WO2009152615A1

WO2009152615A1 - A production system and method for manufacturing lightweight fiber reinforced concrete panels

Info

Publication number: WO2009152615A1
Application number: PCT/CA2009/000849
Authority: WO
Inventors: Wanda Arnold; Shannon Mcnair; Todd Leblanc
Original assignee: Vidabode Group Inc.
Priority date: 2008-06-20
Filing date: 2009-06-19
Publication date: 2009-12-23
Also published as: CA2669873A1; CA2635509A1

Abstract

A production system and method for manufacturing individual building blocks or panels of lightweight fiber reinforced concrete, the method consisting of generating raw materials, conveying measured ingredients, mixing ingredients in accordance with a formula of additives, fiber, cement powder, water, and specially coated and sized Expanded Polystyrene (EPS) beads, and conveying the resultant lightweight admixture through distribution into molds on casting elements, is provided. The production line for manufacturing the lightweight fiber reinforced concrete panels has a main conveyance system, material lifts, storage racks, climate controlled curing facility, yard conveyor system, cross-transfer units, return conveyor, wash station, drying station, release agent station, framework manufacturing equipment. The main conveyance system has casting elements which are designed to receive in an operable arrangement frames and molds. The formwork or frames are determined based on the design specifications shapes and sizes determined by a CAD system or such other input, be it mechanical or manual, to achieve the panel output production.

Description

A PRODUCTION SYSTEM AND METHOD FOR MANUFACTURING LIGHTWEIGHT

FIBER REINFORCED CONCRETE PANELS

FIELD OF THE INVENTION

The invention relates to a system and method for manufacturing lightweight fiber reinforced concrete articles, such as, for example block-shaped or flat rectangular concrete elements. More particularly, the invention relates to a system and method for manufacturing concrete blocks or panels comprising coated EPS particles or beads.

BACKGROUND OF THE INVENTION

Concrete materials have been made and used, in particular, in the construction field in the past years. Light weight concrete building materials, that incorporate foamed polystyrene particles which are coated, prior to their addition to the concrete mixture, have gained significant importance in the recent years for their improved performance and relative low cost manufacturing.

Research and development into lightweight concrete began, and the idea of lightweight concrete with EPS beads was introduced, in Germany in the early 1980s. Previous early attempts at lightweight concrete did not venture much further than adding EPS beads to concrete in different volumes and mixing it, without addressing the difficulties arising from using foamed polymer particles as ingredient of concrete mixtures.

Use of foamed polymer particles, such as, for example expanded polystyrene, as an additive for building materials is not straightforward. The introduction of granules or beads of foamed plastic material into concrete or plaster posses difficulties in obtaining adequate binding between the concrete and the granules. It is a known problem of building materials of this type that the granules are easily broken away from the concrete or plaster, with the result that the material tends to disintegrate at the edges as the granules break away. Additionally, EPS contained in high volumes in a concrete mix can reduce the strength of the overall composite block or panel which may cause sheer and movement issues.

Production line equipment to manufacture these lightweight concrete building materials, for example lightweight concrete panels, using various concrete mixtures are known in the art.

For instance, U.S. Patent No. 3.904,723 issued September 9, 1975 to Prince discloses a method of manufacturing concrete. U.S. Patent No. 4,098,563 issued July 4, 1978 to Prince is a divisional of the above-identified U.S. Patent directed to the concrete product manufacturing apparatus.

U.S. Patent No. 4,547,331 issued October 15, 1985 to Batstra describes a method and system for manufacturing lightweight shaped concrete materials incorporating sphere- shaped particles of a foamed plastic material with a binder. Batstra's teachings describe that the foamed plastic material is coated with a first portion of dry cement and a second portion of dry cement and sufficient water to harden the cement. Batstra teaches that adding a binder and cement and admixing the cement with the spheres of plastic material ensures that the spheres which have been individually coated with the binder will adhere to the cement so that a firm product is obtained consisting of spheres of foamed plastic material lying in a matrix of cement.

