Re ROCKCRETER OPTIMIX 1.5 User manual

OPERATORS MANUAL
FOR
ROCKCRETER OPTIMIX 1.5
SOUTH AFRICAN SHOTCRETE TECHNOLOGY
Designed to perform, the power to succeed!
P. O. Box 18924 Sunward Park 1470●361 Crocker Road, Wadeville, Germiston, South Africa
Co. Reg. no: 1947/24677/07
TEL: [phone]
e-mail: [email protected]
www.rockcrete.co.za
As part of our policy of constant product development and improvement information and
specifications contained in this document are liable to change.

OPERATORS MANUAL
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CONTENTS LIST
Figure Description Page
No
1. SAFETY PROCEDURES 1
2. TECHNICAL SPECIFICATIONS 2
3. PRINCIPLES OF OPERATION 2
3.1 Materials 3
3.2 Flow 3
3.3 Setting Time 3
3.4 Pumping Distance 3
3.5 General Procedures 4
4. OPERATING PROCEDURES 6
4.1 Set-Up 6
4.2 Priming with Water 6
4.3 Prime with Material 7
4.4 Prevent Blocking 8
4.5 Spraying 8
4.6 Pressure Relief Procedure 9
4.7 Flush 9
4.8 Shutdown 11
5. TROUBLESHOOTING 12
PRE USE CHECK LIST 14
6. ILLUSTRATED PARTS CATALOGUE 15
.

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OPERATORS MANUAL
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1. SAFETY PROCEDURES
Recommended items to keep pumping safe:
a. Hard hats.
b. Safety goggles.
c. Dust masks in confined spaces or unventilated areas.
d. Good lighting.
e. Whip check cables and chain safety couplings on air supply
hoses.
f. Rubber gloves to protect workmen with skins sensitive to cement
burns (also use barrier cream).
g. Sturdy and safe lifting devices, platforms and scaffolding for
those many pumping operations that are performed off the
ground. All platforms should be equipped with safety rails.
h. A qualified electrician must do all electrical connections.
i. Do not remove the screen/sieve supplied on the hopper whilst the
machine is in operation.
j. Do not carry out any maintenance whilst the air or electrical
connections are connected to the machine.
k. Do not poke or prod any instrument of any sort into the hopper
whilst the machine is in operation.
l. Use safety straps on all grout hose connections.
m. Keep arms, hands, fingers etc away from moving parts.
n. Disconnect power/air before attempting to clean or repair
equipment.

OPERATORS MANUAL
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ROCKCRETER OPTIMIX 1.5
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2. TECHNICAL SPECIFICATIONS
ROCKCRETER OPTIMIX 1.5
Dimensions
Length 1780 mm
Width 580 mm
Loading Height 970 mm
Weight 105 kg
Output Up to 1,5m3/Hr
Aggregate size Up to 4mm
Outlet 32mm
Conveying Distance
Horizontally Up to 30m – material dependant
Vertically Up to 15m
Electric drive – 3kW. 220V/380V/525V
3. PRINCIPLES OF OPERATION
NOTE:
The principles of operation offered herein are intended as an aid to
help the operator identify some of the factors that need to be taken
into consideration when mixing and pumping cementitious grouts.
Because wide varieties of materials are available for many
different applications, it is important the operator becomes familiar
with the specific characteristics of the material he intends using.

