Steelfields Brochure

S U P P O RT I N G T H E C O N S T R U C T I O N I N D U S T RY

Manufacturers of concrete batching and mixing plant

www.steelfields.com

Pioneers in concrete batching and mixing plant for over 50 years

Steelfields is the UK's leading manufacturer and exporter of high performance concrete batching and mixing plant. Founded over 50 years ago, we specialise in the design and build of concrete plant for the production of high quality ‘wet’ mix, ‘half wet’ mix, ‘dry’ batch, ‘slurry’ batch and mortar.

Whether you are looking for a compact plant for precast production or a large unit for high volume output of readymix, Steelfields will help you find the plant solution that is the best and most cost effective for your application.

Exporting to over 50 countries worldwide, we have developed a reputation for expertise and versatility. Maintaining a proactive research and development programme ensures that we keep pace with the concrete industry’s changing needs and we invest in training to enhance our existing skills and resources.

To complement our extensive range of plants, we can provide reclaimers and recycling systems, plus silt-water treatment solutions for wastewater and washout material.

Skilled team Professional, dedicated and friendly, our highly skilled engineers and technicians have many years’ experience of concrete plant, equipment and applications. We treat all our customers as individuals and work closely with them to develop plant solutions that suit their specific requirements and offer outstanding value and return on investment.

We are always happy to discuss your project with you, and our team of design consultants can provide you with expert advice and guidance.

Flexible benefits Thanks to the advanced modular design of our units, our plants can be easily adapted to suit any site. Many components, such as mixers, silos, storage hoppers and conveyors can be supplied separately, as can operating systems and moisture probes.

Designed and built in-house to strict quality standards, each plant is designed to be durable, reliable and virtually maintenance-free. As you would expect, Steelfields plant meets or exceeds all the requirements of the Health and Safety at Work Act and the Mines and Quarries Act. Our plants can be supplied anywhere in the world and we offer a full range of technical support, spares and maintenance services.

‘Green’ priorities Environmental considerations and aesthetics are a high priority at Steelfields. We have developed low profile plant, special filters for the control of dust and equipment to recycle washout water or reclaim sand and aggregates.

Custom build Steelfields can design and manufacture a custom built plant to individual requirements. Whatever the size or scale of your project or site, we can develop a plant that suits your needs.

Readymix Flexible modular solutions for production of high quality readymix Since the first readymix plant was established in the UK in 1930s, commercially produced concrete has become one of the most important building materials to be used in the expansion of towns and cities, highways, buildings and tunnels demanded by an ever-growing world population.

Steelfields plant has a proven track record. It is used by many leading readymix producers, including companies such as Cemex, Lafarge, Anglo American Group, Hanson (part of the Heidelberg Cement Group), and Aggregate Industries (part of Holcim Group) as well as a host of independent commercial concrete producers in Europe, the Middle East, China, Hong Kong and Southeast Asia.

Site batching Innovative plants designed and manufactured to strict quality standards For over half a century, Steelfields has been manufacturing high performance concrete batching plant, capable of producing concrete to the correct specification, mix and quantity, however demanding the requirement.

Larger civil engineering projects, in particular, often require dedicated, on-site concrete production facilities to meet the stringent technical and quality demands of the main contractors. Steelfields plants have been successfully commissioned on many major construction projects, including dams, wind farms, airports, roads, tunnels and bridges.

The Steelfields range includes ‘wet’, ‘half-wet’, ‘dry’ and ‘slurry’ batching plant systems, as well as mixers of all types and sizes and ‘wet’ concrete recycling systems.

Recent UK projects include concrete batching plant for contractors involved in the construction of new aeroplane parking aprons at Gatwick, Manchester, East Midlands and Stansted airports, the high-speed rail link between the UK and France, major sporting stadia, and the widening of the M25 motorway.

Precast Versatile modular plants that provide consistent concrete even under the most demanding conditions

Steelfields’ concrete batching and mixing plants can be configured to provide high quality concrete for the production of a wide range of precast concrete products, such as hollow core panels, blocks, beams and railway sleepers.

