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AAC and Mortar Making Plants By Buildmate Projects Private Limited

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(http://www.build-mate.co.in) We are a technology driven manufacturer, supplier and exporter firm dealing in an extensive range of AAC and Mortar Making Plants. Our wide range of product includes Autoclaved Aerated Concrete Plants, Dry Mix Mortar Plant and Lime Plants. Our offered machinery gained us a huge repute globally for its precision engineered design, highly reliable performance and cost effectiveness. We ensure to provide the best service and best quality of products to our clients. Our wide range of quality products makes us vivid in the market.

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AAC and Mortar Making Plants By Buildmate Projects Private Limited

  1. 1. AAC BLOCK PLANTS WWW.BUILDMATE.IN
  2. 2. Flyash / Sand 75 % Cement 12-15 % Gypsum 1-2 % Lime 7-9 % Alumina 400-500 g per cu.m Water • Light weight blocks • Eco-friendly material • Considerable savings in mortar • Greater sound insulation • Greater fire resistance • Quicker construction • Higher overall savings Raw Materials and ratios: Advantages of AAC blocks: AAC BLOCKS Aerated Autoclaved Concrete or AAC Blocks which are very light weight blocks which are still strong enough for most applications. They are easy to install, cut and drill for various construction purposes and consume less cement and plastering material. Properties Burnt Clay Brick Concrete Blocks AAC blocks Dry Density (kg/m3 ) 1800-2000 1700-2000 450-1000 Compressive strength 30-80 30-150 30-60 Block size 229x114x70 400x200x200 400x200x150 400x200x100 L:600/500/400 W:100/150/200/250 H:200/250/300 Thermal conductivity 0.7 1.1 0.21-0.42 based on density Sound Insulation Normal Good Best Ease of use Normal Hard Easiest Environmental friendliness Poor Normal Green
  3. 3. Advantages of AAC blocks: Requirements to set up an AAC Block plant AAC Block plant layout • Land area: Minimum 2 acres • Land dimensions: min of 75m x 20 m • Proximity to affordable flyash / silica sand / river sand * • Proximity to urban markets • Minimal human labor for automated plants * Exact requirements will vary on project to project basis. S.no Range Plant Capacity in cu.m per day Plant type 1 Mini 100 expandable to 200 Low capital cost 2 Small 100 expandable to 200 Low capital cost 3 Medium 300 to 600 Buildmate, European 4 Large 600 to 1800 Buildmate, European
  4. 4. AAC PROJECTS BY BUILDMATE Buildmate has several plants under operation and in execution in India and abroad. Here are a few: ** Indicates AAC plant was one of the multiple product lines we incorporated in the same project. Other product lines include Dry Mix Mortar, Concrete brick/block/pavers, etc. Buildmate also takes up AAC projects on existing plants which consist of providing specific parts, modernization & upgradation. • 500 m3 /day AAC plant expandable to 750 with fly ash near Guntur, Andhra Pradesh, India • 380 m3 /day AAC plant with fly ash near Vijayawada, Andhra Pradesh, India • 960 m3 /day sand based AAC plant in Industrial City, Al Jubail, Saudi Arabia. • 500 m3 /day AAC plant along near Hyderabad, Telangana, India ** • 190 m3 /day AAC plant expandable to 380 with fly ash near, Nagpur, India • 500 m3 /day AAC plant expandable to 750 with fly ash near Raipur, Chattisgarh, India. • 300 m3 /day AAC plant with fly ash near Khammam, Telangana, India • 2000 m3 /day AAC plant near Vijayawada, Andhra Pradesh, India** • 435 m3 /day AAC Plant (expandable to 653 cu.m) near Visakhapatnam, Andhra Pradesh, India • 1000 m3 /day plant expandable to 1450 with sand and fly ash near Chennai, India • 169 m3 /day plant expandable to 338 with fly ash near Karur, Tamil Nadu, India • Spare parts for existing AAC plant run by Ultratech product at Shankarapalli near Hyderabad and Wada in Maharashtra. • Spare parts for existing AAC plant run by ESPAC in Dammam, Saudi Arabia. Completed plants : Plants under execution :
  5. 5. These are some of the unique machines we make for a superior end product. Such special machines and quality engineering has placed us among the top manufacturers of AAC plants in the world. Mould Handling Crane Mould Tilting Machine Grab and Shift Crane
