1

Flomix

Manual

Ready-To-Use Mortars & Plasters

ON-SITE ON-TAP

2

Roadstone Limited

Flomix Customer Receipt Form

Customer Name : ______________________________

Site Address : ______________________________

______________________________ Silo No.: _________________

RPL Contact Name: ______________________________

Items Supplied

Cables Hose Panel

I confirm that I have received instruction on the Safe Operation and Cleaning of Flomix Silo:

S 40 Control Panel :

D 50 Mixer Unit :

And the following Documents:

(i) Flomix Problem Solving & Procedures Guides

(ii) The Flomix Safe Operation & Maintenance Manual

(iii) Instructions for the Placing of Silo’s on Buildings

(iv) Procedure for the Silo Refilling with Tankers

(v) Material Safety Data Sheets for Cement

I also accept responsibilities for operation of and for any damage or loss, which may

occur as a result of mis-use.

Notes:

(a) Flomix products, once hydrated, should be used within 2 hours in wintertime and 1 hour in

warm weather.

(b) All persons who use the machine must receive full instruction on relevant documentation

before use.

Signed : _________________________

Date : _________________________

Trained By: ______________________________

THIS FROM IS TO BE SIGNED BY CUSTOMER & ROADSTONE COMMISSIONING PERSON AND FILED IN

ROADSTONE LOCATION

3

Roadstone Limited

Flomix Problem Solving Guide ( D 40 / S 40 / D 50)

Power & Water Requirements

1. Power : 16amp, 3 phase + n + e5 pin socket from a 16 A MCB with 3 phase RCD fitted

2. Water : All hoses fittings, etc. mist be at least ¾ inch internal diameter. When taken from a mains, the

pressure must be at least 2.5 bar, with a volume 900 ltr. per hour, alternately water can be taken from

a header tank. This must be at least ½ meter above the height of the control panel.

Fault Cause Cure

1. Motor will not run - No Power

- Magnetic Switches

- Check fuse & RCD. If Q1

has tripped check & clean

mixing chamber.

- Check alignment of

switches

2. Motor makes humming

sound

- 1 phase is missing

- Check power cable & plugs

3. Mixer only works when

green button pressed in

- Timer set at zero

- Increase time on mixer timer

4. Motor tries to turn but trips

out Q1

- Set material in mixer tube

- Strip & clean mixer

5. Mortar too dry - Not enough water

- Blocked water filters

- Air lock in system

- Water inlet to mixer blocked

- Open water valve

- Remove filters & clean

- Bleed system

- Remove hose & clean inlet

5. Mortar too wet - Too much water

- Build up around dosing screw

- Dosing screw worn

- Reduce water volume

- Strip mixer & clean

- Replace dosing screw

Report of Damages

Date Details of Damage Silo No. Customer Signature

4

Roadstone Limited

Flomix Procedures Guide

Finished Work – Essential Maintenance & Cleaning

1. D 50 Mixer

(i) Close The Hopper Flap & Secure It With The Cotter Pin

(ii) Remove Vibrator Plug From The Switch Cabinet.

(iii) Switch The Continuous-Flow Mixer On At The Push Button “On/Off” & Wait Until Only

Water Emerges From The Continuous-Flow Mixer.

(iv) Allow The Water To Run For Approx. 60 Seconds Until Clear Water Emerges.

(v) Switch The Continuous-Flow Mixer Of At The Double Push Button “On/Off”.

(vi) Switch Isolator Switch To “0”

(vii) Every Week Take off front tube & Clean Mixing Shaft.

Correct Cleaning Tonight Means Easy

Starting Tomorrow

2. S40 Control Panel

(i) Switch Metal switch on Control Panel to the UP position. This is the position for draining the

water from the panel.

(ii) Turn off the water supply to the panel or disconnect supply going into panel

(iii) Open up the 2 small valves on the bottom of the panel. The right hand side valve empties the

water from the pump and the left hand side valve empties the water from the solenoid and flow

meter.

(iv) Leave these valves open until EVERY LAST Drop of WATER in drained from the Panel

(v) In cold weather, the panel should be stored inside as well as draining all the water

Water Not Drained in Evening = Problems in

Morning

5

Roadstone Limited Instruction for Placing of Silo’s on Building Sites

Base for Silo

Prepartion of Groung for Silo – Ground underneath MUST Concrete –

Min 100mm Deep

On the left is a layout of the typical base for the

Flomix Silo.

