Parry/ITW Electric and Hand Powered Vibration Screeding Machines

Manufacturer:
JPM Parry & Associates Ltd
Overend Road, Cradley Heath,
West Midlands B64 7DD
United Kingdom
Tel. [..44] 1384-569171 or 564991
Fax. [..44] 1384-637753

Description

The Intermediate Technology Workshops (ITW) is the research and consultancy function of JPM Parry and Associates and were the first to develop and manufacture vibration screeding machines for the production of fibre concrete roof tiles. They are thus the most experienced manufactures of these machines, of which several types are available catering for various production scales and energy inputs, and producing several different types of roofing element.

The following types of electric powered machines are available:

· MV Table Top Unit

This consists of the essential Multivibe vibrator, screeding plate, screeding frames and mould holding arms only.

· MV Workstation

Consisting of the Table Top Unit but fitted in a steel Workstation giving the correct working height and a storage shelves for interface sheets etc.

· MV Workstation & Hopper

As above but with the addition of a raised container to hold mortar within easy reach of the operator.

The above machines are all capable of the same output, but in the case of the more basic model the operator must provide his own table (workstation) on which to place the Table Top Unit and also a mortar container (hopper) from local sources. Production capacity depends upon the number of moulds used with the machine and also the number of workers employed. In practice a single machine will usually be able to fill a maximum of 600 moulds in an 8 hour working day. Typical production plants are as follows:

· Parry MV Tile machine, 2 workers, 200 moulds plus accessories

- output 200 tiles per day.

· Parry MV Tile machine, 3 workers, 400 moulds plus accessories

- output 400 tiles per day.

· Parry MV Tile machine, 5 workers, 600 moulds plus accessories

- output 600 tiles per day.

In order to achieve the above outputs it will usually be necessary to use a concrete mixing machine, also available from Parry Associates, Alternatively mixing can be done by hand, but this may require an additional worker.

On request, Parry can also supply a Fast Moulding system whereby one machine can produce 800 to 900 tiles per day.

All the parry electric plants use the Multivibe detachable vibrator (described in a separate leaflet in the GATE Product Information Folder on Concrete Block Producing Equipment), which runs on 12 volt DC power from a car battery or transformer-rectifier connected to a mains power source. The advantage of the Multivibe is that it can be used with alternative moulds and accessories to manufacture a number of other concrete building components.

The smallest Parry tile machine is the Table Top Unit, a standard screeding machine which can be transported by one person. When in use the machine is usually bolted to a workbench or into a workstation. As with all tile machines, output depends upon the number of workers and the organisation of the factory. The typical range is from two workers filling 200 moulds per day up to 5 workers filling 600 moulds per day.

The Parry Workstation machine uses the standard screeding machine fitted into a frame set at the most convenient height for working. The workstation has tool tray and shelves for holding interface sheets etc. The hand powered machines are always supplied in workstation format. Rubber mounted mould brackets and screed transfer flaps are fitted to all Parry machines, making it easier to slide the wet tile onto the mould.

The Workstation plus Hopper machine includes a second raised framework with a container to hold a quantity of mortar within easy reach of the machine, plus extra shelves.

Hand Powered Parry Tile Machine - This is supplied in a workstation to which parts of the mechanism are attached. The main advantage of hand-powered screeding machines is that they are completely independent of all power sources, but completely replicate the functions of the electric machines. Although slightly more working space is required, the output of the hand powered machines is the same as that of the electric, and in plants producing significant quantities of tiles the labour requirements is not increased. Cranking the handle once per second (60 rpm) generates a vibration at 3000rpm. By using hand powered rather than pedals, the second worker is free to move about the workplace handling moulds, interfaces, mortar etc.

The Workstation and Workstation plus Hopper versions of the above machines are also available in Hand Powered form, suitable for remote areas where power supplies are unreliable or do not exist at all. The vibrator is set in motion by a second worker who cranks the handle on the side of the machine, producing vibrations of identical amplitude and frequency to the electric machines. It has been found that the work of powering the machine can usually be carried out by an operator who is also carrying out tasks such as taking away the filled moulds and handling interface sheets etc., it is therefore not usually necessary for additional workers to be employed, compared to where an electric plant is being used.

A duel power Electric and Hand Powered machine is available on request.

The standard roof tiles produced on these machines are Pantiles and Roman II tiles, 50cm long, 25cm wide and 6, 8 or 10mm thick. To cover one square metre of roof 12.5 tiles are needed. As an alternative, Parry Associates also offer equipment and moulds to produce larger tiles. The latest development is a Super Roman tile which has a coverage of 8 tiles per square metre. Super Roman plants are available in the same specifications as the Pantile and Roman II machines. Maximum outputs are slightly lower, eg. 2 workers with 1 Super Roman machine could fill around 150 moulds per day.