PCT International Application No. WO95/9723 published on April 13, 1995 to Nordin et al., discloses a method and device for producing reinforcement fibres and adding them to concrete. PCT International Application No. WO01/19584 published on March 22, 2001 and U.S. Patent No. 6,676,862 issued January 13, 2004 to Jensen, both describe a method and apparatus for efficiently forming individual building units. The method of Jensen provides the ability to measure the amount of cementitious slurry in each batch in order to control to the extent possible the quantity of cementitious slurry poured into each mold and the ability to precisely control the dimensions of each building unit produced.

Increasingly, structural stability and ability to withstand major weather events and cope with climates issues (extreme heat/cold) is a key concern of concrete construction.

The invention was made in recognition of the need for a system and method for manufacturing individual building blocks or panels of lightweight concrete with a view to minimizing labor costs, and shortening occupancy waits to meet the demand of the growing market for affordable housing.

SUMMARY OF THE INVENTION

An object of the present invention is, thus, to provide a method and system for manufacturing individual building blocks or panels of lightweight concrete.

In accordance with an aspect of the present invention, there is provided a method for manufacturing lightweight concrete with coated EPS beads, the method including providing a hopper containing particulate EPS raw material; pre-expanding a measured volume of the EPS raw material to form EPS beads; passing the EPS beads through a fluid bed dryer; blowing the EPS beads through an EPS coating system, whereby the beads are coated with a functional composition; transporting the coated EPS beads to a measuring bin; and transferring a measured amount of the coated EPS beads from the measuring bin to the mixing device for mixing with the other ingredients used to produce the lightweight concrete. In accordance with another aspect of the present invention, there is provided a lightweight concrete product manufacturing system having storage means for storing raw materials including water, cement, coated EPS beads, and water reducer; conveying means for transporting the raw materials from the storage means to a mixing device, the mixing device being positioned to receive the raw material from the storage means and to mix the raw materials with an aggregate, additives, fibers, inhibitors, air entrainment material, or mixtures thereof, so as to form a lightweight concrete mixture suitable to be poured into molds; measuring means for measuring the raw materials to be introduced into the mixing device; and curing means, including a climate-controlled curing area for curing the lightweight concrete mixture contained in the molds.

In accordance with still another aspect of the present invention, there is provided an apparatus for mixing ingredients used to produce a lightweight concrete material with EPS beads, the apparatus having a mixing receptacle, the receptacle being adapted to discharge the lightweight concrete mixture containing EPS beads coated with a functional composition through a plurality of discharge openings into molds; first and second rotating shafts, the shafts having their axis of rotation parallel, whereby the shafts rotate in opposite directions; mixing blades operably mounted on the first and second shafts, the blades being structured and dimensioned to pull the ingredients down into the mixture mass and then throw the mixture outward and upward evenly for homogenous and fast mixing and to preserve the functional coating of the EPS beads.

In accordance with still another aspect of the present invention, there is provided a multi-level transfer system comprising conveyor tracks arranged in parallel on multiple levels for lengthwise transportation of molds or concrete panels disposed horizontally on the parallel conveyor tracks, the system having transverse cross transfer conveyor tracks between each parallel conveyor track and lifting means operable between each level of parallel conveyor tracks, the system further including an infeed conveyor and an outfeed conveyor. A panel flip station can be disposed next to the outfeed conveyor for moving the concrete panels from the horizontal position into a vertical position through a vertical conveyor to a storage means.

According to the method of the present invention predetermined amounts or quantities of water, water reducer, cement, aggregate such as, for example, sand, additives, and/or an air entrainment agent are introduced into the mixer according to a predetermined sequence and the ingredients are mixed for a predetermined amount of time.

The apparatus for mixing ingredients used to produce a lightweight concrete material with EPS beads has a number of discharge openings, preferably, as many as seven, which are provided in a bottom wall of the receptacle. The discharge openings can be, for example, sliding gates which can be operated by hydraulic cylinders or clamshell apparatus running on hydraulic or pneumatic cylinders.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present invention will now be described, by way of example only, in conjunction with the following drawings, in which:

Fig. 1 shows a diagram of the concrete product manufacturing system of the present invention;

Fig. 2 shows a perspective view of the curing station in accordance with an embodiment of the present invention;

Fig. 3a and 3b show a side and front sectional views, respectively, of the distribution head in accordance with an embodiment of the present invention;

Fig. 4 shows the Washdown/Dry-Off/Release Agent Application Station in accordance with an embodiment of the present invention; and