  6. 6. SALIENT FEATURES • AAC plants of multiple models • Customized plant solutions • Plant capacity from 200 m3 to 2000 m3 per day • High end automation • Minimal man power • Optimization of resources • Designed for zero wastage • Built-in scope for expansion • Efficient use of land • World class machinery
  7. 7. THE BUILDMATE ADVANTAGE Superior Design • Extensive in-house design facility • Tested and proven technologies • Innovation based on industry experience • Conforming to international standards Meticulous Manufacturing • In-house manufacturing unit in Hyderabad, India • Advanced fabrication facilities and modern machine shops • Testing equipment of International standards Immaculate Quality • Quality assurance from concept to commission • Stage-wise quality checks to ensure trouble-free plant performance • An ISO 9001: 2015 certified company
  8. 8. Batching BuildMate’s AAC block plants have high accuracy batching plants, flexible design and high capacities. They can be completely customized to meet the needs of available raw materials and product range. Casting In the casting section we have several customizable options to provide you with the appropriate mixer and mould com- binations. Along with the common variant of fixed mixers and movable moulds, we also supply a movable mixer. This movable mixer and stationary mould prevents settling of raw materials by minimizing time between mixing and casting and decreases the wear and tear of the moulds. Our mov- able mixers ensure the pour is even and uniform, and fixed moulds decrease rising cracks to produce a green cake that has uniform aeration and produces superior blocks. Cutting Cutting is a crucial part in the AAC block making process. The right process and quality machinery in this section minimizes waste and ensures dimensional accuracy and blocks will be superior. We have two variants of cutting machine. In the typical cutting process, the cake passes through the trimming, horizontal cutting and vertical cutting machines to produce different sizes of block as per market requirements. In the BuildMate process the cake remains fixed while the trimming, horizontal cutting and vertical cutting take place. This reduces the strain on the green cake as it’s movement is minimized. This process has decreased the wastage drastically and consistently produced the blocks of finest finish with less cut waste.
  9. 9. Curing After cutting, the AAC blocks have to be cured to attain maximum strength in the autoclaves. We have improved every step of this process to optimize the steam consumption, increased strength, and ef- ficient movement of the blocks. We are one of the few manufacturers in the world to provide you with a green separator, a push pull transfer car system and an efficient autoclaving process. Packaging Once the cured cake is produced, it needs to be stored and packed. For efficient transfer and minimizing the labour, we provide a grab and shift crane which will move the blocks from the curing section to storage. This transfer system through cranes and conveyors can be customized for full automation upto loading of trucks. Our improvements at various stages of production process have saved our customers millions in material, energy and handling costs.
  10. 10. BUILDMATE LAUNCHES LOW CAPITAL COST AAC BLOCK PLANTS DESIGNED FOR SMALL CITIES
  11. 11. No compromise AAC block plants at affordable prices! Small plants capable of competing with Big players SALIENT FEATURES PLANT CAPACITIES • Sturdy and reliable machinery • Bottom waste removal system • Designed for zero wastage • Mechanized operations • Higher automation (upgradeable to complete automation) • Low production costs • Minimal man power • Built in scope for expansion • Efficient use of land • Optimization of resources • 100 m3 per day expandable to 300m3 • 150 m3 per day expandable to 450m3 • 200 m3 per day expandable to 600m3
  12. 12. • Autoclaved Aerated Concrete (AAC) plants • Concrete block plants • Precast concrete plants • Fly ash bricks plants • Dry ready mix mortar plants • Concrete Batching plants with • Planetary, Twin-shaft, pan mixers. • Crushing Plants and Jaw crusher, Cone crusher, VSI/sand maker etc. • Pre Engineered Buildings We setup the following plants from concept to commissioning. Buildmate Projects Private Limited Sy no. 60,61, 62. Gundlapochampally VIllage Hyderabad, Telangana, India - 500014 Ph no: +91 7676989911/61 Email: marketing@buildmate.in Visit our website at www.buildmate.in We excel at any Special projects and plants in construction or building materials.
