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CONCRETE ROOF MACHINE OPERATION MANUAL
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1. ELECTRIC PREPARATION
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The electric needed to
supply the machines and
accessories is depend on
the numbers of the
machines .
For the basic plan ( 2
Pressing Machines , 1
Mixer , and 1 Sand
Siever ) , you will have
to prepare 15 Kva of
electric plan .
There are 2 choices of
preparing the electric
plan :
A. Using the Electricity
, you need to have at
least 12 Kva from the
Electricity Company .
B. Using an Electric
Generator . In this case
you have to prepare a 15
Kva of Electric
Generator . There are
many kinds and brand of
electric generator , and
we also provide electric
generator , please click
here to see our offer
for electric generator .
It is also recommended
to have both electric
plan ( the electricity
and the generator ) , so
you always has back up
power when the
electricity down .
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2. SETTING UP THE
MACHINE : |
The pressing machine's
oil tank need to be
filled by hydraulic oil
as the tank isn't
supplied with the oil .
There are many kinds of
hydraulic oil in the oil
shop at the market , you
can use the hydraulic
oil with measurement of
SAE 10 or SAE 20 . SAE
is a measurement number
of oil thickness . Or
you can just use the car
or motorcycle engine oil
, with measurement of
SAE 20 .
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2.0 Setting Up
The Electric
Power to the
Machine |
Photo 1 |
Photo 2 |
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2.1
For safety
reason during
shipment , we
always separate
the pressing
machine and the
power pack , and
put some
important
spareparts into
the oil tank .
So please open
the oil tank and
take out all the
spareparts . Set
the machine with
the power pack
like in the
pictures .
( The black hose
is set for
hydraulic
pressure and the
white hoses for
circulation
system ) .
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2.2
First after you
put the machines
and the
accessories to
right place ,
you need to set
the electric
wire to each
machine . Each
machine have one
electric motor ,
and the electric
motor type is
3-phase electric
consumption . So
you need to set
4 wire from the
factory electric
outlet ( 3
positive and 1
negative pole )
. Open the
electric motor
pole cover and
see the
instruction on
the back of the
pole cover .
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2.3
After you put
the electric in
, before you
turn the
electric on ,
please check the
Machine Valve ,
and make sure
the both valves
are in open
state ( anti
clockwise ) .
Because if the
valves are
closed when you
turn the
electric power
on , then the
hydraulic press
will operated
and pressing an
empty mold which
may cause damage
on the mold .
But if the
valves in open
condition then
the hydraulic
press will
remain inactive
.
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2.4
Now you can turn
the electric on
and check the
moving direction
of the electric
motor by
checking at the
arrow direction
printed on the
hydraulic pump .
It should be
anti clockwise ,
if not then you
should reverse
two of the three
electric pole
you put into the
electric motor .
Then the
direction will
spin to the
correct
direction .
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2.5
You may also
adjust the
pressure by
adjusting the
relief valve .
Check the
pressure shown
on the pressure
gauge . The
normal pressure
for casting roof
is 100 to 200
bar , for barge
or verge is 100
bar , and for
casting pave is
also 100 bar .
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2.6
You should also
prepare a table
beside the
Machine too , to
make the work
easier .
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And because the process will have wasted
water , you also need to prepare a
gutter around the machine for wasted
water going out of working area .
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3. MATERIALS : |
3.1 BASIC
MATERIAL .
The basic
material for
producing
concrete roof
tiles are :
CEMENT and SAND
. But for making
the surface
smoother with
low cost , some
factories
especially in
Indonesia using
calsium powder .
We get Calcium
Powder in
Indonesia from
Calcium Mountain
. But in several
places , which
don't have
Calsium Powder ,
you can use
another material
as long as looks
like powder and
cheap enough .
But if there are
no another
material like
that , we can
use only Cement
and Sand , but
for surface
smoothing you
should use
pre-sieved sand
.
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3.2 SECONDARY
MATERIAL :
Secondary
material , are
materials that
are used to help
the production
easier , and
some of them are
necessary . The
second material
are :
1. Textile : We
need textile for
layering the
Production Plate
, and we use
ordinary textile
that usually
used for making
trousers .
2. Brush : We
need Brush for
oiling the upper
mould surface ,
each time the
roof casted ,
for releasing
the roof tile
from the upper
mould .
3. Mould Oil :
The mould oil is
needed for
oiling the upper
mould surface
each time the
roof casted .
You can make the
Mould Oil by
yourself from 1
Liter Engine Oil
( better if you
use Engine Oil
for MotorBike )
, mixed with 10
Liter Kerosene .