Fig. 5 shows a plan top view of the EPS plant layout in accordance witrh a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following description is presented to enable a person skilled in the art or science to which the present invention pertains to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art or science, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. Thus, the present invention is not intended to be limited to the embodiments disclosed, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

With reference to the Fig. 1 , shown is the concrete product manufacturing system, which includes raw material storage bunkers 1 which include, but are not limited to, Expanded Polystyrene (EPS), sand, and cement silos (5, 7, 11), and EPS, sand, and cement bins (6, 8, 12). At least one bunker 13 may be provided with separate compartments for additives, fibers, and water. In a preferred embodiment each additive can be placed in a separate vessel which can be placed in a leak-proof basin, the basin being, preferably located near the mixer. In another preferred embodiment the fiber can be taken from large bags emptied into the fiber feeder which is fitted with a weight scale. The feeder can blow the fiber into the mixer so that the fiber does not get lumped when it gets discharged to the mixer. The sand silo or aggregate bin 7 is provided with sand via a sand conveyor 9 which runs from a sand bunker 10, preferably remotely located. Preferably, the sand conveyor can be covered to protect windblown debris, rain, snow, etc. The EPS silo 5 is provided with the EPS beads by an EPS beads conveyor 4. The EPS beads are conveniently foamed polystyrene coated with a coating composition which improves adherence of the beads to the cement. From the bins 6, 8, 12, and/or 13 measured quantities of ingredients are poured into the mixer 20. A water bunker can be placed outside, the water bunker being preferably protected from weather and pollution.

VPS Process Flow

Formwork System

The Formwork framing is assembled and sent to the lnfeed Panel Casting Prep Station where it is placed on a 9' wide X 19' long X 1" thick Casting Element. The top of the casting element effectively becomes the bottom of the panel mold while the Formwork frames the perimeter of the mold.

EPS System

EPS Raw Materials are fed into a hopper. A weighing system meters the raw material & a blower unit draws the raw material into the EPS Pre Expander. Steam is provided to the EPS Pre-Expander by a boiler. Steam expands the EPS material to form beads which are forced into a heated Fluid Bed Dryer.

A steam heating coil and forced air blower move the beads through An EPS Bead Coating System. From there the coated Beads are blown into storage silos.

Concrete Batching System

Cement, water, sand, EPS Beads, fibers, and additives are conveyed or blown, as indicated herein, to a Mixer. In an embodiment of the invention a weight scale for cement can be provided above the mixer. A weight scale for sand can also be provided, for example, below the sand silo and, preferably a moisture sensor can be installed in the sand bin to indicate for example the amount of free water in the sand and accordingly adjust the amount of water to be added. A weight scale for the fiber can be provided with the fiber feeder. A water meter can be, for example, installed on the mixer and admixture meters, for SPC, CIA, AIRX, can be installed at the pumps close to the admixture vessels. EPS is measured in volume and measuring bins can be installed at the end of the feed line. A CAD System can be integrated with the Mixer to provide EDI & MRP data. A Batchtron or other PLC control software system can be configured to interact with batch scales, conveyors, and the mixer. The mixing PLC system can be configured, for example, in a total auto mode in which the mix can be produced, for example, by giving the system the desired quantity of the mix. Such total auto mode allows mixing of the ingredients for as much time as needed. Software for Labeling & Inventory Control is also incorporated. In a preferred embodiment, barcodes can be used with each panel so that the system can identify the shape and size of the panel with a view to discharging the concrete in the mould, accordingly. Vidacrete™ is dispensed from the Mixer to the distribution system onto the Casting Element and into each Formwork Assembly to create a panel of specific length, width and thickness.

Curing System

The Assembled Formwork Framing and Casting Element is conveyed to the Curing Station from the lnfeed Panel Casting Prep Station. Vidacrete can be poured into the Formwork on the Casting Elements as they move under the Mixer. Steam, vibration and time in the Curing Station result in a completed panel exiting the Curing Station.

Prep System

The Prep System ensures Formwork Assemblies are returned to the Curing System on clean Casting Elements treated with release agent. OutFeed Shipping / Storage System

After exiting the Curing Station, completed Vidacrete panels are pushed off the Casting Element by an actuator or stripper onto a holding pallet. Completed Panels are conveyed to Shipping or to Storage.