Parry Associates also offer a much larger machine and moulds to produce Semi Sheets, 60cm long and side, requiring only 4 per square metre of roof coverage. In practice a single Semi Sheet machine will be capable of filling a maximum of 250 moulds in an 8 hour working day. Typical production plants are as follows:

· Parry Semi Sheet machine, 2 workers, 80 moulds plus accessories

- output 80 Semi Sheets per day.

· Parry Semi Sheets machine, 3-4 workers, 200 moulds plus accessories

- output 200 Semi Sheets per day.

· Parry Semi Sheet machine, 4-5 workers, 250 moulds plus accessories

- output 250 Semi Sheets per day.

Operation and handling of the Semi Sheet equipment are principally the same as for the standard roofing tiles.

The moulds are injection moulded polypropylene or vacuum formed polyethylene and are self-stacking, ie the interlock when placed on top of each over, saving space and providing air tight humid chambers for the wet tiles to set during the first 24 hours after moulding. Wooden frames need to be attached to the moulds and these are usually supplied in standard plants by Parry Associates, but may be sourced locally. Additionally, interface sheets are provided with full plants but again these may be sourced locally.

Full accessory packs can be supplied with machines and moulds which include comprehensive instruction manual, batching boxes, mortar measuring scoop, fibre balance, demoulding and quality control gauge, sample sieve, sample tile, sample dry mortar mix, 2 trowels and spare parts kit. Alternatively Parry Associates supply a minimum accessory package to suit users requirements.

Additional items such as mains electricity transformers, concrete mixers, tile testing and quality control equipment, special tile kits (Valleys, Hips, Top Row, Edge, etc.), plus various other items such as handling equipment, mobile curing bins etc. are also available.

Semi-sheet screeding table: spreading mortar.

Placing wet Semi-sheet on the setting mould.

Semi-sheet moulds stacked to set overnight.

Operating the Parry Screeding Machines

An interface sheet is placed on the screeding plate and clamped down with the screeding frame. An appropriate level scoop or scoops of mortar is measured and spread out on the screeding surface with a trowel. With the Multivibe vibrator switched on, the mortar is smoothed out such that the surface is level with the screeding frame. Finally the nib-forming box is filled under vibration and, if desired, a wire loop is inserted.

The mould is then placed on the mould holding brackets, the frame released carefully, making sure not to damage the nib, and the interface sheet with the flat screeded mortar pulled onto the mould. Care needs to be taken to ensure that the edges of the tile are exactly in line with the guide markings on the mould. The mould is then placed aside on the curing stack.

Technical Details - MV Tile Plants		1000 tiles/week	2000 tiles/week	3000 tiles/week
Size of machine (l x w x h)		38 x 65 x 19 cm	38 x 65 x 19 cm	38 x 65 x 19 cm
Weight of machine		32 kgs	32 kgs	32 kgs
Size of crate for shipping		1 box total 0.80 m3	1 box total 1.44 m3	2 boxes total 2.24 m3
Weight of packed plant		210 kgs	360 kgs	525 kgs
Standard tile size (Roman II or Pantile)		50 x 25 x 0.6/0.8/1 cm	50 x 25 x 0.6/0.8/1 cm	50 x 25 x 0.6/0.8/1 cm
Number of moulds: roof tiles		200	400	600
energy input/transmission		electric/mechanical	electric/mechanical	electric/mechanical
Output: No of tiles per cycle/per day		1/200	1/400	1/600
Labour force required		2 men	3 men	5 men
Price Ex-Works Valid Dec 1996	with Multivibe detachable vibrator	2093 £ Sterling	3533 £ Sterling	4973 £ Sterling

Technical Details - HP Plant		1000 tiles/week	2000 tiles/week	3000 tiles/week
Size of machine (l x w x h)		65 x 67 x 92 cm	65 x 67 x 92 cm	65 x 67 x 92 cm
Weight of machine/workstation		61 kgs	61 kgs	61 kgs
Size of crate for shipping		1 box total 1.00 m3	1 box total 1.74 m3	2 boxes total 2.54 m3
Weight of packed plant		240 kgs	400 kgs	570 kgs
Standard tile size (Roman II or Pantile)		50 x 25 x 0.6/0.8/1 cm	50 x 25 x 0.6/0.8/1 cm	50 x 25 x 0.6/0.8/1 cm
Number of moulds: roof tiles		200	400	600
Energy input/transmission		manual/mechanical	manual/mechanical	manual/mechanical
Output: No of tiles per cycle/per day		1/200	1/400	1/600
Labour force required		2 men	3 men	5 men
Price Ex-Works Valid Dec 1996	with hand powered vibrator	2369 £ Sterling	3809 £ Sterling	5249 £ Sterling