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3.3. MATERIAL
COMPOSITION :
BASIC MATERIAL :
For Roof :
The basic
materials
composition for
roof usually are
1 Cement + 2
Calsium Powder +
2 Sand . The
explanation of
this composition
is : Cement is
used for
Strength as the
tile need Cement
for it's final
strength .
Calsium Powder
is used for
surface
smoothing but we
also can use any
other material
for smoothing if
there isn't
calcium powder
in your area ,
like smaller
size sand , etc
.
In Indonesia we
use Calsium
Powder for
surface
smoothing
because it is
cheap . But in
some area which
Calsium Powder
aren't available
, then we can
use smaller size
sand ( sieved
sand ) . And the
last basic
material is Sand
, we need sand
for filling
material , sand
is the cheapest
material .
We can adjust
the 1 + 2 + 2
composition as
needed . We can
use 1 + 2 + 3 ,
or 1 + 2,5 + 2,5
. It is depend
on the kind of
material in your
area , and
depend of the
the roof quailty
you want to
produce .
For Pave :
The basic
materials for
Pave is just
Cement and Sand
, with
composition of :
1 Cement + 8
Sand , or 1
Cement + 10 Sand
, or 1 Cement +
12 Sand . The
more cement
factor the more
strong result
but also will
increase the
product cost and
price .
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3.4 FINISHING
MATERIAL :
The finishing
material for
concrete roof is
PAINT . The
painting method
is using spray .
You need Air
Compressor Unit
and Spray Gun .
And you can used
any kind of
Paint for the
roof . But the
best Paint are
Concrete Roof
Paint , the
paint specially
produced for
concrete roof .
There are two
kind of concrete
roof Paint ,
water base and
oil base . Water
base is cheaper
, but Oil Base
is Shiny .
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3.5. RACK :
You need to
prepare Racks
for temporary
tiles stay
during casting
process and to
leave the tiles
one day before
the tiles are
strong enough to
be released from
the pallets .
We usually use
Racks made from
wood / timber .
But you can use
any kind of
racks you like .
Our wood racks
model and
measurement is :
Length 300 cm ,
Width 25 cm ,
High 10 cm .
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3.6. PALLETS
:
You need to
prepare
pallets ,
just use the
supplied "
Pallet Maker
" to produce
the pallets
. You only
need 1000
pcs of
pallets for
each roof
machine ,
and the
pallets can
be use for
more than 3
years . When
some pallets
broken ,
just use the
" Pallet
Maker " to
produce new
pallets .
Please Click
Here to
refer to the
Pallet Maker
explanation
. And
Click Here
for the
explanation
of Pallet
Preparation
for your
first time .
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4. WORK FLOW AND
OPERATORS
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Explanation
of each worker
function :
Worker number 1
Works to sieve
sand and supply
the sand to dry
mixer
Workers number 1
also work at the
mixer and supply
the mortar to
the machine (
supply the
mortar
to temporary
container on the
table besides
the roof machine
) . These
workers are very
important , they
control your
material
composition (
cement and sand
) for your roof
production .
Worker number 2
Casting the roof
and deliver the
results to
worker number 3
.
Worker number 3
Worker number 3
also helping
serving to put
mortar to the
supporting plate
for the worker
number 2 .
Worker number 4
And helping
release the roof
from the
supporting plate
, reverse it on
to the pallet
and put to the
racks .
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These Videos ( uploaded
at YouTube ) will show
you how the workers work
:
VIDEO 1 ( ROOF MACHINE )
VIDEO 2 ( ROOF MACHINE )
VIDEO 3 ( WALL ART
MACHINE )
VIDEO 4 ( PAVE MACHINE )
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5. CURING THE PRODUCTS : |
No particular system
needed to cure the
concrete roof , just
build some water tank
with any demension you
like , depend on the
capacity of the roof you
want to cure . Ususally
we use some water tank
with demension L4m x W3m
x H1m each . The best
curing time for concrete
products is minimum 24
hours , but will reach
the better strength if
we cure them for 3 x 24
hours ( 3 days ) .
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6. PAINTING : |
We can paint the
roof tiles after
they already dry
and strong
enough , usually
after 2 weeks
from the day we
take them out
from curing
water . Just use
the air
compressor and
spray gun to
paint the roof
tiles . Some of
factories paint
their roof tiles
on the top of
the roof's house
.
Two workers
usually can
spray 1000 tiles
per day ( 7
hours ) . Today
, there are many
brands of roof
paint , you can
easily buy the
roof paint in
the paint shop .
But we can also
give you the
formula to
produce your own
roof paint if
you want to
produce roof
paint by
yourself .
Click Here
for the
explanation of
how to paint the
roof tiles . |
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If you have any questions regarding the
production of concrete roof tiles or
paver , please feel free to email us at
:
rudyiskandar86@hotmail.com or
rudy@supersonicmch.com
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