  13. 13. CRUSHING, FEEDER & SCREENING EQUIPMENT WWW.BUILDMATE.IN BRINGING NEW DIMENSIONS TO THE CRUSHING INDUSTRY
  14. 14. WHO WE ARE WHAT WE CAN DO BuildMate is a strong technology oriented, high-tech engineering project and execution company providing technology and supply of machinery and equipment for Building Material projects. We are among the top manufacturers in the world for AAC Plants and have considerable experience in creating other building material plants and machinery. BuildMate’s commitment to being a partner for your building material projects from concept to commissioning is so strong that is part of our name and identity. For over 30 years we have provided a complete range of project services needed to conceptualize, plan, design, engineer and set up building material projects to meet the specific requirements of its clients to generate considerable value. Our vast experience of operating and setting up various building material manufacturing facilities ranging from stone crushers and concrete block plants to cement and lime plants, helps us make better machinery that is not just better design wise but is ideal for productive plant operations. We now bring our considerable expertise to the world of stone crushing equipment and concrete batching plants with innovative solutions to unresolved industry problems.
  15. 15. Buildmate can now to provide the following for your crushing needs: • 150 TPH / 2, 3 and 4 Stage plant • 200 TPH / 2, 3 and 4 Stage plant • 300 TPH / 2, 3 and 4 Stage plant • Jaw Crushers • Cone Crushers • Sand makers • Vertical Shaft Impact Crusher • Horizontal Shaft Impact Crusher • Grizzly feeders • Vibrating screens and Conveyors • Sand plants with classifiers in both dry and wet • Robust construction • Excellent performance • High production capacity. • High reduction ratio • Large feed size • Solution oriented innovative plant layouts • Minimal maintenance • Easy operation • Continuous operation • Superior support and service • Completely automated plants Range of Products The BuildMate Edge
  16. 16. JAW CRUSHER BuildMate jaw crushers are single toggle type and have been designed after studying the day to day problems of crusher owners. They are made for more production, tough & large feed conditions, easy operation, minimum maintenance, and longer life while producing output at lowest cost per ton. These improve upon existing designs to give the most efficient crushing and optimized performance. The incredibly high output and high reductions are possible because of its deep crushing chamber design with optimized nip angle for smooth material flow. High level of engineering combined with top grade components are the ingredients for reliable and longer life of our machinery.
  17. 17. • Wide and long intake openings to allow larger feed • Deep crushing chamber for higher output • Optimized nip angle for smooth flow and greater reduction • Welded and robust construction for high strength and durability for impact loads • Heavy cast flywheels for smoother operation even under momentary overloads • Reversible jaws for maximum utilization • Auto setting adjustments for ease of operation • Electrical hoist for safe maintenance • Centralized lubrication (auto-lubrication) system Salient features Options Technical Data & Capacities Model Specification BM-SJC 3624 BM-SJC 5032 BM-SJC 5040 Feed Opening mm 900 x 600 1250 x 800 1250 x 1000 inch. 36 x 24 50 x 32 50 x 40 Max. Feed Size (mm) 500 650 800 Drive Motor Cap. in kW (HP) 75 (100) 132 (175) 160 (220) Speed (rpm) 245 225 200 Closed Side Setting (CSS) Capacities in Metric ton per hour (Mtph) mm inch. 50 2 75-90 75 3 100-130 125-175 100 4 120-150 180-250 240-330 125 5 140-180 220-275 275-375 150 6 170-220 250-320 345-410 175 7 300-375 385-450 200 8 350-400 445-525 225 9 495-580 250 10 545-650
  18. 18. CONE CRUSHERS BuildMate offers GP & HP series cone crushers for secondary and tertiary crushing applications. The robust design along with high quality BuildMate components and optimized wear parts make is possible to maintain high crushing performance to keep production up and operating costs down. BuildMate cone crushers feature a unique combination of cavity design, speed and throw which provides higher capacity and superior product quality in wide range of applications. These cone crushers combine extremely high performance with low production cost per ton.