Technical Details - Semi Sheet Plants		400 sheets/week	1000 sheets/week	1250 sheets/week
Size of machine (l x w x h)		96 x 93 x 94 cm	96 x 93 x 94 cm	96 x 93 x 94 cm
Weight of machine		100 kgs	100 kgs	100 kgs
Size of crate for shipping		1 box total 1.74 m3	2 boxes total 3.18 m3	2 boxes total 3.48 m3
Weight of packed plant		320 kgs	570 kgs	670 kgs
Standard tile size (Semi Sheet)		60 x 60 x 0.8 cm	60 x 60 x 0.8 cm	60 x 60 x 0.8 cm
Rubber moulds: roof tiles		80	200	250
Energy input/transmission		electric/mechanical	electric/mechanical	electric/mechanical
Output: No of tiles per cycle/per day		Jan-80	1/200	1/250
Labour force required		2 men	3 to 4 men	4 to 5 men
Price Ex-Works Valid Dec 1996	with Multivibe detachable vibrator	2809 £ Sterling	5299 £ Sterling	6337 £ Sterling

The next day the mould and green tile are placed upside down on the demoulding gauge so that the mould can be lifted off and the plastic interface sheet peeled off. Any rough edges of the tile are trimmed off and the tile is then placed in a curing chamber. (More experienced producers often demould without the use of the gauge and use this only to quality control the shape of sample tiles from each batch made.) Two methods of curing can be used. The most basic being to simply place the products in a water filled tank for up to two weeks. More rapid curing (3 to 4 days in hot climates) is possible by using a humid chamber. Fixed high humidity curing chambers can be constructed on site (instructions provided by Parry), or the Parry system of mobile high humidity curing bins can be used.

Koma Rock, Nairobi/Kenya: The largest single housing scheme with fibre concrete roof tiles made with Parry/ITW equipment.

On request, special training courses are offered at the Intermediate Technology Workshops Cradley Heath, UK and by their local representatives in other countries. The courses not only cover the technology of lightweight concrete roofing elements and building construction, but can also include other production technologies with Parry Equipment. These include various other concrete building components plus clay bricks and roof tiles and compressed earth blocks.

Course duration can vary to suit the time available to the trainee, but are usually between 3 and 10 days. Costs are around £300 to £600, but purchasers of equipment will usually be trained free of charge at the UK workshops.

ADDRESS LIST OF OVERSEAS AGENTS, REPRESENTATIVES, DISTRIBUTORS

Angola

Cemtec LDA
Rua Conego
Manuel das Neves
No. 106, CX postal 1402
Luanda

Tel/Fax: +244 2 349035

Bangladesh

Castle Construction Co. Ltd.
PO Box 2680
House No. 50, Road 2A
Dhanmondi Road R/A
Dhaka 1209

Tel: +880 2 507497 / 502404
Fax: +880 2 863044

Belize

Gush & Emy Ltd.
5 Mapp Street
PO Box 1237
Belize City

Tel: +501 2 45953
Fax: +501 2 31042

Cameroon

Revetement Jacal
PO Box 7331
Douala
Bassa

Tel: +2237 409413
Fax: +2237 428423

Ghana

Parakuo Estates Ltd.
Plot 7, block 5
Dadeban Street, Ring Road
PO Box 3727
Accra

Tel: +233 21 223245 / 226757
Fax: +233 21 2292
e-mail: [email protected]

Kenya (East African Representatives)

ITW (KENYA) Ltd.
4^th Ngong Avenue
PO Box 45156
Nairobi

Tel: +254 2 720962/3
Fax: +254 2 727657
e-mail: [email protected]

Kenya (Agents and Distributors)

Kate Freight & Travel Ltd.
Ufanisi House
PO Box 28330
Nairobi

Tel: +254 2 543716
Fax: +254 2 544446
e-mail: [email protected]

Madagaskar

Famokarand Tao Trano
BP 3508
Antananarivo 101

Tel: +261 2 295 10
Fax: +261 2 242 48

Nigeria

Niger Equipment Ltd.
Jagal House
Jagal Road
Oregun, PO Box 3959
Ikeja, Lagos

Tel: +234 1 900010-19
Fax: +234 1 964409

Senegal

Fibre-Mac
Domaine Industriel
BP 5872, Dakar

Tel: +221 257384

Sudan

Maria Enterprises Ltd.
PO Box 2519
Street 47
Khartoum 2

Tel: +249 11 45392

Surinam

Hesdy Landburg
Sureineve Kanehai Weg 53
PO Box 5147
Paramaribo

Tel: +597 65643
Fax: +597 10555

Sri Lanka

HDL
Construction & Property Trades (PVT) Ltd.
No. 78, Cannal Road
Hendala, Wattala