OPERATORS MANUAL
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3.1 Materials
1. Among the commercially manufactured materials available in today’s
market are materials for structural repairs, floor toppings, high strength
non-shrink grouts, special linings and other specialty materials.
2. Each of these materials has unique characteristics, which must be well
understood to insure a successful application.
3.2 Flow
1. In general, most materials need to be a flowable or pourable
consistency for successful pumping. This means that if the material can
be poured out of a pail or bucket, it can likely be pumped.
2. The exception to this requirement is repair mortars, which tend to be
mixed in a thicker consistency and require special pumping techniques.
3. Materials that contain aggregates pump best and perform best when
the consistency is kept to the lower range of pourable, that is, not too
wet.
3.3 Setting Time
1. Some materials contain accelerating admixtures to reduce the setting
time. This is particularly true of repair mortars and other spray applied
materials so that strength gain can be fairly rapid. It is important to
keep moving when using these types of materials.
2. Once the material is mixed, it must be pumped immediately and kept
in motion and subsequent batches must be mixed and pumped as
rapidly as possible. Any delays in the application process could result
in plugged hoses and equipment.
3. Temperature also has an effect upon these materials to the extent that
exposure of the hose to the sun on a hot day will accelerate the set
time even more, therefore this should be avoided. It may even be
necessary in some cases to cool the material, the mix water, or even
the hose itself.
3.4 Pumping Distance
1. Pumping distances should always be kept to a minimum, and hoses
should run as straight as possible no matter what material is being
used.
2. Sometimes circumstances require longer than usual hose lengths,
when this occurs, every effort should be made to use every advantage
possible to insure a successful application. Some materials simply
cannot be pumped for long distances, so it’s best to know the

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proposed material characteristics before attempting a production
procedure.
3.5 General Procedures
1. Before attempting to mix and pump production materials, it is important
to rinse and charge the pump hopper with sufficient water to
thoroughly flush the pump and all grout lines. This is to purge the
grouting system of any residual materials or scale that may exist.
2. Once that is completed, remove the grout hose from the pump and
drain out all water by elevating one end, or by progressively elevating
the entire hose, at one end and proceeding to the other.
3. Mix slurry composed of Portland cement in approximate proportions of
25 litres of water to ½ a bag of cement, and pump this through the
grouting system. This is to remove any residual water from the hose,
lubricating it for the production material to follow. Now the production
grout may be mixed and pumped immediately behind the slurry mix.
4. The slurry mix may be retrieved in a bucket.
NOTE: DO NOT attempt to pump production material through a dry
hose. Occasionally, no matter how conscientious an operator may
be, a hose will get plugged. Once this happens, the only sure way to
remove the plug is to empty it of material. Beating on it with a
hammer or running over it with a vehicle will not usually be
successful. A prudent operator will be prepared for such
eventuality.

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Figure 1

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4. OPERATING PROCEDURES
4.1 Set- Up
1. Insert the drive/mix shaft into the hopper and engage the flat end into
the slot of the rotor.
2. Slowly swing the motor assembly into the closed position, stopping
before the motor shaft adapter and drive/mix shaft touch.
3. Align the shaft adapter and drive/mix slots so that they engage, If they
do not align then rotate until correct position is achieved.
4. Swing the motor completely shut and secure in place with motor latch.
5. Secure the hopper gate onto the top of the hopper.
6. Connect the motor cable to the power out connector.
7. Connect the power cable to the main power in connector.
8. Connect the power cable to an appropriate power source.
4.2 Priming with Water
1. Attach a water feed hose to the water inlet.
2. Attach the main hose to the water system bypass outlet and attach the
spay nozzle to the hose outlet.
3. Place the nozzle into a waste container.
4. Turn the main power disconnect switch to the “ON” position.
5. Open the ball valve directly before the water system bypass outlet.
6. Press the water drain button to turn on.
7. Run the water until water flows from the end of the nozzle.
8. Press the water drain button to stop the water and close the ball valve
directly before the water pump bypass outlet.
NOTE: Do not run the water pump without water. The water pump
will overheat and cause damage.
9. Run clean-out ball(s) to coat the inside of the hoses:
a. Remove the nozzle from the end of the hose.
b. Remove the hose inlet from the water system bypass outlet and
insert a clean-out ball into the hose inlet (The ball must be soaked in
water before inserting).
c. Attach the hose to the water system bypass outlet, open the ball
valve and press the water drain button to resume flushing the hose.
d. The clean-out ball will be pushed out of the hose after several
minutes.
e. When the task is complete, close the ball valve, remove the hose
inlet from the water system bypass outlet.