  19. 19. • Increased head diameter for high production & larger feed acceptance • Hydraulic system for easy and safety setting adjustments • Auto lubrication for greater reliability • Low power consumption • Auto setting adjustments • Automatic tramp release Salient features Options Technical Data & Capacities Model Specification BM-SCC 900 BM-SCC 1100 BM-SCC 1300 Feed Opening mm 180 220 230 inch. 7 8.5 9 Max. Feed Size (mm) 150 180 190 Drive Motor Cap. in kW (HP) 90 (120) 160 (220) 225 (300) Closed Side Setting (CSS) 28-36 28-40 30-45 Capacities in Metric ton per hour (Mtph) 80-180 160-290 220-380 Technical Data & Capacities Model Specification BM-TCC 900 BM-TCC 1100 BM-TCC 1300 Feed Opening mm 200 230 250 inch. 8 9 10 Max. Feed Size (mm) 160 190 200 Drive Motor Cap. in kW (HP) 90 (120) 160 (220) 225 (300) Closed Side Setting (CSS) 24-38 25-45 25-45 Capacities in Metric ton per hour (Mtph) 90-210 180-320 250-410
  20. 20. HORIZONTAL SHAFT IMPACT CRUSHERS BuildMate’s horizontal impact crushers are for operating conditions where there are demands for high production. Our HSIs are for secondary and tertiary crushing applications They have a combination of heavy rotor design, wear material and crushing chamber design. This improves capacity, product quality and in reducing operating and wear costs. Impact crushers have been designed with a bigger crushing chamber, optimized liners and specific rotors for more production and low maintenance resulting in low cost per ton.
  21. 21. • High reduction ratio • Good cubical shape • Less sensitive to sticky material than other machines • Extremely versatile machine - suitable for quarrying and gravel pit industries, cement industry, concrete and asphalt cycling, and slag recycling. • Various sizes for different type of stone • Electrical hoist for safe maintenance • Auto lubrication Salient features Options Technical Data & Capacities Model Specification BM-HSI 1210 BM-HSI 1214 BM-HSI 1316 Max. Feed Size (mm) 200 250 400 Capacities in Metric ton per hour (Mtph) 75-150 150-250 250-350 Drive Motor Cap. in (kW) 110 132 225 Rotor Speed (rpm) 550 550 485 Rotor Diameter X Width (mm) 1200 X 1000 1200 X 1400 1300 X 1600
  22. 22. VERTICAL SHAFT IMPACTORS (VSI) BuildMate VSI crushers are designed for tertiary applications and these will produce quality aggregates for concrete products, road construction, etc. The VSIs can handle everythign from hard and abrasive rocks to soft rocks. The crushing principle in VSIs is rock-on-rock action i.e. rock fed into the machine to crush itself. This rock-on-rock/ autogenous crushing offer the lowest cost per ton. Rotating rotor in VSIs gives high velocity to the rock to generate high crushing forces which improve the shape and soundness of the material and produce high quality cubical shape products. BuildMate VSIs are provided with cascading option where some material can be diverted into the crushing chamber, bypassing the rotor which facilitates the control on product grading and optimizing quality. • Rock-on-Rock principle to produces quality products with superior cubical shape • Ability to control product grading by tip speed and cascading option • Lowest wear cost per ton due to Rock-on- Rock crushing • Quick and easy replacement of wear parts to reduce downtime for productive. Salient features Technical Data & Capacities Model Specification BM-VSI 700 BM-VSI 850 BM-VSI 1000 Max. Feed Size (mm) 30 40 40 Capacities in Metric ton per hour (Mtph) 100-150 200-250 300-350 Drive Motor Cap. in (kW) 75-150 150-220 330-450 Rotor Speed (rpm) 1200-1400 1200-1400 1200-1400 Rotor Diameter (mm) 700 850 1000
  23. 23. VIBRO FEEDERS BuildMate vibro feeders are designed to give regulated, controlled and continuous feed for secondary cone crushers & impact crushers and for the tertiary sand makers resulting in choke feed conditions for better performance which in turn reduces the wear cost. These vibro feeders are provided with unbalanced electrical vibro motors for effective vibratory motion. Model Dimensions width x length (mm) Capacity (Mtph) Drive Motor Cap. in (kW) BM-VFM820 800 x 2000 150-250 2x 1.5 BM-VGF1217 900 x 1500 300-350 2x 1.67 BM-VGF1220 1200 x 2000 450-500 2x 2.30