Tel: +94 930650
Fax: +94 930817

Thailand

CVBT
Km 147 Udonthani-Nongkhai Road
Group 5, Ban Thin
Tambon Ban That
Phen District
Udonthani 41150

Tel: +66 1 2130801
Fax: +66 42 241712

Uganda

Magric (U) Ltd.
Kitgum House
PO Box 3218
Kampala

Tel: +256 41 232100
Fax: +256 41 244606

Zambia

Lutanda Ltd.
PO Box 20516
Moseshi Road
Kitwe

Tel: +260 2 218166

or

Compresstair Ltd.
PO Box 33139
Washama Road
Lusaka

Tel: +260 1 216110

Development Alternatives TARAcrete MCR Tile Production Kit

Manufacturer
T.A.R.A. - Technology and Action
for Rural Advencement
B-32, TARA Crescent
Qutab Institutional Area
New Delhi-110 016
India
Tel. [..91] 11-696 7938 or 685 1158
Fax. [..91] 11-686 6031
e-mail: [email protected]

Figure

Description

Technical Details		TARAcrete production kit
Size of machine (l x w x h)	without seat............	........................ 100 x 54 x 50 cm (40 x 21 x 20 in)
	with seat ................	........................ 115 x 54 x 87 cm (45 x 21 x 34 in)
Weight of machine	without seat ...........	................................................................. 35 kg
	with seat ................	................................................................. 45 kg
Size of crate for shipment ..	.............................	........................ 113 x 63 x 76 cm (44 x 25 x 30 in)
Weight of packed machine.	.............................	.................................... 160 kg
Standard tile size / weight ..	.............................	48.8 x 24 x 1.0 cm (19.2 x 9.4 x 0.4 in) / 2.85 kg
Energy input .....................	.............................	............................................. electrical (80 watts)
No. of tiles per cycle/output rate ..........................		............................................. 1 / 25 tiles per hour
Labour force required (incl. Mixing and stacking)		................................................................ 4 men
Price (ex works)	TARAcrete Vibrating table (incl. accessories) .. 16800 Rs (» 480 US$)
valid Dec. 1996	Polystyrene mould (on wooden frame) ......... 280 Rs (» 8 US$)
Rs = Indian Rupees

The TARA Vibrator is the result of design and production research at the Regional Centre for FCR/MCR Technology at Development Alternatives, New Delhi. The roofing tiles are being produced since 1988 and the TARA Vibrator since 1989.

The TARA Vibrator consists of an aluminium table top, which is vibrated by a rotating eccentric mass at a frequency of 2800 rpm, and an interchangeable hinged frame for the production of different shapes and thicknesses of tiles. The machine is powered by an electric motor (1/4 hp), driven from a mains supply of 230 volts.

A clear disadvantage of some of the vibrating machines available is their inability to control the vibration. The TARA Vibrator provides a unique mechanism suspended on leather belts, which allows for the vibration to be controlled by adjustable tie rods, depending on the type of cement mix, availability of materials and water-cement ratio. The machine operation is optimized to give a vibration time of about 45 seconds for high strength and minimum porosity of tiles.

Another special feature of the machine is a swivel seating arrangement for the operator to sit on, reducing the physical strain during tile making and permitting free rotation when the fresh tile is transferred to the mould stack at the side of the machine.

The machine requires very little maintenance, which is normally restricted to the changing of bearings after prolonged operation.

The TARA Vibrator is preferably used to produce micro-concrete tiles, because fibre reinforcement has proved to be a major constraint towards achieving high production and consistent quality of tiles. The micro-concrete mix consists of 1 part cement, 2 parts of graded sand and 1 pan of stone grit passing through 4 mm mesh. This mix requires a water-cement ratio between 0.45 and 0.5. With this mix and a labour force of 4 persons, a production rate of up to 200 tiles a day is easily achieved.

Together with the vibrating table, Development Alternatives supplies 200 self-stacking, high-impact polystyrene moulds (mounted on wooden frames) and the necessary accessory tools, such as trowels, scoops and quality control implements.

Training

Development Alternatives conducts training courses in MCR tile production for supervisors and masons. The courses, which are held in New Delhi or at one of the many collaborating institutions in India, not only deal with practical aspects, but also with economical aspects, management and marketing.

Operating the TARA Vibrator

Theoretically, MCR tiles can be made on the TARA Vibrator by a single person, but for an uninterrupted and constantly high production rate of about 200 tiles per day, a team of 4 persons is required.

The production process is principally the same as for all other screeding machines: clamping down a plastic sheet with the screeding frame, placing a measured amount of mortar on the screeding surface, spreading it out under vibration and smoothing the surface, filling the nib construction box, lifting the screeding frame, removing the plastic sheet with the screeded mortar and placing it on a the mould for setting. The main difference is that the operator can remain seated during the whole operation, even when placing the fresh tile on the mould, making the work less tiresome. The 3 helpers are mainly occupied with supplying the operator with fresh mortar and moulds, as well as other odd jobs.

