Concrete build-up a thing of the past thanks to WALTER

Once raw materials are mixed, residual concrete and concrete build-up can become a significant headache for virtually all readymix producers. Although commonly associated with the mixer, build-up can also block the discharge chute and truckmixer loading chute, even affecting the truckmixer itself.

At a ‘major’ producer’s plant in South Yorkshire, batching ~1500m³ of concrete per month, the 4m³ twinshaft mixer and discharge chute proved difficult to keep clean and blockage free.

The mixer was installed with an OEM washout system which was ineffective, and after a short period, became inoperable. What’s more, due to the shallow discharge chute, it was difficult to clean without removing it. As such, the batcher relied on a high-pressure handlance for interim cleaning of the mixer and chute. This was time consuming, taking 20 minutes, four times a day.

(Mixer cleaned with hand lance alone – full of build-up)

Ultimately, cleaning via handlance only controlled a limited percentage of concrete residue in both the mixer and chute. As a result, significant build-up occurred in the mixer. The chute would also block completely, which led to the mixer door failing to close. To combat this, contractors were hired monthly to chip out build-up in both the mixer and chute, costing ~£1000 and accruing 10 hours of downtime – affecting production capacity.

(Discharge chute – removed, to chip out the build-up)

Having successfully used WALTER elsewhere within the group, the Area Operations Manager for the plant in question contacted ConSpare to enquire about a cleaning system upgrade.

WALTER washouts are renowned for keeping mixers clean and staff safe, but the systems can also be configured & extended to provide a holistic cleaning solution for the wider concrete plant.

Liaising with our Capital Division, the Area Operations Manager chose a WALTER 4 head RD3maX mixer washout system, with an additional dedicated cleaning head in the mixer discharge chute – providing autonomous cleaning to both of the problem areas.

(RD3maX system keeping the mixer clean)

Importantly for the site in question, as chute blockages were a real concern, the chute cleaner was programmed to allow independent operation from the mixer washout. This enables the batcher to quickly clean the chute “on demand” throughout the day, even when a full mixer clean isn’t required.

A year after installation, we visited the batcher to get some feedback:

The batcher reported that the WALTER system has kept the mixer clean, and the chute hasn’t experienced any blockages. This has eliminated many hours of manual cleaning for the site team.

(Autonomous chute cleaner eliminates blockages)

Furthermore, the monthly cost of contractors to chip out the mixer & chute has been eliminated – with only an annual inspection and manual clean required. In the first year, this has saved ~£11,000, and eliminated well over 100 hours of downtime.

“It’s sh*t hot! I can just stick WALTER on after each batch, and I don’t have to worry about spending extra time doing LOTOTO. The installation from ConSpare was great too; the heads are well positioned, so the system still looks brand-new.”