| Information on Kilcarrig Quarries Eco-Mortar |
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| Reduces Carbon Footprint Of Your Build |
| High Performance |
| Sustainable |
| Durable |
| Ease Of Use Using Traditional Methods |
| Future Proof |
| Customer Site Preparation Requirements. The Customer shall supply | |
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| 1. | The IBC enclosed Tank (preferably black so no algae will grow) with Ball Cock for Automatic Supply of water. Open Tanks are not acceptable. |
| 2. | The fitting to the IBC tank for a 1”ID Rubber Hose OUT. There must be a dedicated water supply for the Silo. 25mm feed at 2 bar pressure if using an IBC Tank. |
| 3. | The 1” flexible Rubber Hose must be long enough to reach the Mixer, it is recommended a valve is installed onto the hose itself to turn off the water, this stops unnecessary climbing of the scaffolding to turn off the valve at the IBC. The hose must be 1”(25mm) ID Standard Duty Yellow Rubber Hose 20 bar pressure and it generally comes in large rolls but is useful everywhere. The Site must not use the plastic Hydra-Air Hose from Hardware’s. We can supply the Yellow Rubber Hose at an extra cost if necessary. |
| 4. | A concrete base or bases for the Silo's are necessary and it is strongly advised to install. (A drawing of the base with the proper cut-out size for the Mortar tub to sit into can be found in the brochure).The Concrete base should be placed on good firm ground that is layered with hard cored and rolled before the concrete is placed. A full Silo can weigh in excess of 35 tonnes when full. Hard-core should be placed around the Base or Bases of the Concrete Slab therefore the Silo-truck can access them safely and drop the Silos directly and precisely. |
| 5. | Minimum size of 20kva dedicated Generator if no ESB available on site. If ESB is available then one wall mounted 5 pin 32amp Industrial Socket is required per Silo in close proximity to the Silo. It should be wall mounted to reduce the chance of issues as Cables on the Ground are not advised. It should also be a Motor Rated MCB (or 32A MCB if not Motor Rated). The Electricity Supply to the Silo must be backed up by a 30mA RCD which is exclusive for the Silo use. Our extension leads that extend from the wall Socket to the Mixer Panel are 10 meters only and only one extension lead is permitted per Silo. It is not advised to have the Silo further than 5 meters from the ESB or Generator. |
| 6. | Delivery will be made only using a prepared roadway suitable for a 6 axle Artic Truck with a 44 tonne gross weight. Site Access must remain as agreed and not be impeded for deliveries. If the Driver decides the access is unsuitable then the load may be aborted with the costs to the contractor. |
| 7. | Attached is a Care of Equipment procedure for End of Day and End of Week Cleaning. If Cleaning is not carried out regularly it will lead to difficulties and down time for the Contractor. Damages to the Panel or Mixer can interfere with normal operating of the system. It is extremely important the Mixer is cleaned and maintained only by the designated staff on site. We advise one person only be responsible for all Silo works on site to reduce costs and maintenance. |
| 8. | In frosty weather the panel should be drained and removed and put into a heated container to avoid Frost Damage. This is best practice. |
| Daily Mixer Cleaning procedure | |
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| 1. | Ensure Butterfly Valve is closed, the vibrator is turned off and no material is going into the Dry Chamber at the Rear of the Mixer. (Do not hammer or put a lever on the Butterfly Valve as it will break) |
| 2. | Run the Mixer and Water until the Water Runs completely clean. |
| 3. | Drain the Water IF Cold Temperatures are expected. If heavy Frost is expected remove the Panel completely and store indoors while the Frost and Cold Temperatures are present. (A number 10 spanner will remove the 4 bolts holding the panel on the side of the Mixer) |
| 4. | When removing the panel pay close attention to where the plugs go so that when they are reattached that they are in the correct position and completely inserted into the power receptacle. |
| 5. | Wet Material should not be left in the mixer for longer than 2 hours and often causes difficulty when operators forget to come back and clean out the Mixer. We advise to clean the Mixer such as this after every use if the site is not very busy. Busy Sites can use a full Silo in approx 3 days. |
| Weekly Mixer Cleaning procedure | |
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| 1. | Follow the Daily Cleaning Procedure first. |
| 2. | Isolate the Mixer and Remove the Power Cable to ensure no power is present before starting any cleaning of the Mixer. |
| 3. | Tools required are a number 17 and 24 Socket & Wrench or Spanners, a Midsize or large Flat Headed Screwdriver and a Clean Rag. |
| 4. | Remove the front of the Mixer by removing both side clamps and undoing the 3 nuts with a 17 Spanner or Socket. |
| 5. | Remove the Mixing Shaft and clean it down completely leaving no material on it. Do not wet the rear of the Mixing Shaft as this goes into the Dry Chamber at the rear of the Mixer and no Moisture should be present here. Clean any material from between the galvanised front spout and the main Mixing Chamber so that both parts meet with no material between. |
| 6. | Remove any remaining Material from the Yellow Flexible Wet Chamber and the Yellow Head Unit from the front of the Mixer. |
| 7. | Every Week the Dry Chamber at the rear of the Mixer should be completely cleaned out. Remove the Inspection Hatch (size 24 socket or spanner) at the underside of the Dry Chamber at the rear of the Mixer. Some hard Material can form in the chamber and all traces should be removed. The Shaft should be out at this stage and you can look up at the Butterfly Valve above. There should be no trace of cement or any hard material here. A large Flathead Screwdriver can remove any Hard Material that does build up. If this is not removed it may stop the Butterfly Valve from functioning properly. |
| 8. | Before putting the Mixing Shaft back please clean out the point on the Motor where the Mixing Shaft is inserted. It is a Circle with 2 prongs and the shaft should be inserted fully into it to ensure the Mixer will close properly. Please ensure that the Motor is turning when you turn the shaft by hand. It is important that the Mixer Shaft is properly and fully inserted here as this is a common problem we encounter. Ensure the Mixing Shaft is completely Dry or this will cause problems when the Dry Material enters the Dry Chamber from above again. Use a dry, clean Rag to ensure the Mixer Shaft is dry for reinsertion. |
| 9. | Reattach the front of the Mixer with all 3 Nuts and both Clamps. The shaft should easily fit and it should not be tight at all. Do not run the Mixer if you have difficulty in closing the 3 nuts and 2 Clamps on the Mixer Head as this is a sign that something is not assembled correctly. Disassemble and clean again and check the Shaft is inserted correctly and that the point where the Mixer Shaft and Motor meets is completely cleaned out and no Hard Material is present in the Dry Chamber |
| 10. | Run Mixer and ensure it is running correctly before leaving. The Dry Mortar that fell on the ground while cleaning out the Dry Chamber can be added to the last tubs batched out. |
| 11. | This procedure should be carried out at least every week, more often if large volumes are being used through the Mixer. The entire process takes no more than 10 minutes if done regularly. |
| 12. | Allow for one pump of Grease into the Nipple on the Butterfly Valve every 2 weeks also. |