To ensure that all the mix ingredients are accurately controlled to tight tolerances, we can install additional features, such as horizontal belt feeders, vibratory feeders, multi-jog feed and variable speed drives. Cement screws are available with variable speed drives, as well as second stage micro-screws for ultimate flow control during the weighing up cycle.

Concrete distribution High quality systems for the efficient distribution of concrete As part of its supply package, Steelfields offers customers a complete range of proven distribution systems from leading German manufacturer, Dudik GmbH. The range includes roll-over buckets and flap type discharge options, with systems to suit mono-rail or twin-track applications. Curved tracks and inclines plus cross-feed distributors are available to suit almost any factory layout.

Wear protection Branded under the name ‘Wear-Flex’, this PU based product is now available in a wide range of moulded components to suit most popular European mixers. Steelfields has many years’ experience of wear protection and can advise customers on the best way to improve mixing performance, using optimised mixing blades and a system of planned maintenance.

Recycling and water treatment Environmentally-friendly recycling and water treatment systems to drive down costs of waste transport and wastewater disposal Steelfields can supply and install an extensive range of ‘wet’ concrete recycling plant and concrete water systems, suitable for applications in the precast and readymix industries. We offer two design concepts based on a simple screw conveyor and submerged trough system.

Screw reclaimer This basic low cost 'wet' concrete reclaim system is compact, easy to install and offers excellent value for money. It produces an 'all-in' ballast from waste concrete, together with a controlled discharge of 'grey' water, which is dispersed into existing settling tanks or a 'closed loop' circuit for return to the mix design.

Trough reclaimer A range of five Ecofrog waste concrete reclaimers is available. These work on the principal of flotation, with a separating cut at approximately 0.25 mm. The water overflows into a stirring tank and can then be returned into concrete production as part of the mix design, if desired. Sand and gravel is discharged via a vibratory chute, which simultaneously dewaters the mixture.

The range is available with an optional scoop wheel, ideal for handling washout from concrete spreaders, slip formers, extruders and concrete pumps – without the need for an elevating screw conveyor.

Siltwater processing Steelfields, in collaboration with Ecofrog GmbH, offers a range of unique units developed to separate wastewater into fractions for recycling, eliminating the need for settlement pits and wastewater disposal. These include clarifying tanks, filter presses, dewatering containers, plus CO2 injection to balance the pH values.

Control systems Fully automated plant control systems for a wide range of applications Steelfields offers an extensive choice of plant automation.

Batching systems range from simple automatic presets up to the latest 'state-of-the-art' technology, incorporating moisture control, plant graphics, load scheduling, and modem support providing 24 hour-a-day cover from almost anywhere in the world.

Options include multiple aggregate bin, cement silo, water and admixture weighers, unlimited mix design, multimixer control; order entry/delivery ticket printing; remote batching, temperature readout and multilanguage display screen options.

Moisture control Controlling the amount of water in the mix design is essential for the production of high quality concrete. Steelfields can supply the latest microwave technology with probes fitted directly in the aggregate and sand storage bins, as well as sensors for virtually all mixer designs. The moisture probes interact directly with the control system to adjust batch water content and compensate for wet sand, guaranteeing that the resulting production batch meets the requirement of the original mix design.

Bin mounted moisture probe

Concrete plant An extensive range of high performance concrete plant, offering outstanding flexibility and value Major 1000 The smallest unit in the Steelfields plant range, the Major 1000 series was developed to cater for the Mini-Mix market. The aggregate storage and batching system utilises ‘back-weighing’ technology matched to a digital controller. A plant can be ordered with a single storage hopper, with the option to add extra hoppers and transfer conveyor at a later date, if required.