- It is practical to use 3 courses of 4” blocks on the

flat in order to remove mortar bins on pallets from

outlet of silo mixer

- Note That: These measurements are minimum

measurements and are in mm.

Positioning of Silo On-Site – All Silo’s MUST be positioned as close as possible to

Site Entrance and must have the room for an articulated truck to turn and reverse up to

silo. This would require approx 18m length space in front of silo. ALL Deliveries and

Silo Movements are by Articulated Trucks.

Angle of Load Distribution = 30 - 40

Benchmark

Trench Depth x 1.7 = Minimum Distance of Silo from Trench Floor

Example

Trench Depth = 1.5m x 1.7 = 2.55m = Minimum Distance of Silo from Trench Floor

(As shown in diagram)

6

Roadstone Limited

Flomix Filling Procedure

1. When the tanker driver receives the order details from the dispatch office he/she will get the following:

Name of Customer

Site Address

Silo Number to be re-filled

Name of person in charge

Contact number

2. The tanker driver MUST have the silo filter bag with him

3. Once on site, the driver must locate the correct silo number according to delivery docket

4. The person in charge/user must then be informed and the necessary preparations made for pumping

material into silo

5. The driver and the user must ensure that the silo level is low enough to accept full load

6. For the Pumping process, the following steps MUST be followed:

Close Butterfly Valve on silo

Remove the cap on the venting pipe

Connect the silo filter bag

Open ball valve on Filling/blowing in pipe

Connect the tanker pumping hose

Blow the material into the silo using the conveying air(Valve L), loosening air(valve R) and by

opening butterfly Valve B

Pressure inside the tank MUST NOT exceed 1.4 bar (valve A on top)

On completion, remove pumping hose and silo filter bag

Replace the silo caps on both the venting and filing pipes

The the user is now free to resume the operation of the system.

7

FLOMIX UPDATE

1. Flomix Colour Mortar Now Available In Silo

Light Brown

Dark Brown

Straw

Plum

Charcoal Grey

2. Flomix Plaster Now Available In Silo

3. Flomix Brick Mortar Now Available In Silo.

4. Flomix On Site Refills From Tanker Now Available for Natural

Mortars and Renders

5. Flomix Blow-On Plaster Now Available In 25kg Bags & Silo

Important Contact Numbers:

Dispatch Belgard 1890 444 333

Plant/Technical Tomas Ryan 086 3882966

Sales All Reps

8

Mortar & Render

Approximate Spread Rates – No allowance for waste

1. FLOMIX MORTAR

1 tonne of Flomix will lay (10mm joint):

1300 Standard Bricks

650 100mm Solids on Edge

325 100mm Solids on Flat

325 215mm Hollows

1.40 tonne of Dry Flomix Mortar @ 16.5% water content = approx. 1m3 of Fresh

Mortar

16 tonne of Dry Flomix Mortar = approx. 11.5m3 of Fresh Mortar approx.

2. FLOMIX RENDER

1 tonne of Flomix Silo Render when mixed will cover:

10mm thick 69m2 approx.

12mm thick 55m2 approx.

15mm thick 34m2 approx.

24mm thick 27m2 approx.

16 tonne of Dry Silo Render = approx. 11m3 of Fresh Render @ 15 / 16% water

content for workability.

3. TROWEL READY MORTAR

Approximate Spread Rates – no allowance for waste, using 10mm joint.

1m3 will lay:

1800 Standard Bricks

900 100mm Solids on Edge

450 100mm Solids on Flat

450 215mm Hollows

4. FLOAT READY PLASTER (APPROXIMATE COVERAGE)

1m3 will cover:

100m2 @ 10mm thick

80m2 @ 12mm thick

66m2 @ 15mm thick

40m2 @ 25mm thick

9

Normal Portland Cement

Rapid Hardening Portland Cement

Sulfate – resisting Portland Cement

1.1 Product Description

An odourless fine grey powder mainly insoluble in water. Portland

cement, when mixed with water, is used as a binder for construction applications.

1.2 Manufacturer

Irish Cement Limited,

Platin,

Drogheda, Co. Louth. Tel. 041 9876000

2.1 Chemical Description

Predominantly compounds of Calcium, Silica, Alumina and Iron. Small

amounts of calcium sulfate, lime, alkalis and chlorides are also present

together with trace amounts of chromium compounds.

