarkable service and support. Top that off with the fact Blastcrete is located just a few hours away from K&G's headquarters in Theodore, and Sternfels was sold.
He also recognized the value of working with a company that specializes in refractory installation equipment and has plenty of experience close to the industry. Blastcrete was previously a division of Southeast Refractories until 1999, when Southeast was sold and Blastcrete became a stand-alone company. With years of manufacturing knowledge under its belt, Blastcrete had developed a variety of refractory equipment including high-pressure mixer/pumps and dry gunite machines. Beyond refractory, the company offers mixers and pumps for a variety of other industries, including commercial and residential construction, masonry, mining, underground and building system such as ICF and SCIP.
Tripp Farrell, sales manager for Blastcrete, was eager to help out and pleased to be working with Sternfels again. "We already had a great relationship with Kirby [Sternfels], working with him at his previous company, and I knew we'd be able to provide the right equipment and the support he'd need," he said. "Because we're very in tune with the refractory industry, we know how crucial time and efficiency is to K&G's clients. We do everything we can to give them, not just the equipment they need, but the service and support as well."
And as far as the equipment goes, it's among the most technologically-advanced in the industry. Thanks to years of research, development and simply listening to customer's requests, Blastcrete evolved its machines to be technologically advanced, yet easy to operate and maintain. "The machines offer high performance, but also user-friendly features to enhance operation and reduce cleaning and maintenance efforts," Sternfels said.
K&G's fleet consists of two Blastcrete MX-10 mixer/pumps and twelve AA 020 Genuine Piccola gunite machines. The MX-10 is an ultra high-pressure swing-tube style mixer/pump used for wet shotcrete applications. Featuring a simple, one-bolt clamping system, the AA 020 Piccola machine is ideal for dry shotcrete, or gunite, installations. K&G stocks more Piccola units, as the company typically prefers to do dry shotcrete installation. However, some customers specify a wet shotcrete must be applied; in those cases, K&G has the MX-10 units ready to go.
"The company doesn't offer just one model of equipment. There are several to choose from," Sternfels said. "So that's great for us because it allows us to accommodate each client's request. And it takes our customer service up a notch." Blastcrete even goes so far as to customize pieces to customer's exact specifications, an option Sternfels says he's considered.
Sternfels was also pleased that Blastcrete was able to get him several pieces for his fleet. He anticipated K&G would have multiple jobs going on at the same time, so he wanted to have several pieces of equipment on hand so he'd never have one job waiting on another.
"Sometimes we'll have a few different jobs in different parts of the country," Sternfels said. "We can't hold up a job in Texas because we're waiting on the piece of equipment to arrive from a completed job in New York. That just wouldn't be efficient and it wouldn't work for our customers."
Another factor Sternfels can't tolerate - broken equipment. "We can't afford for the equipment to break down and be in need of frequent repairs," he said. "That's one thing I really like about the Blastcrete machines. They just don't break."
And on the off-chance anything would go wrong, Sternfels has peace of mind knowing Blastcrete will be there to provide service and support, not just because the company is nearby in Alabama, but because it's such a customer service-focused company.
"From day one, we made it our mission to provide the best customer service," Farrell said. "Now, customers have high expectations, and we strive to live up to those expectations any way we can."
Speaking of expectations - another Blastcrete not only meets but exceeds is the expectation to manufacture equipment that's easy to own and maintain. As far as the routine maintenance and cleaning, K&G takes care of it all, right at its shop in Theodore. Both the MX-10 and Piccola machines, along with all of Blastcrete's equipment, are designed to be very easy to maintain, including a simplified cleaning process. To equipment owners in other industries, that might sound like more of a detail. But Blastcrete knows how important it is in the refractory business.
"Let's face it, with any piece of equipment, routine maintenance and cleaning is often neglected when companies get busy," Farrell said. "But with any type of refractory installation equipment, you absolutely cannot afford to skip these steps. They have to be done every day."