  24. 24. • Double shaft mechanism in an oil bath offers extended service intervals • Easily dismounted mechanism ensures easy servicing • Robust design enables to accept the material impacts from dump trucks • Two/Three step models ensures maximum efficiency to remove quarry fines/clay. Salient features VIBRATING GRIZZLY FEEDERS BuildMate’s vibrating grizzly feeders are designed for the toughest applications, high capacity and able to process abrasive material in wide range of primary feeding applications. These grizzly feeders maintenance is easy to carry out, allowing you to maximize uptime and productivity. The heavy-duty double shaft mechanisms with gears are in an oil-bath for extended service intervals and for a long life. Model Dimensions width x length (mm) Step Drive Motor Cap. in (kW) BM-VGF1040 1000 x 4000 Single 10 BM-VGF1245 1200 x 4500 Single/ Double 15 BM-VGF1555 1500 x 5500 Double/ Triple 22
  25. 25. • Rugged construction • Circular motion keeps material moving and prevents plugging • Combines high throughput without blinding • High material velocity for added efficiency Salient features VIBRATING SCREENS BuildMate’s circular motion screens are designed for heavy-duty, medium and fine screening applications. This flexible inclined screen is ideal for use screening after primary, secondary and tertiary crushing. Model Dimensions width x length (mm) Screening Area (Sq.m) No.of Decks Drive Motor Cap. in (kW) BM-VSM1540 1500 x 4000 6.0 1 2 3 4 11 11 15 15 BM-VSM1850 1800 x 5000 9.0 1 2 3 4 11 15 18.5 22 BM-VSM1860 1800 x 6000 10.8 1 2 3 4 15 15 22 22 BM-VSM2160 2100 x 6000 12.6 1 2 3 4 15 22 22 22 BM-VSM2463 2400 x 6300 15.12 1 2 3 4 15 22 30 30
  26. 26. • Autoclaved Aerated Concrete (AAC) plants • Concrete batching plants with planetary, twin-shaft, pan mixers. • Crushing plants wih jaw crusher, cone crusher, VSI/sand maker etc • Concrete block plants • Dry ready mix mortar plants • Pre-cast concrete plants • Pre Engineered Buildings, cranes etc We setup the following plants from concept to commissioning. Buildmate Projects Private Limited Sy no. 60,61, 62. Gundlapochampally VIllage Hyderabad, Telangana, India - 500014 Ph no: +91 7676989911/61 Email: marketing@buildmate.in Visit our website at www.buildmate.in We excel at any Special projects and plants in construction or building materials.
  27. 27. CONCRETE BATCHING PLANTS INNOVATIVE LAYOUTS AND EFFICIENT DESIGN FOR A WIDE VARIETY OF OUTPUTS WWW.BUILDMATE.IN
  28. 28. WHO WE ARE BuildMate is a strong technology oriented, high-tech engineering project and execution company providing technology and supply of machinery and equipment for Building Material projects. We are among the top manufacturers in the world for AAC Plants and have considerable experience in creating other building material plants and machinery. BuildMate’s commitment to being a partner for your building material projects from concept to commissioning is so strong that is part of our name and identity. For over 30 years we have provided a complete range of project services needed to conceptualize, plan, design, engineer and set up building material projects to meet the specific requirements of its clients to generate considerable value. Our vast experience of operating and setting up various building material manufacturing facilities ranging from stone crushers and concrete block plants to cement and lime plants, helps us make better machinery that is not just better design wise but is ideal for productive plant operations. We now bring our considerable expertise to the world of stone crushing equipment and concrete batching plants with innovative solutions to unresolved industry problems.