Batching facilities Plant designation Typical output range

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'dry' Modular/horizontal 10 to 50 cubic metres per hour

Major 2000e Based on the popular Major 2000 series, the Major 2000e is an ideal on-site plant for production of precast, for smaller readymix operations, and for civil engineering contractors. Composed of three basic modules which can be combined to meet virtually any site requirements, the Major 2000e offers a choice of SFP, PM or PMS mixers with capacities of 300, 500, 750 or 1000 litres compacted concrete output, plus a larger 2000 litre counter-flow mixer for producing foam concrete.

Batching facilities Plant designation Typical output range

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'wet' or ‘dry’ Modular/horizontal 10 to 50 cubic metres per hour

Major 2000 The modular design of the Major 2000 can be configured to meet virtually any customer or site requirements. The standard in-line aggregate section can be constructed with three or four compartments, while a Lloyds-approved ISO container design is ideal for overseas markets. Available with direct shovel loading or conveyor feed, the Major 2000 can be equipped with 'common' aggregate storage bins to double the plant output capacity.

Batching facilities Plant designation Typical output range

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‘wet’ or ‘dry Modular/horizontal 30 to 240 cubic metres per hour

Major 3000 The Major 3000 series has been developed on a modular concept using interchangeable components from the Major 2000.

Aggregate storage is in overhead compartments with material feed via belt conveyor. One Major 3000 plant operating in the Gulf Region has produced over 1,000,000 cubic metres of concrete though a single 2.25 cubic metre mixer!

Batching facilities Plant designation Typical output range

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'wet' or 'dry’ Modular 30 to 240 cubic metres per hour

Major 60 Versatile enough to meet almost any mixing or batching application, the efficient, competitively-priced Major 60 requires minimal groundwork and is easy to transport and install. Widely used for readymix and civil engineering projects around the world, the Major 60 is based on a monocoque design with an extensive range of options to suit virtually any customer requirement.

Batching facilities Plant designation Typical output range

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'wet' or 'dry' Modular/mobile/compact 30 to 120 cubic metres per hour

SM 3000 Designed to offer maximum flexibility, the SM 3000’s modular units can be combined to meet virtually any site requirement.

The standard overhead aggregate section is available in three or four compartment construction, whilst cement storage can be supplied from freestanding silos.

Batching facilities Plant designation Typical output range

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'wet' Mobile 10 to 80 cubic metres per hour

SM 60 Offering outstanding value, the SM 60 has a robust 'space-frame' design and is available with a wide choice of aggregate and cement storage options. Easily transportable, the plant requires minimal groundwork and is widely used for readymix and civil engineering projects around the world.

Batching facilities Plant designation Typical output range

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'wet' or 'dry' Modular/mobile/compact 30 to 210 cubic metres per hour

Major 90 Compact and reliable, the Major 90’s small footprint makes it ideal for longer-term applications. Designed for consistent high quality concrete production, the plant offers a choice of integral cement storage silos and can be supplied with environmental cladding if required.

Batching facilities : 'wet' or ‘dry’ Plant designation : Modular/compact Typical output range : 30 to 120 cubic metres per hour

Plant options Huge range of plant, storage and mixer options for all types of concrete production The range of plant options Steelfields offers is almost limitless.

To meet customer demand, we can provide plant cladding, steel and poly-fibre dispensers, dust extraction systems, special painting schemes, hot or cold water systems and noise suppression – please contact us for further details.

Cement and powder storage silos Steelfields has a wide range of storage silos with choice of vertical, horizontal and mobile designs. Typical silos are of fully welded construction with the option of bolted or section design for export shipment. Silo exhaust filters, aeration systems, support structures, bin activators, discharge valves, screw conveyors, silo monitoring and safety systems are all available to order.

We can also offer customers operating in the Middle East a local fabrication facility for the production of vertical storage silos up to 250 cubic metres in size.

Mixers A range of heavy-duty, low maintenance mixers suitable for the production of heavy, normal or lightweight concrete Pan mixers Tried and tested in all kinds of environments over the last 30 years, Steelfields’ high-speed 'turbo' pan mixers can cope with almost any type of concrete production, anywhere in the world.