Farrell explains the machine's performance will suffer, and it can become severely damaged without proper care. It's common knowledge that concrete material will harden over time. So if the material isn't cleaned every day, it will harden, and eventually build up and damage the equipment. Recognizing that companies don't have an hour to spend on cleaning and maintenance every day, Blastcrete designed its machines to make the process as quick and easy as possible.
"Everything from the swing-out hopper designs to the way we positioned the platform and engine on the MX-10 model was purposeful and planned. It's all been strategically and carefully designed for best results and to reduce the amount of time spent on cleaning and maintenance," Farrell said.
Sternfels notes that the cleaning and maintenance process is quick and simple. And while he's quick to point out that it isn't difficult, he does recognize that it must be done regularly. "We can just handle it here at the shop and have the piece ready to go out on the next job," he said.
And indeed it does go, almost instantly, to the next job because K&G remains a busy company that is growing and adding customers. In fact, the company recently added a second facility in Texas to better serve customers in the area.
Sternfels certainly has a lot of pride in his company. Despite all the growth and success K&G has experienced, he's remained very humble.
"We simply keep our word to customers," he said. "There's no magical business model I've discovered, no cutting-edge, new way of doing things that I try to brag about. We just do what we say we will, and do it well." Bottom line: K&G makes sure its clients get back to work as quickly as possible - keeping downtime to a minimum.
Kirby Sternfels, owner of K&G Industrial Services, has been in the refractory service industry for more than ten years. K&G Industrial Services provides refractory demolition and installation to a variety of industries, including cement production plants, paper mills and chemical plants and services clients in more than 20 states across the Southern, Eastern and Midwest regions of the U.S. For more information, contact K&G Industrial Services at 251.443.7440.
For 60 years, Blastcrete Equipment Company has been manufacturing safe, reliable and user-friendly solutions for the refractory and shotcrete industries. The company's complete product line includes concrete mixers, pumps and related products. For more information, contact Blastcrete Equipment Company at 800-235-4867, e-mail info@blastcrete.com, or visit the Web site at www.blastcrete.com.
]]>Farrell and Jollay, along with Blastcrete's Craig Maddox, originally sat down to help resolve material handling issues for masonry grout in specific job applications. It was then that Jollay, whose company boasts an impressive resume as mason contactor on such projects as Turner Field, Phillips Arena, and the Georgia World Congress Center, really got Farrell's attention with one powerful comment.
"Even with all the equipment and material improvements over the last 50 years, many of the basic installation and logistic challenges have remained the same," Jollay said. He continued on to explain the current design emphasis by structural engineers is to increase amounts of grout fill for CMU walls, even when non-loadbearing. This, combined with the challenge of alternate wall systems, cost inefficiencies, lack of job site storage, and safety concerns with dust exposure, proves there is truly a need for an engineered solution for grouted CMU walls, particularly for interior scope and high rise structures. Jollay qualified his final comment is true if masonry is going to stay competitive and increase market share in the buildings of the future.
Farrell, who purchased the 60-year old Blastcrete Equipment Co. in 1983, had a history of thinking outside the box and really listening to his customers. While Blastcrete did not have a long history in the masonry business, Farrell recognized that a willing resource with as much experience as Jollay could be the architect to help the company develop an innovative machine for the mason. It was then the idea for the Mason Mate was born.
"When Dave [Jollay] and I sat down, the first basic idea we agreed on was the machine should be placed as close to the masons as possible," recalls Farrell. "Sounds simple, but it was a revolutionary idea."
Indeed it was. That's because, historically, grout and mortar have been mixed and transported, either pumped, or hauled long distances in a mortar box with an expensive telehandler. Both Jollay and Farrell thought it would be more cost effective to move a dry pre-blended material in a package when labor costs, waste, dust and safety are considered. Once the two were in agreement on such a huge modification of the grouting process, Jollay began to point out other issues he felt needed to be addressed.
"I explained to Jim [Farrell] that we needed a machine that was safe, simple, portable, compact and, obviously, cost effective," Jollay said, when recalling the meeting. As the men talked, Farrell and Maddox pointed out proven components that Blastcrete had developed for other applications. They took the footprint discussed earlier and Jollay laid out the components of the machine. That produced drawings, which eventually resulted in the decision that Blastcrete would build a prototype.