Prep System

After Vidacrete Panels are removed, empty Casting Elements are conveyed to the Washdown / Dry-Off / Release Agent Application Stations.

It should be noted that the EPS beads can be manufactured to a predetermined size and density for the process. Preferably, EPS pre-expanders 2 which come equipped with "fluid bed dryers" for the finishing of the EPS beads once they have been expanded to the proper size from their original resin state are employed. Once the EPS beads have been treated with the coating composition, they are transported by the EPS bead air conveyor 4 to the EPS silo 5 after which they are sent to specially measured EPS bin 6. The beads in the EPS bin 6 are emptied into the automated concrete batch mixer 20 at the correct time and with the precise volume amount. Sequencing of time and conveyance of EPS and all other materials/ingredients may be handled by a computer automated system 60, such as a concrete batch automation system software.

As stated above sand is delivered and dumped into a sand bunker 10 located near the concrete manufacturing system. From the sand bunker 10 the sand is conveyed by the sand conveyor system 9 to the 150 ton sand silo 7, preferably located adjacent to the manufacturing plant building near the mixers. The sand can be aerated and warmed in the sand silo 7 before being conveyed to the mixer 20, as needed by the computer automated system. In a preferred embodiment the sand bunker or hopper 10 can be provided with heating and aeration conduits through which, for example, a steam generator can heat and aerate the sand. Preferable, sand can be, additionally, pre-heated and/or aerated in the sand bed if necessary because of inclement climate or frozen and lumped supplies. In a preferred embodiment, the concrete mix's temperature can be between 10⁰C and 25°C. After pouring, the poured panel can go through heated curing, at a temperature of, for example, not greater than 120F. Preferably, sand can be added at SSD (surface dry density).

Sand from bin 8 and cement from the cement bin 12 come into the mixers where they are mixed with the other admix items in preparation for distribution.

The lightweight concrete mixture is prepared using a formula of additives, fiber, cement powder, water, and specially coated and sized EPS beads, all of which is bound together in a precise sequence (a) in a twin shaft mixer 20 (b). It is to be noted that in accordance with a preferred embodiment the system includes a twin shaft mixer. The twin shaft mixer has two horizontal shafts with counter current rotations; shafts have mixing blades mounted on each shaft. Counter current rotations minimizes the horizontal dynamic vibrations; therefore the mixer can be used on the ground or on elevated hoist without causing dynamic effects during operation. Also the twin shaft mixer gives faster mixing and blending of materials.

The Vidacrete™ mix is desirable since it provides a bond between cement and coated EPS beads; however, longer mixing can damage the bead coating and the cement- bead bond; longer mixing can be detrimental to the overall production process.

The blades of the twin-mixer pull the materials down into the mixture mass and then throw the mixture upward and outward evenly for perfect and fast mixing; the use of the above-described twin shaft mixer may be desirable to minimize a situation wherein light weight EPS and fibers remain segregated and lumped.

In a preferred sequence: (a) the twin shaft mixers make up a component of the manufacturing system. In operation, one mixer cycle can be approximately 90 seconds, meaning that from the time the mixer is loaded with cement, sand, water, additives and EPS beads approximately 90 seconds will elapse until the pour. Thus, the mixer, in a preferred embodiment, can be operated at a speed of about 24.3 RPM. Research and development has shown that EPS beads are susceptible to abrasion damage in the mixers. The mixers are designed such that they thoroughly finish the mixing of each batch without damaging the EPS beads; in particular, the twin shaft mixer 20 has mixing paddles designed to draw the EPS beads down into the base admixture, and if said paddles are not designed to specifications, the EPS beads will float on top of the mix without properly becoming a part of the mass mixture, and will wear down through the abrasive action of the aggregate in the mix. Consolidation of the mix cannot be realized without the proper mixing technique: and

(b) in the sequence the sand, cement, and water can be placed in the mixer 20 first, and after several turns of the drum, the additives and fibers can be added (specific by weight and volume), and the mixer further rotated. For example, the following sequence and timing of ingredients coming in the mixer can be observed: sand - 2 min; pre-water- 30 s; cement - 45 s; additives - 1.5 min; final water - 30 s; fiber 30 s; beads 6 min. Once it is clear that the contents are thoroughly mixed, the EPS beads are added and the mixer runs for a short time, approximately 10-15 seconds, in order to draw the EPS beads completely into the mix. The entire mixing process takes approximately 90 seconds, and should not exceed 120 seconds.

