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Mixing plants for Emirates City

Supplier: German Plant Experience
06 April, 2010

In one of the largest building projects in the UAE, 72 high-rise buildings are currently under construction in the Emirates City in the EmiratAjman, about 20 minutes by car from Dubai Airport.

Each is between 20 and 50 storeys high and features both commercial and residential floor space. The high-rise buildings are surrounded by artificial lakes and green areas. In addition to that there are shopping centres and luxury hotels.

The project has a total value of 4.1 billion US dollars. As one of the leading suppliers of concrete mixing plants, German Plant Experience has delivered three ready-mix plants with a capacity of 120 m³/h each for this building project

Mixing plants for high demands Each plant consists of 6 aggregate boxes with a total storage volume of 240 cbm. In order to guarantee rapid aggregate dosing, two independent weighing belts are each dosed by 3 boxes.

Hence two aggregates can always be dosed simultaneously. The two weighing belts discharge centrally onto an elevating conveyor with a cleated belt and a belt width of 1,200 mm. The elevating conveyor discharges then into a preliminary silo with a volume of 4,500 litres.

The mixers are twin-shaft compulsory mixers with a concrete output of 3 cbm per batch. In order to offer the operator optimum possibilities, each mixer is equipped with a special camera. Hence, at the push of a button, the operator can check the consistency of the concrete during mixing at any time via a colour monitor.

Besides that, dry loading is also possible, i.e. all raw materials can be fed directly to the ready-mix truck, bypassing the mixer. In order to always have a sufficiently large reserve of cement even during periods of peak activity, each plant is equipped with a total of 3 cement silos (300 metric tons each) and a microsilica silo with a storage volume of 100 metric tons.

In order to fulfil the stringent emission requirements, a separate filter system is installed in the plants that ensures virtually dust-free production.

WebCon – For highest demands
I
n order to meet the demands placed on the plant software by the client, the GPE control software WebCon is used. The software has proven itself not just in the construction of the Burj Dubai; hence, more and more plants are being converted to WebCon.

The latest web technology in conjunction with standard software components guarantees the user a high degree of flexibility and operator-friendliness. Clear menus and self-explanatory buttons make operation convenient for the operator and provide him with a very good overview.

Two TFT monitors are connected to the master computer. The operator can hence effortlessly select recipes, input orders or set plant parameters, whilst the second monitor provides him with a visualisation of the complete production process.

The plant visualisation consists of an overview page, from where the operator can zoom in per mouse click on the individual parts of the plant and get detailed information.

The delivery note printout was specially adapted to the customer’s requirements. Comprehensive statistics allow the customer to view consumptions, fill levels and other production parameters quickly and easily.

All statistics can be output at freely selectable time intervals. Consumption statistics with administration of material withdrawals and nominal/actual comparisons with differential calculation can be retrieved, as can customer, building site or vehicle statistics and order statistics with the output of all components contained in the recipe.

In order to provide the user with the greatest possible transparency and operat - ing convenience, WebCon has been integrated in a company Intranet. Hence all employees have the possibility to view the data and production processes that are relevant to them online direct from their workplace. The use of software standards allows the customer to perform the installation with little expenditure of time and costs

GPE mixing plants have thus once again supplied the entire concrete for a large project in the Middle East. Besides the fulfilment of numerous quality features, the deciding factor for the award of the contract was the assurance of a complete service package comprising permanent availability of spare parts and 24-hour service. With a total of 10 service technicians, GPE is able to offer the customer perfect after-sales service.