Blastcrete's recent design of a two-stage continuous mixer that matched the output of its 2-inch squeeze pump was a radical change from historical batch mixers. But the two-stage continuous mixer met all of the requirements that Jollay had suggested relative to cost, portability, labor savings, and reduction of waste and dust.
After months of testing the Mason Mate, things were moving full steam ahead - then a roadblock was encountered. Blastcrete was shocked to learn that the American Society of Testing Materials (ASTM) 476 specifically pointed out there was a minimum five-minute mixing time for masonry grout. There was no language in the rules that addressed continuous mixing, even though continuous mixing of mortar and grout had been used in Europe and Asia for decades. At that point, Blastcrete pulled the plug on promoting the machine for its original design - masonry grouting and mortar. But the door wasn't closed yet.
In 2008, inquiries from new customers provided an opportunity for Blastcrete sales manager, Tripp Farrell, to modify the Mason Mate for applying shotcrete in underground coal applications. These modifications resulted in the Mine Mate, and also provided an excellent opportunity to get real-time experience on the two-stage continuous mixer ? in extremely harsh conditions underground. A modified version of the original Mine Mate, the Mine Mate 1100, is now being used successfully for a patented rock dusting process, developed by BASF (the world's leading chemical company), to improve safety in coal mines.
Blastcrete had now established credibility and confidence in the level of its two-stage continuous mixer. Almost immediately, other opportunities emerged for the Mason Mate and modified versions of it. For example, several machines have been sold to stucco and plaster contractors. And recently, the Mason Mate technology has been used for applications in asphalt and concrete overlay materials, more specifically Tensar International Corporation's Endurablend Polymer Cement Slurry Surfacing system. Endurablend is used primarily as a pavement preservation solution for asphalt and concrete surfaces, as well as crack filling applications, and provides an aesthetically pleasing and durable new surface. Tensar's patent-pending material is unique in that it has excellent bond characteristics on both asphalt and concrete surfaces.
It was clear there was demand for a product like the Mason Mate. Everyone at Blastcrete knew, and Farrell still hadn't given up on his new product. As he and his crew would soon find out, others also saw potential and weren't ready to give up either.
By 2009, a leading manufacturer of pre-blended mortar and grout had developed interest in the use of a continuous mixer for their silo systems. Two representatives from the company led the group to help modify ASTM C476, specifically item 5.2.1.1 in Section 3. This allows for the use of a continuous mixer for masonry mortar and grout, provided these pre-blended materials are mixed with water based on the recommendation from the manufacturer of the pre-blended materials. One employee from the manufacturing company is also a member of the C12 committee, which helped make the change. Thanks to the help from all these industry leaders, ASTM, as a group, recognized the benefit of continuous mixing.
These changes now allow Blastcrete to continue with the original 2006 plan ? and the goal of revolutionizing the masonry industry with the Mason Mate.
"It's exciting to see that things finally might work out for the Mason Mate as originally intended, and really see if it can change and modernize our industry, " Jollay said. "I think the machine meets the original criteria of being very portable and safe, while emitting less dust, and being quick and easy to clean." And Jollay feels if it's as cost effective as Blastcrete says it is, that will be the real icing on the cake.
Always looking on the bright side, Farrell feels the delay to the original design, as a result of ASTM rules, was actually a blessing. "It provided other opportunities and helped us gain confidence in a radical change on how we mix the water with mortar and grout," he said. "Masonry contractors have our assurance that the Mason Mate will put more profit in their pocket, and that's the bottom line."
The all-hydraulic Mason Mate is available with an optional 1,000-pound capacity lifting arm for bulk bags, and the choice of gasoline, diesel or electric power. Its compact size allows the machine to be hauled in the bed of a ¾-ton pickup, and moved around the job site with a pallet jack, forklift and freight elevator. As an added benefit, Blastcrete also offers free training to customers at its manufacturing facility in Anniston, AL. Additional information can be found by visiting www.blastcrete.com, calling 800-235-4867 or e-mailing info@blastcrete.com
]]>Unlike traditional, tedious masonry methods, the Mason Mate is designed to be a fast, efficient, one-man solution. Rather than mixing material and water offsite, then transporting the blended material with expensive telehandlers to be installed, the Mason Mate is able to perform the entire process from start to finish right on the jobsite, and requires just one operator. The unit saves valuable time by being operated onsite and in close proximity to the mason, while also eliminating the need for several pieces of large, expensive equipment, wheelbarrows and ?bucket brigades? consisting of multiple laborers.