Prior to the production process of Vidacrete™, the molds 63 can be assembled onsite to meet the specifications of the panels to be created. The design specifications, shapes and sizes are determined by a CAD or other platform software system 60 and communicated to the Entreprise Resource planning software (ERP) which controls the PLC system. Once the frames or molds 63 are prepared, they are queued for placement on the casting elements. The casting (galvanized face) elements 102, which are preferably custom designed honeycomb core, are lightweight and extremely rigid. These highly rigid casting elements 102 receive the formwork or molds and are transported along the main conveyance system 30 to the mixer 20.

As the casting element 102 passes under the mixers 20 the correct proportion of concrete will be laid into formwork/molds upon the casting elements. In accordance with a preferred embodiment this step is computerized and fully automated. Next the element will pass along the main conveyance system 30 to an automatic roller consolidation process screed (not shown), i.e. roller screed, bull float, mag floats, etc., which will smooth the concrete to the necessary finish. Onsite technicians can monitor the quality and finish of each panel and ensure that it meets industry standards or otherwise.

The panels may be coded with visible panel identifiers on three sides or with Radio Frequency ID (RFID) by the labeling system which is connected and controlled by the computer automated system 60. This facilitates the correct "picking" of the panels for shipping. This system may be automated so that the identification and selection of the correct panels in the correct sequence can be achieved both on and off site.

The casting elements 102 and panels will then move along the conveyor system 30 to the climate controlled curing area 31. Once the curing process has completed the panels can be left in the curing area or removed to pallet storage. Once outside they are either placed on a yard conveyance system or upon specially designed pallets for immediate shipping (not shown) which will move them to either immediate transport 50 or temporary storage 40. The casting element 102, which remains on the conveyance system once the panels are removed as noted above, is cleaned and prepared for the next cycle while the panels are being conveyed out of the building. The conveyor system component handling the panels will maintain them in a horizontal position as they move out to storage.

As the casting element 102 moves down the system, it is pressure washed 32 to remove any concrete residue that may be sticking to the casting element. It will go through a drying process facilitated by an air dryer and/or Squeegee removal system 33 to the next step after which a mold release agent 34 will be applied as part of the automated concrete batch plant and conveyor system.

The casting element will continue along to form placement and onward to the mixers where the concrete will be distributed into the formwork on the casting element in the next cycle.

Panels can be designed to meet the customer's needs for a house, commercial building, residential garage, and other structures. The current design for the housing market consists of 4" and 6" thick panels The shape of the panel is determined by door and window openings as well as adjacent panel attachment be it another wall panel or a roof panel. The edges of the panel have to meet dimensional tolerances desired for adjacent panel connection.

When the labelled panel is removed from the casting element at the end of the curing area 31 it will have identification and production information as well as an electronic readable and human alpha numeric barcode for identification and "picking". In the yard, the panels are placed in a simple stacking yard system and then moved to storage or offsite transportation to the construction site.

With reference to Fig. 2 shown is the curing station system. Curing Station

The lnfeed Prepstation Conveyor (101) moves the Casting Element (102) to the Gantry Lift lnfeed (103). At this point in the process the Casting Element (102) carries the formwork assemblies and was sprayed with release agent. The Gantry Lift lnfeed (103) moves the Casting Element (102) vertically to the uppermost level of the Curing Station. From there it is moved horizontally under the Pour Station. Vidacrete is metered onto the Casting Element and into the Formwork Assemblies. (104) shows a Pour Station / Poured Panel. Conveyors and Gantry convey using conventional mechanical drives. The Top lnfeed Cross Transfer Conveyor (105) moves the Pour Station / Poured Panel (104) into position for a 90 degree change of direction. Although not shown at this point to simplify the schematic, a Cross Transfer Actuator as shown by (113) accomplishes the directional change without changing the orientation of the Casting Element. To accommodate changes in direction of the casting element, speed changes are made by drive controllers. A Cross Transfer Actuator (113) is located at every 90 degree corner. The Top lnfeed Center Transfer Conveyor (106) moves the Casting Element into position for the next change in direction. The Curing Station Enclosure (107) maintains the ambient conditions of temperature and humidity inside the Curing Station. In a preferred embodiment, three temperature control units are provided for maintaining a desired temperature and humidity inside the Curing Station; each control can be attached to a separate steam pipe. This way the curing station chamber can be divided into three zones to control the temperature. Controls can shut off the steam supply and turn it back on to maintain the temperature in the curing chamber.