The TARA Vibrator with a stack of moulds

Locally made polystyrene tile moulds

The TARA BALRAM soil block press (*), which is described in the GATE Product Information "Soil Block Presses". The BALRAM is a manually operated block press, which turns out two blocks per cycle and can achieve an output rate of 124 blocks per hour. The moulds can easily he changed, making it possible to produce blocks of different sizes and types, including perforated blocks.

Development Alternatives / TARA

Development Alternatives (DA) is a nonprofit, self-financing corporate organization, established in 1983. Its main objectives are to design and promote better approaches for the sustainable development of India.

The prime commercial partner of DA is its sister organization, TARA (Technology and Action for Rural Advancement). TARA manufactures and markets all products of DA and provides feedback on relevant production engineering and market information to the designers of DA to facilitate the continual adaptation and improvement of the technologies.

The operations of TARA are self-financing and conducted through a decentralized network of franchized enterprises. An enterprise can be an individual entrepreneur, a cooperative, a voluntary organization, an existing business, a government agency, or any other entity capable of manufacturing and marketing the products designed by DA.

Under a contractual arrangement between the franchiser (TARA) and the franchisee (the local enterprise), their respective duties are clearly defined. Broadly, TARA is responsible for technology development, technology transfer and training, standardization, networking, common procurement and bulk purchasing, quality control and marketing.

The franchisee is responsible for manufacturing, selling and providing after sales service to the local market. The franchisee pays a nominal royalty and fees to TARA, which in turn pays royalty and service fees to DA.

The technologies and services of DA include:

· Improved cookstoves (chulhas)
· Low cost housing technologies
· Mudblock presses*
· Improved handlooms
· Biomass energy systems
· Bicycle trailers
· Paper, board making equipment
· Pottery products
· Energy plantations
· Solar energy systems
· Water and sanitation
· Environment management

ECO Systems Concrete Rooftile Machine

Manufacturer
ECO Systems
P. O. Box 938
Blantyre
Malawi
Tel. [. . 265] 603 818 or 603 846
Fax. [. . 265] 603 803

Description

Since 1986 ECO Systems has been producing rooftiles and rooftile machines. The original tiles were manufactured according to the specifications of the Malawi Government Rural Housing Project (RHP) staff.

The RHP/ECO machine, which is basically a wooden box, is vibrated by two flat metal springs that hit it from underneath at a frequency of 2000 per minute. This is achieved by turning a handle, which requires little manual effort to operate.

A disadvantage of the earlier versions of the machine was the noise they produced. Therefore, the machines are now fixed firmly to a brick socle (instead of a light steel frame), reducing the noise and increasing the vibration intensity.

Two types of screeding machines are available: with a flat top for standard tiles and with a concave top for improved tiles (which are 9 mm thick at the troughs and 6.5 mm at the ridges). Thus, with the improved tile machine, a separate machine is required for making moulds and ridge tiles. If standard tiles are to be produced, only a combination machine is needed, which has interchangeable frames to make moulds and ridge tiles.

The concept of ECO Systems is to produce all roofing components without fibres. The MCR mix generally comprises 1 part cement to 2.5 parts river sand. For higher qualities, a mix of 1 part cement to 1 part quarry dust (or fine sharp sand) to 2.5 parts quarry stone of 3 to 4 mm (or similar small pebbles) is recommended.

Concrete Rooftile Machine

Section through screeding machine

Technical Details	ECO Systems Concrete Rooftile Machine
Size of machine (length x width x height) ................................. 65 x 45 x 15 cm (25 x 18 x 6 in)
Weight of machine (combination machine) ................................................................... 15 kg
Size of crate for shipment .................................................... 80 x 76 x 25 cm (32 x 30 x 10 in)
Weight of packed machine .......................................................................................... 29 kg
Standard tile size / weight ......................... 60 x 28.5 x 0.65 cm (23.6 x 11.2 x 0.26 in) / 2.45 kg
Improved tile size / weight ............ 60 x 28.5 x 0.65/0.9 cm (23.6 x 11.2 x 0.26/0.35 in) / 3.15 kg
Energy input ............................................................................................................. manual
No. of tiles per cycle/output rate ........................................................ 1 / 30 - 60 tiles per hour
Labour force required (incl. mixing and stacking) .......................................................... 6 men
Price (ex works)	Standard tile machine ............................................................. 250 US$
	Improved tile machine ............................................................. 290 US$
valid	Combination machine for standard tile ..................................... 325 US$
June 1991	Mould and ridge machine ........................................................ 245 US$
	Mother mould / Ridge mould ................................................... 22/8 US$
	Concrete mould ...................................................................... 0.5 US$
	Stacking frame ........................................................................ 10 US$

The Moulding System

The profile of the tiles has been optimized to provide a closer fit at the overlaps (see profile sketches). This is achieved by making the crest of the tiles thinner (ie 6.5 mm) than the valley thickness (ie 9 mm). In order to obtain these different thicknesses, the screeding machine has a concave top and a moulding frame with a curved profile of 2 mm thickness. An additional advantage of this device is that the frame touches the screeding surface only along the narrow strip of 2 mm, avoiding the accumulation of mortar under the frame, improving tile quality and increasing working speed.