The pan mixer requires only minimal maintenance and is offered with a choice of abrasion resistant liners, mixing blades and discharge door options. Eleven mixer capacities are available, from 250 litres up to four cubic metres.

Customised mixer design For special applications, Steelfields can often incorporate special design options into its standard mixers, such as intensive agitators, side access doors and discharge accelerators, and special discharge gates.

Paddle mixers Designed to keep materials in constant motion and ensure that the mix is rapidly homogenized, our twin-shaft paddle mixers are suitable for a wide range of mix designs/materials. We offer fifteen models, with capacities from 500 litres up to six cubic metres. PMS 2000 and 2500 single-shaft paddle mixers are also available.

Inclined skip hoists Skip hoists are offered as a compact alternative to conventional belt feed conveyors. Skip hoists can be fitted with standard buckets or optional low-profile designs for minimal loading height and removal of loading pits. All skip systems feature position switches, emergency fail-safe devices and track inclinations of 70 to 95 degrees.

Planetary mixers These mixers achieve an intensive transition of materials throughout the mixing zones and can be supplied with an optional discharge accelerator to reduce discharge times.

Capacities range from 300 litres up to three cubic metres.

Mixer washout systems Steelfields’ range of high-pressure washout systems reduce wash time and operating costs. Simple and safe to operate, our mixers will wash 'turbo' pan mixers, paddle and planetary mixers efficiently and effectively and can also be used for travelling skips and concrete hoppers.

For more information please contact us on +44 (0) 1634 280135 or visit our website www.steelfields.com

– the choice of leading construction, civil engineering and readymix companies worldwide Fast track installation for Premco When Premco required a compact concrete batching and mixing plant installed, the company knew exactly which manufacturer to contact to meet its tight deadline. Within a couple of days from initial contact, a representative from Steelfields had visited the site and produced a competitive quotation, together with site layout drawings for customer approval. Premco LLC, part of the Saudi Binladen Group based in Jeddah, Saudi Arabia, opted for two SM 60 plants. Compactly designed and quickly assembled, the SM 60 was an ideal choice for supplying readymix for the company’s new operation in Mafraq, Abu Dhabi.

To maximise production, each of the SM 60’s turbo pan mixers were fitted with two doors to enable them to feed two trucks situated sideby-side simultaneously. The plant also incorporated the latest automated batch control system, as well as a facility for adding ice to the concrete mix.

Engineer Ricardo P. Dosal, Technical & QA/QC Manager of Premco Ready Mix LLC, Abu Dhabi, UAE, said: “During my 17 years in the concrete industry, I have worked with various concrete batching plants, but in my experience, Steelfields plants, particularly the SM 60, are really different when compared with other plants.

The SM 60 is very reliable because it provides a totally homogenous mixture in less mixing time, improving production output and profitability.”

Flexible plant fits the bill for Caribbean site A Steelfields Major 2000e plant was shipped to the Caribbean as part of a major investment programme for Studley Park Quarry.

The plant, ordered by NSG Exports Limited, was selected for its flexibility, which enables it to be adapted to suit a wide range of customer requirements and site specifications. It included a standard three compartment aggregate batching section, low-angle feed conveyor and SFP 1500 1.5 cubic metre counter-flow mixer with batch holding hopper and 'semi-dry' leg bypass feature.

The project also included the shipment of two no.

100 tonne capacity 'export' silos, a pneumatic handling system to suit bulk tankers, and a polyfibre dispenser, together with a fully automatic batch control system.

Philip Hobson, CEO of NSG Exports, said: “The Steelfields team were extremely professional and a pleasure to work with. Nothing was too much trouble: they were happy to adapt the basic design of the Major 2000 and incorporate the additional technology and components we required. The resulting plant was tailor-made for the project and represented very good value for money.”