CAS No. 65997-15-1 EINECS No. 266-043-4

2.2 Hazardous Ingredients

The lime, calcium silicates and alkalis within the cement give rise to a

strong alkaline solution when mixed with water. Chromium salts in

cement are soluble and when mixed with water may give rise to allergic

contact dermatitis.

Skin or eye contact with wet cement may give rise to burns or

ulceration. Repeated contact with fresh mortar or concrete mixes may cause irritant/allergic contact dermatitis.

10

Irritant contact dermatitis is due to a combination of the wetness,

alkalinity and abrasiveness of mixes.

Allergic contact dermatitis is caused mainly by the sensitivity of a

person’s skin to chromate in cement. However this is rare.

Skin contact

Wash with soap and water immediately. If there is irritation or pain seek medical advice.

Eye contact

Wash with plenty of clean water and immediately seek medical advice.

Ingestion

Do not induce vomiting. Wash out mouth with water and take plenty of water to drink.

Inhalation

If irritation occurs, move to fresh air. If nose or airways become inflamed seek medical advice.

Portland cement is not flammable and will not support the combustion

of other materials.

Cleaning up

Recover the spillage in a dry state if possible. Minimise generation of

airborne dust. The product can be slurried by the addition of water but

will subsequently set as a hard material. Keep children away from clean-up operation.

The performance of cement will be adversely affected by unsuitable

storage conditions. The material should be stored dry and protected from wind and rain.

Bags should be stacked in a safe and stable manner.

11

8.1 Exposure Limit Values

Occupational Exposure Standard (OES) OES 8 hour Time Weighted Average (TWA):

Total inhalable dust 10 mg/m3

Respirable dust 4 mg/m3

8.2 Personal Protection

Protection of the eyes mouth and nose should be worn in circumstances when dry cement may become airborne.

When working with wet concrete or mortar, suitable protective clothing

should be worn.

Clothing or the internal lining of footwear contaminated with wet

cement, mortar or concrete should be removed and cleaned before further use.

If cement, wet concrete or mortar enters the eye it should be washed

out immediately with clean water and medical advice sought. Concrete or mortar elsewhere on the skin should also be washed off immediately.

Whenever there is persistent or severe irritation or pain a doctor should

be consulted.

Physical State: Particulate Mean particle size: 15-20 micron Relative Density: 3.15 PH of wet cement: 11-13.5 Melting Point: >1000° C

Portland cement, when mixed with water, sets and hardens into a

generally stable mass. This is generally unreactive in normal

environments.

11.1 Short Term Effects

Eye Contact

Mild exposures can cause soreness. Gross exposures or untreated mild exposures can lead to chemical burning and ulceration of the eye.

Skin

Cement powder or any cement/water mixture may cause irritant contact dermatitis, allergic (chromium) dermatitis, and/or burns.

12

Ingestion

The swallowing of small amounts of cement is unlikely to cause any

significant reaction. Larger doses may result in irritation to the gastro-

intestinal tract.

Inhalation

Cement powder may cause inflammation of mucous membranes.

11.2 Chronic Effects

High repeated exposures in excess of the Occupational Exposure

Standard have been linked with rhinitis and coughing. Skin exposure

has been linked to allergic dermatitis. Allergic dermatitis more

commonly arises through contact with cement/water mixtures than dry cement.

The addition of cement to water may cause the pH to increase and,

depending on concentration levels, could pose a risk to aquatic life in the short term.

After hardening with water or moisture, cement presents no toxicity

risk.

Surplus cement should only be disposed of in a safe manner at a

location authorized to receive builders waste.

Bulk cement should be transported in sealed containers. Bagged cement

should be kept dry during transport and opened with care.

15.1 S.I. No. 116 of 2003

Classification - Irritant

15.2 Risk / Safety Phrases

Risk Phrases

Irritating to eyes, respiratory system and skin.

13

May cause sensitization by skin contact

(Chromium VI).

Safety Phrases

Avoid contact with skin and eyes.

In case of contact with eyes, rinse immediately with plenty of

clean water and seek medical advice.

After contact with skin, wash immediately with plenty of water.

Do not breathe dust.

Wear suitable protective clothing.

Keep out of the reach of children.

European Communities ( Classification, Packaging, Labelling and

Notification of Dangerous Substances ) Regulations 2003.

S.I. No. 116 of 2003 For further information contact: Technical Marketing Dept.,

Irish Cement Limited,

Platin,

Drogheda, Co. Louth.

Tel: 041 9876000 or 041 9876464

Fax: 041 9876400

www.irishcement.ie