  29. 29. Standard Series: With minimum maintenance, guaranteed high output and low wear and tear BuildMate’s batching plants will give are reliable, robust and efficient. Available in 30 cu.m, 60 cu.m, 90 cu.m and 120 cu.m capacities. Tech Series: Along with all the features of the Standard Series, the Tech series models have advanced plant operation features including MIS reports, can come in innovative layouts and have optional features Available in 30 cu.m, 60 cu.m, 90 cu.m and 120 cu.m capacities. • Robust construction with less wear and tear • Advanaced technology for excellent performance • Higher output and low maintenance • Easy, continuous and automated operation • MIS reports • Optional features • Superior support and service BuildMate’s reliable and heavy duty components ensure long life and high mixing homogeneity. Salient Features Batching plant models We make the following types of mixers: 1. Pan mixers 2. Ribbon mixers 3. Blenders 4. Twin shaft mixers 5. Planetary mixers
  30. 30. The plants offered by BuildMate incorporate aggregate hoppers which are in-line and can be placed at right angle to the inclined conveyor or in-line with it. These structures are manufactured from high quality steel sections to immaculate dimensional accuracy and finish. Under the aggregate hoppers is located the weigh conveyor, which is slung on load cells. The sequentially batched material is accurately weighed on this conveyor. The weighed material then moves on to the inclined conveyor. The load cells and pneumatic actuators fitted to the hopper gates are controlled by the control station. The inclined conveyor is positioned at an angle of 28 degrees connecting the weigh conveyor discharge point and the entry point at the mixer or the holding hopper. There by creating stock of a batch above the mixer, this feature enhances productivity considerable on plants such as 90 cum / hr and above. The conveyor is covered by a hood is order avoid dust contaminating the environment.
  31. 31. This picture shows the placement of the holding hopper and the cement, water and admix weigh hoppers placed over the twin shaft mixer. Also the discharge hopper of the mixer is shown, to which the transmit mixer will engage for transporting concrete. A control cabin installed at the job site. In this control cabin is housed the electrical panel, which contains all the electrical switch gear, control circuit software and the HMI which enables the operator to operate the entire plant effortlessly. Our mixers are controlled hydraulically and are equipped with necessary electronics to ensure smooth start, and long service life. They need very little routine maintenance.
  32. 32. GENERAL ASSEMBLY DRAWING OF A TYPICAL BUILDMATE BATCHING PLANT BUILDMATE’S BATCHING PLANTS COME IN VARIOUS LAYOUTS: • COMPACT • STANDARD HORIZONTAL • TOWER TYPE • MOBILE
  33. 33. Models BM 500 TS BM 1000 TS BM 2250 TS BM 3000 TS AGGREGATE HOPPERS UOM U n i t s 1 In line nos 4 4 4 4 2 Capacity each cum 7 10 15 22 3 Loading width meters 2.8 3.1 3.3 3.3 4 Hopper gate pneumatically operated nos 4 4 4 4 5 Loading height meters 4.7 5.2 5.4 6.2 WEIGH CONVEYOR 1 Belt width mm 650 800 1000 1200 2 Geared motor drive capacity kW 7.5 11 15 22 INCLINED CONVEYOR 1 Belt width mm 650 800 1000 1200 2 Geared motor drive capacity kW 15 22 30 45 3 Length of conveyor c/c m 14 18 20 23 TWIN SHAFT MIXER 1 Mixer capacity Dry liters 750 1500 3350 4500 2 Mixer capacity Wet liters 500 1000 2250 3000 3 Drive nos 2 x 11 2 x 18.5 2 x 37.5 2 x 55 4 Auto lubricator nos 1 1 1 1 5 Hydraulic power pack nos 1 1 1 1 CEMENT WEIGHING 1 Capacity cum 0.5 0.75 1.5 2.5 2 Vibrator nos 1 1 1 1 WATER & ADMIX 1 Water weigh hopper liters 125 200 300 400 2 Water pump nos 1 1 1 1 3 Admix weighing jar nos 1 1 1 1 4 Load cells nos 1 1 1 1 5 Admix pump capacity lpm 30 45 60 60 OTHERS 1 Electrical panels set 1 1 1 1 2 All internal wiring set 1 1 1 1 3 HMI set 1 1 1 1 PLANT OUTPUT APPROX. cum/hr 30 60 90 120
  34. 34. • Autoclaved Aerated Concrete (AAC) plants • Concrete batching plants with planetary, twin-shaft, pan mixers. • Crushing plants wih jaw crusher, cone crusher, VSI/sand maker etc • Concrete block plants • Dry ready mix mortar plants We setup the following plants from concept to commissioning. Buildmate Projects Private Limited Sy no. 60,61, 62. Gundlapochampally VIllage Hyderabad, Telangana, India - 500014 Ph no: +91 7676989911/61 Email: marketing@buildmate.in Visit our website at www.buildmate.in We excel at any Special projects and plants in construction or building materials.

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