Saudi Readymix Company Saudi Readymix Limited has been a long time supporter of Steelfields products. The company was one of Steelfields’ first customers in the Middle East and has maintained an excellent track record since commissioning its first Major 60 plant in 1975.

Saudi Readymix Limited was established in 1978 and is the undisputed market leading supplier of quality readymix concrete throughout The Kingdom of Saudi Arabia.

Saudi Readymix now operates more than 70 concrete plants, 540 truckmixers and 190 concrete pumps from 29 strategically located sites across Saudi Arabia, with a combination of fixed plant installations and a mobile concrete fleet for site-based applications - the company have been enthusiastic supporters of Steelfields equipment since originally purchasing a number of Major 60 concrete plants in the 1970’s and 80’s and both companies still maintain regular technical and supply contracts to this day.

As a testament to the quality of the original Major 60 plants, most of their units are still in active service today and contribute towards the Group’s annual yearly production in excess of 6,000,000 cubic metres of concrete !

This long lasting relationship demonstrates Steelfields commitment to its customers.

Saudi Readymix is a wholly owned subsidiary of The Khalid Ali AlTurki & Sons Group employing a workforce of 2,800 people.

Steelfields takes on Olympic challenge The installation of a large ready-mixed concrete batching plant at the London Olympic Park site in Stratford proved quite a challenge for Steelfields and London Concrete.

"We needed a plant that could meet the high volume requirement and challenging material sustainability targets of the Olympic Park contractors,” said David Barrett, Director of London Concrete.

Steelfields’ solution was to design and build a special version of its Major 2000 plant in the form of two separate plants joined together. This enabled it to deliver the high volumes required, and also ensured that the components could be dismantled easily after the project was completed.

The adapted Major 2000S plant consisted of a dual ‘wet’ leg plant, featuring two 4.5 cubic metre twin-shaft paddle mixers, six aggregate storage bins, four ground loading hoppers and seven cement storage silos. All the bins and silos were equipped with ultra-sonic probes and micro-cells and the plant incorporated twelve colour cameras to allow operators to keep a close eye on the entire plant.

To meet the sustainability challenge, London Concrete used both secondary aggregates and cement replacements. The mixes delivered ranged from C6/10 to C50/60. These materials were used for a variety of projects within the Park, including the Olympic Stadium itself, as well as the Aquatics Centre and the Velodrome. Mix applications included products for piling, precast, walls, bridges, and roads.

Although timing was tight, the initial plant installation was completed in just 25 days, with an additional 10 needed to complete the plant wiring ready for commissioning, set up and testing.

“Steelfields went to great lengths to work with us and design a plant that would exactly meet our specification and site layout we required. The Major 2000 plant performed well and consistently produced high quality concrete material for three years at a peak rate of up to 200,000m3 per year,” said David Barrett.

S U P P O RT I N G T H E C O N S T R U C T I O N I N D U S T RY

Worldwide service Outstanding sales, service and support through an international network of experienced agents.

At Steelfields, we ensure all plant is fully factory tested before despatch. Our trained engineers will run trial batch tests on-site prior to handover and we can provide operator training if required. After-sales technical support and assistance is provided by our qualified team of experienced engineers.

Steelfields plant currently operates in more than 50 countries worldwide, including:

Antigua Australia Bahrain Belgium Bulgaria Chile China Czech Republic Egypt France Ghana Grenada Guyana Holland Hong Kong Hungary Iceland

India Indonesia Iran Iraq Ireland Kazakhstan Kenya Kuwait Lebanon Libya Malaysia Malta Morocco Nigeria Oman Portugal Qatar

Saudi Arabia Seychelles Sri Lanka Sudan Sweden Thailand Tobago Tunisia Turkey Turkmenistan United Arab Emirates United Kingdom USA Uzbekistan Vietnam

To find out how we can add value to your installation, please contact one of our sales team on +44 (0)1634 280135, email sales@steelfields.co.uk or visit www.steelfields.com

Manufacturers of concrete batching and mixing plant

www.steelfields.com