Internal temperatures can for example be monitored through PLC, visual temperature gauges or through temperatures modules attached to panels.

Main steam-pipes are laid below the conveyors of EPS and each main pipe, preferably, branches into 8 sub-lines; 4 sub-lines go under each, oncoming and off going conveyors. Each branch ends at a nozzle that releases the steam; nozzle is installed at an angle with horizontal and is faced down so that steam gets dispersed as soon as it hits the floor.

The Live Steam Pipe / Nozzle Assembly (108) is controlled to provides optimum conditions. Top Conveyor Level 1 (109) moves the Casting Element to the next Cross Transfer Conveyor (1011). A Vibrator (110) consolidates the mix for a preset time period after the pour. A Cross Transfer Center Conveyor (112) moves the Casting Element into position for the next change in direction. Again, a Cross Transfer Actuator (113) accomplishes the directional change without changing the orientation of the Casting Element. Curing Downflow Gantry (114) moves the Casting Element to the next level down. Curing Conveyor Level 2 (115) moves the Casting Element to Cross Transfer Conveyor Level 2 (116).

A Cross Transfer Center Conveyor similar to (112), but located on Level 2 moves the Casting Element into position for the next change in direction. A Cross Transfer Actuator similar to (113), but on Level 2 accomplishes the directional change without changing the orientation of the Casting Element. Curing Downflow Gantry (114) moves the Casting Element to the next level down. Curing Conveyor Level 3 moves the Casting Element to Cross Transfer Conveyor Level 3 (117).

A Cross Transfer Center Conveyor similar to (112), located on Level 3 moves the Casting Element into position for the next change in direction. A Cross Transfer Actuator similar to (113), but on Level 3 accomplishes the directional change without changing the orientation of the Casting Element. Curing Downflow Gantry (114) moves the Casting Element to the next level down. Curing Conveyor Level 3 moves the Casting Element to Cross Transfer Conveyor Level 4 (118).

A Cross Transfer Center Conveyor similar to (112), located on Level 4 moves the Casting Element into position for the next change in direction. A Cross Transfer Actuator similar to (113), but on Level 4 accomplishes the directional change without changing the orientation of the Casting Element. Curing Downflow Gantry (114) moves the Casting Element to the next level down. Curing Conveyor Level 3 moves the Casting Element to Cross Transfer Conveyor Level 5 (119).

A Cross Transfer Center Conveyor similar to (112), located on Level 5 moves the Casting Element into position for the next change in direction. A Cross Transfer Actuator similar to (113), but on Level 5 accomplishes the directional change without changing the orientation of the Casting Element. Curing Downflow Gantry (114) moves the Casting Element to the next level down. Curing Conveyor Level 3 moves the Casting Element to Cross Transfer Conveyor Level 6 (120).

Outfeed Chain Deck Conveyor (121) moves the Casting Element out of the Curing Station. After exiting the Curing Station the completed panel is pushed off the Casting Element by a Cross Transfer Actuator (113). The Casting Element is conveyed to the Wash / Dry / Release Conveyor Washdown Station by the Cross Transfer Conveyor to the Washdown Station (125) where the soiled Casting Element is cleaned with a washdown solution, dried and sprayed with release agent. From there it is conveyed to the Panel Casting Prep Station where the Formwork Assemblies are placed on the Casting Element. From here the process is repeated by moving the Formwork Assembles on the Preped Casting Element on the lnfeed Prepstation Conveyor (101) to the Gantry Lift lnfeed (103).

The Completed Panel (124) moves to Conveyor Outfeed Shipping / Storage System (131) for further processing.