The mothermoulds, which were previously made of concrete, are now of preformed plywood, in order to ensure greater uniformity and reduce weight. For the same reasons the grand-mothermould has been omitted.

The machines are supplied together with a set of mothermoulds, with which two types of concrete moulds can be produced: with and without stacking brackets. Moulds with stacking brackets can be piled up in stacks of five tiles, while plain moulds, which are made much faster, are stacked in simple wooden frames.

OLD AND NEW TILE PROFILE (Dimensions exaggerated to show differences more clearly)

Plain moulds are stacked in simple wooden frames: 5 tiles and moulds per frame; maximum 7 frames stacked on top of each other.

Tile moulds with stacking ridges can be piled up in stacks of 5 tiles.

TYPICAL ROOF CONSTRUCTION FOR ECO BETON TILES

DCS Foot-Powered Vibrating Table

Manufacturer
Development and Consulting Services
P.O. Box 8
Butwal
Nepal
Tel. [..977] 73-20391
Fax. [.. 977] 73 - 20465
e-mail: bhusan%[email protected]

Description

The DCS Foot-Powered Vibrating Table is a one-person operation screeding table, manufactured in Nepal since 1987. The vibrating surface and drive mechanism are mounted on an angle iron frame. Connected to this is a seat, which is adjustable to suit the tile maker's stature, so that he can sit comfortably at the table while making the tile. He rocks the two foot pedals back and forth at an easy speed, driving a bicycle wheel, which in turn drives an eccentric weight assembly beneath the aluminium vibrating surface at a speed of 2500 to 3000 rpm. Careful fitting of all nine sealed bearings ensures easy operation and long life for the machine. The screeding table has a one year guarantee.

The screeding frames for tiles (6 and 8 mm thick) are shaped to provide an "interlock" at the mitre - the diagonal mitre has been replaced by a dog-legged mitre. The frames also provide nib construction boxes for a wind proof fixing of all tiles. Experience shows that wind forces are sufficient to lift tiles, so all tiles are made with a lower fixing nib. A second nib may be made at the top for special conditions (top line of monoslope roofs, edges with long overhangs). When they are not needed, these nib boxes can be swung out of the screeding area (to leave it unobstructed for quick working) and positioned when needed.

The moulds are 535 mm long concrete elements fixed into galvanized sheet stacking frames, which also serve to protect the fresh tile from drying out during setting. DCS sells fitted moulds and frames with the screeding tables. This ensures that the moulds used are accurate and of good quality and allows the entrepreneur to start tile production immediately, so that he soon can produce a demonstration roof to show interested customers and begin to earn money without delay. He can, however, also buy a fibreglass mother mould, with which he can make his own moulds later (when he has sufficient experience), in order to replace broken moulds or increase his production capacity.

In addition to the screeding table and tile moulds, the following accessories are supplied:

· a set of batching boxes for fast measurement of cement and sand to correct proportions and workable batch size;

· a set of tile maker's scoops to enable correct batching of the wet mortar as tiles are made;

· a tile thickness gauge for checking finished tiles according to the standard;

· a batten gauge to aid quick and accurate roof building.

Entrepreneurs may purchase extra tools for quality checking:

· standard vessel to measure water for mixing;
· prism mould, loading jig and thickness gauge for checking mortar strength.

DCS also supplies sieves for screening sand and fine aggregate, shovels, trowels, pliers, tile stack covers, interface plastics etc.

Maintenance

The screeding table is maintenance free for up to 5 years, if cleaned regularly during tile making. The tile frame and screeding surface must be cleaned after each tile is screeded, in order to avoid distorting them. Bearings are protected by seals and cover plates. The bushes for the frame clamping arms and for the vibrating drive should be lubricated before the machine is stored for a period of no production, to avoid seizure from rust. The screeding surface mounting rubbers need replacing every year, as they absorb/damp vibration when they are perished. Replacement rubbers can be hand made from a scrap truck tyre; footwear repairers always have this type of rubber available.

Moulds need regular cleaning to avoid build-up of spilt mortar. Daily cleaning with a cloth or handful of fibre is quick and easy. Mortar left longer can be scraped off without fear of damage to the mould, as it has a hard surface.

