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CLOSE THIS BOOKFibre Concrete (FCR) / Micro Concrete (MCR) Roofing Equipment (GTZ, 1991, 20 p.)
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MATECO Multitile Vibrator


Model "Peru"

Manufacturer MATECO S.A.
Division Equipos
Shell 319 Of. 906
Miraflores, Lima Peru
Tel. [ . . 51] 14 - 44 25 25
Fax. [ . . 51] 14 - 4126 96

Description

The Multitile Vibrator Model ''Peru" was designed and developed by Ing. Raul D'Angelo Kruger as a means to achieve increased productivity in a commercial workshop and produce more competitive FCR/MCR tiles for the open market.

The all-steel workstation has a large screeding table mounted on rubber shock absorbers. The screeding surface is a rubber sheet stuck onto the steel table, in order to ensure a tight fit of the frame and prevent the wet mortar from leaking out during vibration.

The key feature of the machine is that 3 or 4 rooftiles can be made during each screeding operation, depending on the type of interchangeable frame used, of which 5 different types are available: 2 kinds of curved tiles (Pantile and Romana) with 3 tiles per frame, and 3 kinds of plain tiles (Plane, Serrana and Provenzal) with 4 tiles per frame. These allow for a high output rate of 300 to 450 tiles per day, depending on the type of tile made and the skill of the operator.

The vibrator, which acts horizontally, is powered by a 12 volt DC electric motor, which runs on a car battery.

The MATECO Experience

MATECO S.A. is a private enterprise producing FCR products in Lima/Peru since early 1989. Its origins date back to 1986, when contacts were established between SKAT and the Peruvian architect, Manuel de Rivero which resulted in the setting up of a workshop in 1988.

The first FCR tiles were made on equipment obtained from JPM Parry & Associates, U.K., but it was soon realized that the local circumstances required certain modifications of the equipment and production process. Thus, on the basis of extensive experimentation, the following conclusions were drawn:
· Fibres: The most appropriate locally available fibres were found to be eucalyptus waste from the manufacture of wood-wool products. The fibres are already cut to 1.5 cm lengths (as needed for FCR tiles) and only need to be cleaned before use.

· Mortar mix: 10 kg of clay-free sand, 3.85 kg of Portland cement and 25 g of eucalyptus fibre mixed with 2 litres of water constitute a mixture enough to produce 7 pantiles or Roman tiles, or 8 plain tiles. The relatively small proportion of fibres ensures good appearance of the tile without forfeiting the strength needed to avoid damage during transportation and handling.

· Coloured tiles (particularly red ones) are preferred among Peruvians. After numerous trials the ideal combination was found to be a blend of 60 % red and 40 % yellow pigments, added in a proportion of 200 g per unit of mixture. Black coloured tiles are now also in demand, although a uniform appearance is difficult to achieve, because of the variation in the quality of pigments. However, in general, 300 g per unit of mixture IS used.

· Solar curing: Since the tiles cured in water generally had unsightly white stains on the surface, which had to be washed off with a special solution, other methods of curing were tried out. The most ideal method turned out to be a kind of autoclaving using solar energy (called solar curing): batches of 10 - 15 tiles (held in box-like frames) are placed in the curing tanks, which contain just a few centimeters of water. The tanks are deep enough to hold two layers of frames (ie one above the other) and are covered with black plastic sheets so that the tiles remain moist and the tank and its contents are heated up by solar energy. 4 days of solar curing followed by 10 days of air curing were found to give the tiles greater impact resistance than by water immersion curing for 7 days and subsequent air curing for 14 days. This method, therefore, not only saves curing space and time, but also prevents staining and produces stronger tiles.

· Screeding table: The output of one tile per cycle was found to be commercially unsatisfactory, which is why a larger screeding table was developed, incorporating a set of interchangeable screeding frames with which 3 or 4 tiles could be made at a time, thus achieving a considerably higher output rate.

Operating the Multitile Vibrator

To operate the Multitile Vibrator, one man is needed to work at the table, while two other men are occupied (about three quarters of the time) with the preparation of the mix, demoulding the previous days tiles, moving and cleaning moulds and plastic sheets, etc.

For each tile a separate plastic interface sheet is clamped down under the screeding frame. For each tile a lump of mortar, measured with the scoop, is placed in each field, all of which are spread out and smoothed with a float under vibration, which should not take longer than 90 seconds. The frame is opened and tilted up on the side opposite the operator, who moves to the right of the table to place a PVC mould onto the projecting brackets. With both hands, the first interface sheet with the screeded mortar is carefully pulled over the mould and aligned with the guide markings. The mould is removed and placed on the mould stack for initial curing and the procedure is repeated for each of the other tiles, before the production cycle can begin again.

On the next day the tiles are demoulded and placed in solar curing tanks (described below) for 4 days and later air cured for 10 days before the tiles are ready for use.

Technical Details

Multitile Vibrator Model "Peru"

Size of screeding table (1 x w x h)

92 x 65 x 92 cm (36 x 26 x 36 m)

Weight of screeding table

85 kg

Sizes of crates for shipment

a. Machine & accessories

100 x 120 x 90 cm (39 x 47 x 35 in)


b. 300 moulds

100 x 120 x 90 cm (39 x 47 x 35 in)

Weight of the two crates

a + b (132 + 211 kg)

343 kg

Standard tile size (Roman or pantile)

50 x 25 x 0.8 cm (19.7 x 9.8 x 0.31 in)

Energy input

electrical (car battery)

No. of tiles per cycle/output rate

3 or 4 / 36 to 56 tiles per hour

Labour force required (incl. mixing and stacking)

3 men

Price (ex works)

Multitile Vibrator

1350 US$

valid June 1991

PVC Mould

9 US$


Screeding Frame

50 US$


FOB expenses

100 US$

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