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Manufacturing Machineries - Import & Export

Specialize in Machineries for Concrete & Construction Industries
 
Address : Jl. Tidar Tengah No. 6 , Malang City , Jawa Timur - Indonesia 65146
Phone : + 62 -85100640515 . Fax : + 62 -341 - 791645
Mobile Phone / SMS :  +62-811313603 ( Mr. Rudy Iskandar )
Official Email Address : rudy@supersonicmch.com
Alternate Email Address : rudyiskandar86@hotmail.com
Concrete Roof Machine   Concrete Roof Moulds   Wet Mixer   Dry Mixer   Pave Machines   Hammer Pave Machine   Sand Siever   Block Machine   Industrial Mixer   Hydraulic Press Machines   Roll Press Machines   Generators   Tools   Various Mixers   Concrete Mixers   Sand Washer   Crusher Plants   Batching Plants   Pile Machines   Concrete Pipe   Aerated Autoclaved Concrete Production Line   Concrete Wall Panel   Etc

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Super Sonic Mch - Machinery Designer and Manufacutring , Technology , and Service
Established and Supplying Machineries and Equipments for Concrete Roof Industries since 1982

Proved and Used by more than 500 Concrete Roof and Pave Industries in all over Indonesia
 
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OPERATION MANUAL
 
CONCRETE ROOF MACHINE OPERATION MANUAL
 
1. ELECTRIC PREPARATION :
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 .
 
 
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 .

2.0 Setting Up The Electric Power to the Machine Photo 1 Photo 2

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 ) .

Concrete Roof Machine Operation Manual by Super Sonic Machinery Concrete Roof Machine Operation Manual by Super Sonic Machinery

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  .

Concrete Roof Machine Operation Manual by Super Sonic Machinery Concrete Roof Machine Operation Manual by Super Sonic Machinery

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 . 

Concrete Roof Machine Operation Manual by Super Sonic Machinery Concrete Roof Machine Operation Manual by Super Sonic Machinery

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 . 

Concrete Roof Machine Operation Manual by Super Sonic Machinery Concrete Roof Machine Operation Manual by Super Sonic Machinery

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 . 

Concrete Roof Machine Operation Manual by Super Sonic Machinery Concrete Roof Machine Operation Manual by Super Sonic Machinery

2.6
You should also prepare a table beside the Machine too , to make the work easier . 

Concrete Roof Machine Operation Manual by Super Sonic Machinery Concrete Roof Machine Operation Manual by Super Sonic Machinery
 

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 .
 
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 . 
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 .
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 .
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 .
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 .

Wooden Rack for concrete roof production - Super Sonic Mch

And we put the roof with the pallet on the wood rack like the pictures bellow :
 
 1. Put the Roof Tiles ( with the pallet ) on the rack .

Wooden Rack for concrete roof production - Super Sonic Mch
 2. Put another rack on the rack .

Wooden Rack for concrete roof production - Super Sonic Mch
 3. Then put the others roof on the rack .

Wooden Rack for concrete roof production - Super Sonic Mch
 4. Repeat until up to 8 stacks .

Wooden Rack for concrete roof production - Super Sonic Mch


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 .

 
 
4. WORK FLOW AND OPERATORS :
Concrete Roof Machine Operation Manual by Super Sonic Machinery 
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 .
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 )

 



 
 
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 ) .
Concrete Roof Machine Operation Manual by Super Sonic Machinery  Concrete Roof Machine Operation Manual by Super Sonic Machinery 

 
 
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 .
 
   

 
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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