Figure

Technical Details		DCS Foot-Powered Vibrating Table
Size of machine (length x width x height) .......................................................... 102 x 74 x 85 cm (40 x 29 x 33 in)
Weight of machine .................................................................................................................................. 48 kg
Size of crate for shipment.................................................................................. 85 x 85 x 90 cm (33 x 33 x 35 in)
Weight of packed machine plus accessories ............................................................................................. 65 kg
Standard tile size ........................................................................50 x 26 x 0.6/0.8 cm (19.7 x 10.2 x 0.24/0.31 in)
Frame for ridge tile ...................................................................................................... 53.5 x 28 cm (21 x 11 in)
Energy input ......................................................................................................................................... manual
No. of tiles per cycle/output rate........................................................................................ 1/50 tiles per man-day
Labour force required (incl. mixing and stacking)............................................................. 1-5 people per machine
Price (ex works)	Vibrating Machine ...................................... 13000 NRs (» 260 US$)
valid May 1997	Mould with Frame ......................................... 130 NRs (» 2.60 US$)
NRs = Nepali Rupees	Galvanized Stacking Frame ........................... 108 NRs (» 2.20 US$)

Training

DCS selects prospective entrepreneurs from applicants for an 11-day training course in FCR/MCR. The training is held in Butwal and includes theory and practical sessions covering

· production (including raw material selection, quality checks),
· tile use (roof types, construction, tile fitting),
· entrepreneur motivation,
· marketing skills,
· case reports and a tour to an established tile producer,
· book-keeping,
· obtaining finance.

Operating the DCS Vibrating Table

Before production, the tile maker must adjust the seat to enable him to sit comfortably while working. Also the screeding surface must be levelled before beginning. A small backrest is provided to give the light support needed while operating the foot pedals and screeding the mortar. Pedalling is not heavy work for the operator's legs.

When the mortar has been batched and mixed, the operator sits at the table, places a plastic interface sheet on the screeding table, then clamps down the appropriate tile frame. Using the corresponding scoop, a measured lump of mixed mortar is placed on the screeding table, and then this is trowelled out to an even thickness within the tile frame, while generating the vibration by rocking the foot pedals back and forth. When the screed surface is smooth and level with the screeding frame, the nib on the lower tile end is made by swinging the nib construction box into place, filling it with mortar under vibration, and inserting a wire loop for fixing on the supporting roof batten. Depending on the roof design, some of the tiles will need a second nib on the upper end, for which another nib box is provided.

After the nibs are made, the plastic sheet with the screeded mortar is lifted onto the next empty mould. This mould is then moved to the stack of newly moulded tiles and the position of the screed on the mould is checked. It is covered with the next mould and screed, or a mould cover if it is at the top of the stack, to prevent the mortar from drying.

The tiles are removed from the moulds after about 24 hours and subsequently cured for 2 weeks in water tanks or vapour curing beds.

1. Placing mortar on the screeding surface

2. Spreading the mortar under vibration

3. Lifting the plastic sheet with the screeded mortar to place it on the mould

4. Detail of the bicycle wheel drive mechanism

5. Mould stack with fresh rooftile

A Simple Windproof Tile Fixing Method

APPRO-TECHNO Tegulamatic Roof Tile Plant

Manufacturer
APPRO-TECHNO SA
26 Rue de la Ri
B-5660 Couvin (Cul-des-Sarts)
Belgium
Tel. [..32] 60-37 76 71
Fax. [.. 32] 60 - 37 78 87

Description

The Tegulamatic is a roof tile screeding machine that produces 2 tiles at a time. It is supplied with a complete production plant, which, in addition to the screeding machine, comprises 3 frames:

· 1 for 2 overlapping pantiles 49 x 23.5 cm,
· 1 for 1 overlapping under-ridge tile and 1 overlapping edge tile (each 49 x 23.5 cm),
· 1 for 2 49 cm long ridge tiles,

a concrete mixer, a roll of plastic sheeting to be cut locally into 1000 interface sheets, a measuring scoop for mortar, a rubber box to hold fresh mortar, a float, a balance, a 10 litre bucket, a jig to trim the tiles, quality control devices and samples of fibres and colourants. The main bulk of the plant is the set of double tile moulds, supplied in sets of 100 to 400 moulds, depending on the desired production rates (between 190 and 700 tiles per day).

The screeding table is an especially robust steel construction, designed for intensive use over long periods. The electric vibrator has the following characteristics: 3000 rpm, 0.095 kW, 220 V monophase, 220/380 V triphase, 50/60 Herz (tropicalization on request), 24 or 12 V direct or alternating current (also available on request).

The standard thickness of the screeding frames is 8 mm, but frames of 10 mm thickness are also available to produce more resistant tiles.