Featuring a compact design, the Mason Mate can be used in virtually any setting. It easily fits in the back of a pickup truck or in a freight elevator, and can operate within an 8-foot ceiling. Furthermore, the compact design allows easy maneuverability with a pallet jack and placement with a telescoping forklift or crane.
The Mason Mate includes Blastcrete's D3522, 2-inch hydraulic squeeze pump with variable speed up to 6 cubic yards per hour and a high-shear continuous mixer for increased speed and shorter mixing time. The unit is capable of pumping 3/8-inch aggregate mixes at 450 PSI pumping pressure.
To relieve pressure build-up clogs and eliminate potential damage to the pump, the Mason Mate's D3522 can be run in both forward and reverse. Hydraulic controls for the pump, mixer, and remixer are conveniently located on the operator's control dash.
The Mason Mate is designed for easy, simplified maintenance and cleaning. The primary wear part, the rubber pumping tube, can be easily replaced on the jobsite in about 20 minutes. And unlike other types of concrete pumps, clean-up on the squeeze pump is fast and hassle-free. Using just water and a sponge ball, the pump can be cleaned out in approximately 5 minutes.
A 29 HP Kubota water-cooled diesel is standard. The Mason Mate is also available with either a 35 HP Briggs & Stratton gasoline engine or 30-horsepower electric motor with starter and disconnect.
For 60 years, Blastcrete Equipment Company has been manufacturing safe, reliable and user-friendly solutions for the shotcrete industry. With a complete product line consisting of concrete mixers, pumps and related products, Blastcrete Equipment Company is poised to meet the needs of the commercial and residential construction, ICF and SCIP building systems, refractory and underground markets. For more information, contact Blastcrete Equipment Company, 2000 Cobb Ave, Anniston, AL 36202, call 800-235-4867, fax 256-236-9824, e-mail info@blastcrete.com, or visit the Web site at www.blastcrete.com.
]]>Blastcrete's Piccola gunite machine is intended to be a simple solution for gunning applications up to 6-cubic yards per hour. It offers precise material output, with the ability to deliver a maximum of 3/8-inch aggregate.
Designed for user-friendly operation, the Piccola machine features a simplified one-bolt clamping system. Unlike similar systems that typically include three to four adjustment bolts to seal the clamping plate to the rotor, Blastcrete's requires just one bolt. This simplified design makes it quick and easy to adjust, and ensures an excellent seal each and every time. A good seal will prevent dust leakage around the rotor and is essential for optimal results.
The Piccola machine is also designed for trouble-free cleaning and maintenance. The entire unit can be taken apart easily for quick, effective cleaning and convenient access for routine maintenance.
Featuring a small, compact design, the Piccola machine is designed for easy transport and fits in the bed of a pickup truck. It's mounted on solid rubber tires for mobility, and also available skid mounted with forklift pockets. Power options on the unit are either a 5-hp electric motor or 16-AM Gast air motor. Air requirements are dependent on power choice, and range from 250 to 600 CFM.
For 60 years, Blastcrete Equipment Company has been manufacturing safe, reliable and user-friendly solutions for the shotcrete industry. With a complete product line consisting of concrete mixers, pumps and related products, Blastcrete Equipment Company is poised to meet the needs of the commercial and residential construction, ICF and SCIP building systems, refractory and underground markets. For more information, contact Blastcrete Equipment Company, 2000 Cobb Ave, Anniston, AL 36202, call 800-235-4867, fax 256-236-9824, e-mail info@blastcrete.com, or visit the Web site at www.blastcrete.com.