Fig. 3a and 3b show a side and front sectional views, respectively, of the distribution head. The distribution head consists of seven (7) clamshell gates that are aligned straight along the bottom of the unit. Each gate operates independently and is manipulated through batch control software and hardware for opening and closing sequencing. The batched crete is deposited into the distribution gate which receives volumes based on production parameters dictated by CAD drawings as well as data received from the ERP system which determine the volume based upon the dimensions of the panel (width x length). The appropriate sequencing of gates is determined by the placement of the forms on the casting elements. Initially the sequencing will be done manually until the system "learns" the sequencing and a database of volume, sequence and dimension are determined and catalogued.

Fig. 4 shows the Washdown/Dry-Off/Release Agent Application Station.

Out-fed Vidacrete Panels from the Curing Station are removed from the Casting Element (W1). The Casting Element (W1) is conveyed in the prescribed direction (W2) under the Wash down/Dry-off/Release agent application Station (W2). A pump delivers the wash down liquid at a predetermined pressure from a reservoir to the wash-down liquid feed line (W3). A Wash down Supply/Manifold (W4) houses the Wash down Spray Nozzles (W5). The Wash down Spray (W6) is directed onto the Casting Element (W1). A Rotating Brush (W7) scrubs the surface of the casting element as it moves by. The Rotating Brush (W7) is indirectly rotated by a brush drive motor (W8) and a Brush Speed Reducer (W9). The motor may be electric, pneumatic or hydraulic. Drives may be chain, belt or direct. The speed reducer may be a gear type; or use electric speed modulation, pneumatic speed modulation or hydraulic speed modulation. Where practical mechanical, electrical & ancillary components are located on the Hardware Mounting Framework (W10). The Wash down Liquid Containment Hood (W20) minimizes overspray. A Brush to Casting Element Surface Contact Springs Adjustment Assembly (W11) maintains contact pressure between the Rotating Brush (W7) and the Casting Element (W1). A Squeegee (W12) starts the drying process by removing unwanted liquid as the Casting Element (W1) moves under it. In accordance with another aspect there can be provided a Forced Air Blower / Motor Assembly (W13) that develops airflow for drying. The Blower Hood (W14) can direct Forced Air (W15) at the Casting Element (W1 ). A pump delivers the release agent) at a predetermined pressure from a reservoir to the Release Agent Feed Line (W16). A Release Agent Supply/Manifold (W17) distributes liquid to the Release Agent Supply Nozzles (W18) to apply the Release Agent Spray (W19). The steel formwork is placed on the Casting element before it goes to the release station. Placement of the release agent can be effected after formwork placement.

Referring now to Fig. 5 shown is a preferred layout of an EPS plant in accordance with the present invention. The x and y axis are in feet for preferred, but not limited to, placement reference only.

Claims

What is claimed is:

1. A method of manufacturing lightweight concrete with coated EPS beads, the method comprising the steps of: a. providing a hopper containing particulate EPS raw material; b. pre-expanding a measured volume of the EPS raw material to form EPS beads; c. passing the EPS beads through a fluid bed dryer; d. blowing the EPS beads through an EPS coating system, whereby the beads are coated with a functional composition; e. transporting the coated EPS beads to a measuring bin; and f. transferring a measured amount of the coated EPS beads from the measuring bin to a mixing device for mixing with the other ingredients used to produce the lightweight concrete.

2. The method according to claim 1 further comprising the step of introducing a predetermined quantity of aggregate into the mixing device for mixing with the other ingredients used to produce the lightweight concrete.

3. The method according to claim 2, wherein the aggregate is sand, which is provided to the mixing device via a sand conveyor, which runs from a sand hopper to an aggregate bin, wherein the sand prior to being discharged into the mixing device is heated and aerated to adjust the amount of water contained in the sand according to a predetermined lightweight concrete formula.

4. The method according to any one of claims 1 to 3 further comprising the step of introducing a predetermined amount of water into the mixing device for mixing with the other ingredients used to produce the lightweight concrete.

5. The method according to any one of claims 1 to 4 wherein a water reducer is used to control the amount of water in the mixing device according to a predetermined lightweight concrete formula.

6. The method according to any one of claims 1 to 5 further comprising the step of introducing a predetermined quantity of cement into the mixing device for mixing with the other ingredients used to produce the lightweight concrete.

7. The method according to any one of claims 1 to 6 further comprising the step of introducing a predetermined amount of additives into the mixing device for mixing with the other ingredients used to produce the lightweight concrete, each additive being contained in a separate receptacle.