The self-stacking double moulds are made of galvanized steel. There are 2 different types, one for pantiles and one for ridge tiles. Each double mould is 108 cm long and weighs 4 kg. The following table shows the different sets available for different output rates:

Type	pantile moulds	ridge tile moulds	No of tiles/day	m2 of roof/day
AP 100	95	5	190	15
AP 150	145	5	290	23
AP 200	190	10	380	30
AP 250	235	15	470	37
AP 300	280	20	560	44
AP 350	325	25	650	52
AP 400	375	25	700	56

In each case, the nominal output is slightly less than the number of moulds provided, so that the operator can already begin the day's work with the unused moulds of the previous day, while the rest are being demoulded and cleaned.

Figure

Technical Details		Tegulamatic AP 100
Size of screeding table (1 x w x h) ......................................................10 x 50 x 100 cm (43 x 20 x 39 in)
Weight of screeding table............................................................................................................ 148 kg
Sizes of crates for shipment	a. Machine & accessories ...........177 x 135 x 112 cm (70 x 53 x 44 in)
	b. 100 moulds ..................................20 x 120 x 50 cm (47 x 47 x 20 in)
Weight of the two crates	a + b (450 + 600 kg) .............................................................. 1050 kg
Standard tile size / weight ........................................... 49 x 23.5 x 0.8 cm (19.3 x 9.3 x 0.31 in) / 2.1 kg
Energy input ........................................................................................................... electrical (95 watts)
No. of tiles per cycle/output rate ............................................................................. 2 / 60 tiles per hour
Labour force required (incl. Mixing and stacking) ........................................................................ 4 men
Price (ex works)	Tegulamatic AP 100 .................................... 145000 FB (» 4200 US$)
valid June 1991	Tegulamatic AP 400 .................................... 325000 FB (» 9300 US$)
FB = Belgian Francs

Training

Professional training courses (covering both the technology and management aspects) are conducted by APPRO-TECHNO in Belgium or in Abidjan / Ivory Coast, or elsewhere at the customer's request.

1. Spreading and smoothing the mortar under vibration

2. With the frame lifted off the screeding surface, the plastic sheets and screeded mortar are pulled carefully over the mould.

3. The mould is placed on the mould stack for the fresh tiles to cure for 24 hours.

4. View of a Tegulamatic double mould with one tile placed on it.

Operating the Tegulamatic

A variety of design details have been incorporated in the Tegulamatic screeding table to simplify the operator's work. These are, for instance:

· a tray extending on the side of the table to hold the rubber mortar box at working height;

· a foot pedal to clamp down and release the screeding frame, leaving the hands free to do other things, eg hold down the nibs when lifting off the frame (a hand operated lever can also be used instead of the loot pedal, if necessary):

· adjustable screws at the 3 clumping points to ensure a tight lit of the frame on the screeding surface;

· 4 bolts to adjust the level of the table, indicated by 2 water gauges fixed at visible points on the table;

· 3 standardized hinges to facilitate the changing of frames;

· a second foot pedal to switch the vibrator on and off;

· 2 adjustable and retractable brackets to hold the mould and permit the plastic interface sheets and screeded mortar to slip smoothly over the mould.

The production of FCR or MCR tiles on the Tegulamatic is essentially the same as on other screeding machines: clamping down a plastic sheet with the screeding frame, placing measured amounts of mortar on the screeding surfaces, spreading it out under vibration and smoothing the surface, filling the nib construction boxes, lifting the screeding frame, removing the plastic sheets with the screeded mortar and placing them on a the mould for setting. The main difference is that a part of the work is done by means of foot pedals, leaving the operator's hands free to carry out the work more efficiently. Furthermore, the output rate is higher, since two tiles are made per cycle.

After demoulding the tiles the next day, the recommended duration for curing under water is 5 days and subsequent dry curing in a shaded place is 15 to 20 days, after which the tiles are ready for use.

Other APPRO-TECHNO Equipment

APPRO-TECHNO has a long experience record in the manufacture of high standard equipment for the production of building materials. Apart from the Tegulamatic Roof Tile Plant, these are:

1. TERSTARAM, a manually operated mobile soil block press with interchangeable moulds, which can also be used to mould clay bricks and roof tiles:

2. SEMI-TERSTAMATIQUE, a motorized (electric or diesel powered) soil block press with interchangeable moulds, functioning in much the same way as the TERSTARAM, but with a much higher output.

3. TERSTARAM Ground Breaker, a mobile (electric or diesel powered) earth pulverizer, with which the dry clay lumps in the raw material are disintegrated to produce a homogenious soil for brick production.

4. TERSTAMIX (also available under the trade name TETRAMIX ), a mobile (electric or diesel powered) two-paddle planetary mixer, required to prepare the soil for block production but also to prepare mortars and renderings.