]]>With the ability to pump grout materials, 3/8-inch shotcrete and 3/4-inch structural concrete mixes, the RD6536 is a fast, efficient solution for contractors performing a variety of concrete and shotcrete applications. The unit offers a variable speed of 0-25 cubic yards per hour. Vertical pumping distance reaches 50 feet with the use of a rubber delivery line, while horizontal distance can reach up to 250 feet.
A hydraulic agitator is included in the receiving hopper. The agitator's continuous motion keeps the mix well-blended, ensuring aggregate and sand stay evenly suspended throughout the mix. Not only does this result in high-strength concrete, it keeps the aggregate and sand from settling to the bottom of the hopper and clogging near the suction area.
To relieve pressure build-up clogs and eliminate potential damage to the pump, the RD6536 can be run in both forward and reverse. Hydraulically powered controls are located on the pump and also operate both agitator and pump speed.
The RD6536 weighs in at 2,700 pounds and hydraulic oil requirement is 18 GPM at 3,000 PSI. The 48-inch wide frame (55-inch with receiving hopper) is designed to be narrow enough to fit between the wheel wells of most standard work trucks. The unit includes forklift pockets to allow quick and easy loading and unloading from the transport vehicle.
Maintenance requirements for the RD6536 are simple and take just minutes. The steel-constructed unit is designed to prevent any concrete from coming in contact with the pump?s moving parts, further reducing maintenance concerns and ensuring a long service life. The primary wear part, the rubber pumping tube, can be easily replaced on the jobsite in about 20 minutes. And unlike other types of concrete pumps, clean-up on the RD6536 squeeze pump is fast and hassle-free. Using just water and a sponge ball, the pump can be cleaned out in approximately 5 minutes.
For 60 years, Blastcrete Equipment Company has been manufacturing safe, reliable and user-friendly solutions for the shotcrete industry. With a complete product line consisting of concrete mixers, pumps and related products, Blastcrete Equipment Company is poised to meet the needs of the commercial and residential construction, ICF and SCIP building systems, refractory and underground markets. For more information, contact Blastcrete Equipment Company, 2000 Cobb Ave, Anniston, AL 36202, call 800-235-4867, fax 256-236-9824, e-mail info@blastcrete.com, or visit the Web site at www.blastcrete.com.
]]>The MX-10 features a 2,200-pound capacity, high-torque hydraulic pan mixer, which offers a mix time of 2 minutes or less. Combined with an ultra high-pressure, 2,200-psi piston pump, the unit is able to consistently deliver 10 tons of material per hour and achieves vertical pumping distance of up to 300 feet.
In order to prevent material build-up and hardening, as well as possible damage to the unit, the MX-10 must be thoroughly cleaned after each use. Unlike typical swing tube-style pumps that require difficult, time-intensive cleaning and maintenance, the MX-10 has been designed to make the process quick and simple. The receiving hopper features swing-out capabilities, allowing easy access to its lower area and the swing tube for fast cleaning and maintenance. The entire flat pack can be removed from the frame in just minutes to provide easier access for maintenance. For enhanced cleaning ease, a 2,000-psi hydraulic pressure washer is an available option.
To ensure the mix stays consistent and blended, a hydraulic agitator is included in the receiving hopper. The agitator's high intensity mixing action assures that the refractory grains and binders remain in suspension as the material is loaded into the pump. The re-mix hopper with agitator has a capacity of 2,500-pounds.
At 22-square feet, the operator platform on the MX-10 offers more than 50 percent additional space than competitive models. The platform design also allows the electrical controls to be ideally positioned to prevent debris and water from making contact with the electrical components. Lifting eyes are mounted on the platform for easy lifting and transport.
Thermal transfer can cause refractory materials to set prematurely. The MX-10 has been designed to prevent thermal transfer from the engine to the mixer and receiving hopper by positioning the engine safely away from both areas. This also prevents foreign debris from entering and clogging the air intake on the engine.
Mixer liners and carbide wear components for the pumping system provide assurance for long life. For enhanced durability, an automatic lubrication system is optional.