8. The method according to any one of claims 1 to 7 further comprising the step of introducing an air entraining agent into the mixing device for controlling the level of air entrained in the lightweight concrete composition.

9. The method according to any one of claims 1 to 8 further comprising the step of mixing the ingredients introduced in the mixing device for a predetermined amount of time.

10. The method according to claim 9 wherein the mixing device is a twin shaft mixer.

11. The method according to any one of claims 1 to 10, wherein a PLC system which uses data provided by a CAD drawing processed through an ERP system is provided for interaction with and control of the mixing device and for controlling the steps of the method of manufacturing lightweight concrete with coated EPS beads.

12. A lightweight concrete product manufacturing system comprising: a. storage means for storing raw materials including water, cement, coated EPS beads, and water reducer; b. conveying means for transporting the raw materials from the storage means to a mixing device, the mixing device being positioned to receive the raw material from the storage means and to mix the raw materials with an aggregate, additives, fibers, inhibitors, air entrainment material, or mixtures thereof, so as to form a lightweight concrete mixture suitable to be poured into molds or formwork; c. measuring means for measuring the raw materials to be introduced into the mixing device; and d. curing means, including a climate-controlled curing area for curing the lightweight concrete mixture contained in the molds.

13. The system according to claim 12 further comprising treatment means, including a pressure washer means, an air dryer means, and a mold release agent means.

14. The system according to claim 12 or 13 further comprising labeling means for apposing identification and production information labels as well as an electronically readable barcode or RFID for identification and "picking"/ storage on the cured concrete products.

15. The system according to claim 14 further comprising transport means adjacent said treatment and labeling means for successively receiving said cured products from said molds and placing said cured products in a vertical or horizontal palletizing orientation in layers for storage or offsite transportation.

16. An apparatus for mixing ingredients used to produce a lightweight concrete material with EPS beads, the apparatus comprising: a. a mixing receptacle, the receptacle being adapted to discharge the light weight concrete mixture containing EPS beads coated with a functional composition through a plurality of discharge openings into molds or formwork; b. first and second rotating shafts, the shafts having their axis of rotation parallel, whereby the shafts rotate in opposite directions; c. mixing blades operably mounted on the first and second shafts, the blades being structured and dimensioned to pull the ingredients down into the mixture mass and then throw the mixture outward and upward evenly for homogenous and fast mixing, whereby the functional coating of the EPS beads is substantially preserved.

17. The apparatus according to claim 16, wherein up to seven discharge openings are provided in a bottom wall of the receptacle.

18. The apparatus according to 16 or 17 for mixing of at least water, cement, and coated EPS beads.

19. The apparatus according to claim 17, wherein the discharge openings are sliding or clamshell gates.

20. The apparatus according to any one of claims 16 to 19, wherein a concrete sensor is provided so that the level of concrete mixture in the receptacle is continuously measured and monitored.

21. The apparatus according to any one of claims, wherein an oscillating washing means are provided inside the receptacle for periodic cleaning of the receptacle.

22. The apparatus according to any one of claims 16 to 20, whereby the operation of the apparatus is controlled and monitored through a PLC (Batchtron) or such other platform software for plant batching.

23. A multi-level transfer system comprising conveyor tracks arranged in parallel on multiple levels for lengthwise transportation of molds or concrete panels disposed horizontally on the parallel conveyor tracks, the system having transverse cross transfer conveyor tracks between each parallel conveyor track and lifting means operable between each level of parallel conveyor tracks, the system further including an infeed conveyor and an outfeed conveyor and a panel station disposed next to the outfeed conveyor for movement to a storage means.

24. The system according to claim 23 further comprising an enclosure defining a curing chamber along a portion of the system.

25. The system according to claim 24 comprising a means for monitoring the temperature inside the curing chamber at a desired value for curing the lightweight concrete.

26. The system according to claim 24 comprising a means for maintaining the humidity inside the curing chamber at a desired value for curing the lightweight concrete.

27. The system according to claim 25 or 26 comprising a means for monitoring the temperature and humidity inside the curing chamber.

28. The system according to claim 27 wherein the temperature and humidity are monitored and controlled through a Programmable Logic Controller (PLC).