The unit is available with either a John Deere 4045T 99-horsepower or Deutz BF4M 2012 102-horspower water-cooled diesel engine. It's also available with dual 40-horsepower electric motors. The MX-10 is CE Certified, meeting European Union safety standards for equipment operation and backed worldwide by Blastcrete's unmatched customer service and support.
For 60 years, Blastcrete Equipment Company has been manufacturing safe, reliable and user-friendly solutions for the refractory and shotcrete industries. With a complete product line consisting of concrete mixers, pumps and related products, Blastcrete Equipment Company is poised to meet the needs of the commercial and residential construction, ICF and SCIP building systems, refractory and underground markets. For more information, contact Blastcrete Equipment Company or call 800-235-4867.
]]>The Dampcon Rig features Blastcrete's 020 "Piccola" Rotary Gunite machine to offer precise material output control and a delivery rate of up to 6-cubic yards per hour. The user-friendly machine is easy to operate and maintain, and features a simplified one-bolt clamping system. Unlike typical systems that include three to four adjustment bolts, the Blastcrete system has been designed to require just one bolt, making it easy to adjust and ensuring an excellent seal every time.
A 9-cubic foot capacity paddle-style mixer is designed to pre-dampen the gunning materials, and minimize dust and wasteful rebound material. Furthermore, the unit includes rubber wipers that clean out and reduce material build-up in the mixer. A material elevator with cleated-belt conveyor transfers material to the gunite machine's receiving hopper. The mixer is also equipped with a water meter and bar to ensure the proper amount of water is added to each batch.
The entire unit is designed to be extremely easy to clean and maintain. By mounting the gun on casters, it can be easily pushed to the front of the frame so the belt can be cleaned. In response to customer requests, the mixer features swing-out capabilities for further simplified maintenance and cleaning. Simply unclamp, swing out the mixer and open the door for access. The entire unit can be cleaned quickly using just compressed air.
Air requirements for the Dampcon Rig are 250 CFM at 90 PSI. Power options are either a Kubota V1505 29-horsepower water-cooled diesel engine or 20-horsepower electric motor with starter and disconnect. The unit is available as a tandem axle trailer or skid mount with forklift pockets. The trailer-mounted model can be towed with a 3/4 ton pickup and the axles are equipped with electric braking capabilities. A hydraulic water booster pump is also optional and ideal for jobsites with no pressurized water.
For 60 years, Blastcrete Equipment Company has been manufacturing safe, reliable and user-friendly solutions for the shotcrete industry. With a complete product line consisting of concrete mixers, pumps and related products, Blastcrete Equipment Company is poised to meet the needs of the commercial and residential construction, ICF and SCIP building systems, refractory and underground markets. For more information, contact Blastcrete Equipment Company or call 800-235-4867.
]]>With the ability to pump grout materials, 3/8-inch shotcrete and 3/4-inch structural concrete mixes, the RD6536 is a fast, efficient solution for contractors performing a variety of concrete and shotcrete applications. The unit offers a variable speed of 0-25 cubic yards per hour. Vertical pumping distance reaches 50 feet with the use of a rubber delivery line, while horizontal distance can reach up to 250 feet.
A hydraulic agitator is included in the receiving hopper. The agitator's continuous motion keeps the mix well-blended, ensuring aggregate and sand stay evenly suspended throughout the mix. Not only does this result in high-strength concrete, it keeps the aggregate and sand from settling to the bottom of the hopper and clogging near the suction area.
To relieve pressure build-up clogs and eliminate potential damage to the pump, the RD6536 can be run in both forward and reverse. Hydraulically powered controls are located on the pump and also operate both agitator and pump speed.
The RD6536 weighs in at 2,700 pounds and hydraulic oil requirement is 18 GPM at 3,000 PSI. The 48-inch wide frame (55-inch with receiving hopper) is designed to be narrow enough to fit between the wheel wells of most standard work trucks. The unit includes forklift pockets to allow quick and easy loading and unloading from the transport vehicle.
Maintenance requirements for the RD6536 are simple and take just minutes. The steel-constructed unit is designed to prevent any concrete from coming in contact with the pump's moving parts, further reducing maintenance concerns and ensuring a long service life. The primary wear part, the rubber pumping tube, can be easily replaced on the jobsite in about 20 minutes. And unlike other types of concrete pumps, clean-up on the RD6536 squeeze pump is fast and hassle-free. Using just water and a sponge ball, the pump can be cleaned out in approximately 5 minutes.
For 60 years, Blastcrete Equipment Company has been manufacturing safe and user-friendly solutions for the shotcrete industry. With a complete product line consisting of concrete mixers, pumps and related products, Blastcrete Equipment Company is poised to meet the needs of the commercial and residential construction, ICF and SCIP building systems, refractory and underground markets. For more information, contact Blastcrete Equipment Company, 2000 Cobb Ave, Anniston, AL 36202, call 800-235-4867, fax 256-236-9824, e-mail info@blastcrete.com, or visit the Web site at www.blastcrete.com.
]]>Blastcrete Equipment Co., Anniston, Alabama, will celebrate its 60th year as a leading international manufacturer of mixing, pumping, and spraying equipment at World of Concrete 2010 booth C4653. "We take a lot of pride in being a truly customer-driven company," says Blastcrete President Jim Farrell. "Our customers and our employees are our biggest asset and we look upon both as part of the Blastcrete family. All of our employees understand that when we earn a customer's confidence that we have a duty to help that customer bring value to his business with his investment in Blastcrete and to help our customers make money with that investment."
In 2009, Blastcrete completed the design and build of the Model MX-20 CM mixer pump, which will revolutionize the placement of monolithic refractory materials. The MX-20 CM features a highshear, high-production, two-stage continuous mixer with a 4-inch ultra-high-pressure 25 ton per hour swing tube pump.
This machine was been designed for high-volume, mediumvolume, and low-volume mixing, pumping, spraying, and placement of refractories and shotcrete. The versatility is unmatched in the industry. "The footprint, weight, and fuel consumption of the MX-20 is less than our 3-inch MX-10 with a 2,200 pound batch mixer," comments Blastcrete Sales Manager Tripp Farrell. "The two-stage mixer cleans up 80 percent faster than a 3,300 pound capacity batch mixer, and the flat pack (pumping section) includes our popular swing out hopper for easy access to cleaning and maintenance. Oversized differential cylinders lower the pumping pressure, which improves the life of the concrete pump. Best of all, the price of the machine is 30 percent less than competitive machines. Once again, we are providing our customers with more for less."
Blastcrete also delivered its first self-propelled mixer/pump designed for the precast industry in 2009. Designed specifically for a large precast customer in Latin America, this machine features a 9 cubic yard electric/hydraulic remixer, which supplies aggregate concrete material for two 3-inch electric squeeze pumps. The machine was mounted on an in-plant railway, which leads from the ready mix plant to the molds.
A propane powered engine serves as the power pack for the propulsion of the vehicle, as well as the hydraulic system. "This has been a very exciting project for us," says Farrell, "and it has opened up a new market for us (precast) which we plan to take advantage of."
Blastcrete provides opportunities for their customers to grow and diversify their business. MetrockSCIP is an affordable Structural Concrete Insulated Panel System developed for extremely energy efficient and green housing, and this is available for license from Blastcrete.
The Alabama Department of Transportation Research and Development Committee has recently approved a thin shell concrete repair system for storm water culverts, which includes a proprietary high-tensile strain repair material, as well as a Blastcrete mixer, pump, and robot that is available for license from Blastcrete.
The gypsum flooring industry has benefited from a complete line of Blastcrete mixer/pumps that include 2-inch and 3-inch squeeze pumps, as well as a new 4-inch ball seat pump for extremely high-volume applications.
The masonry industry has benefited from the Mason Mate, a compact, self-contained mixer pump that reduces a mason grouting crew by 60 percent and it is also capable of pumping mortar, as well as masonry grout.
The coal mining industry has benefited from the Mine Mate, a continuous mixer that can feed either a squeeze pump or swing tube pump for mine stabilization.
]]>"This device changes everything about how this type of technology can be used,? says Jim Farrell, President of Blastcrete. ?Now you can safely pump shotcrete and concrete 600 feet at a speed that will increase builders? efficiency worldwide."
The HBS 1500 features a 12 cubic ft. hydraulic spiral mixer with hydraulic dump and a 30 second mixing time. The 26 cubic ft. receiving hopper includes a hydraulic agitator and hydraulic dump for quick and easy cleaning of the pumping cylinders. The 4" ball seat assembly is attached to the receiving hopper and flat pack with heavy duty clamps which can be quickly and easily disassembled for cleaning or making routing repairs.
The ball seat pump offers much lower maintenance costs than comparable rotor stator pumps with the average repair cost at less than $.03 per bag of material pumped. The machine is mounted on a high speed dual axel trailer with brakes and lights. Standard features include a 2500 psi hydraulic pressure washer for easy cleaning as well as a 150 gallon water tank with digital water meter.
See the machine at World of Concrete booth N3043, Call Blastcrete at 800-235-4867 or visit www.blastcrete.com.
For More Information contact:
Jim Farrell, Blastcrete Equipment Co. - 256.235.2700 or 800.235.4867 - jim@blastcrete.com
"The Alabama iron and steel industry is not only one of our state's most historical industrial enterprises but each year grows in national scope and importance," said Gov. Riley. "This council was formed to make sure that Alabama continues to be the predominant force in a sector that literally drives the national economy."
"It's truly an honor to have been asked to serve on this important business development council," said Farrell. "The future growth of the state's steel industry will heighten Alabama's profile nationally and internationally."
For More Information contact:
Jim Farrell, Blastcrete Equipment Co. - 256.235.2700
The MetrockSCIP is a cooperative design effort of Mark David Heath, former shareholder, Chief Technology and Chief Operating Officer of Green Sandwich Technologies of Los Angeles, and Jim Farrell, President of Blastcrete Equipment Co., Anniston , AL . Heath is one of the leading experts on SCIP technology and introduced SCIPS to the American Concrete Institute 549 Committee at its annual meeting in Oct. of 2007. Farrell has been involved with SCIPS since 1990 and his company, Blastcrete, has been a leading supplier of mixing, pumping and spraying equipment for SCIPS since that time. Blastcrete has contracted with Metrock LLC to design and manufacture all of the tools required to locally assemble the panels, erect the panels, and mix, pump, spray and finish the cement plaster onto the panels.
The MetrockSCIP was designed in the US specifically for the US market. It features a patented (pending) screed that is made into the 1" x 1" x 14 gauge wire mesh. The screed serves as a visual depth screed for the nozzleman to field apply the cement plaster to the panel, and a mechanical screed for an unskilled worker to cut the cement plaster flat, straight and square. The utilization of the screed, combined with specific mixing, pumping and spraying equipment designed especially for the MetrockSCIP by Blastcrete, results in a savings of over 60% in labor costs, which lowers the cost per sq. ft. of panel to less than $10.
A portable assembly system is used for the MetrockSCIP, so the panels can be assembled right on the job site if required. Heavy-duty wire trusses are sandwiched in the foam insulating core. The mesh, EPS foam insulating core, and trusses are encapsulated with 1" of field applied cement plaster to form the structural monolithic composite. Panels can be made from 12" up to 48" wide, and up to 18 ft. long. Panel thickness can vary from 4" thick with 2" of EPS insulation, up to 12" thick, with 10" of EPS insulation. R-Performances of R- 40 can easily be achieved. It is estimated that insurance and energy cost can be reduced by 60% with the MetrockSCIP when compared to conventional stud-wall buildings.
The MetrockSCIP Package, which includes complete training and certification, is available for license. Composite Building Systems of Arvada, CO., and Envirolast Structures of Greer, SC are the newest licensees of the MetrockSCIP.
Information on the MetrockSCIP can be seen at the World of Concrete Greensite, or by visiting the Blastcrete booth N2253 at WOC.
Contact MetrockSCIP at 1-877-Metrock or www.metrockscip.com.
For an informational video please visit:
http://www.youtube.com/watch?v=0r8I2k3vkb4