The DM-185 is a self-contained stone and concrete manufacturing facility designed for the production of a wide range of concrete products. Rugged trailer mount design allows it to go virtually anywhere and once on site, set up and operational in minutes. It’s large capacity aggregate bin can be either mechanically or manually loaded while individual storage containers for portland cement, water and add mixtures offers batching capabilities for continuos volume production or customizing for as little as one batch.
The DM-185′s versatility permits production of both wet mix for pouring, moulding or pumping and dry mix for high pressure formation of stones, veneers, interlock, pavers, blocks and more. Unparalleled mechanical engineering allows changing from one type of production to the other to be done in under 1 minute. The DM-185 is fully operational with only one operator and once the batch type has been selected, it contains a host of capabilities and features unlike anything else available. It’s performance abilities start with command and control and continues through to the products that are installation ready. With the DM-185 you now have adaptability and performance on any job site. Some of the key features included in it’s systems and operation:
- Uses local raw materials
- Cuts product costs by up to 70-90%
- Sets up in minutes
- Produces what you want, when you need it
- Auto-controlled batching ensures accuracy to +/- 1.5%
- Dry mix mode produces pavers, exterior/interior veneer, interlock, brick, stones, tiles and more at a rate of up to 240 sq ft per hour
- Produces 5 cu yd per hour of wet mix for pouring, casting, moulding or pumping
- Reduces specialty labour and employs existing labour more efficiently
- Eliminates supplier dependency and reduces the need for specialty equipment
- Allows cutting and working the product before curing, reducing installation cost
- On board operator and mechanical safety systems ensure worker friendly environment
With it’s broad range of features and capabilities the DM-185 is ideal for infrastructure and building projects once deemed impractical as it combines reach, self-sustained production capabilities and the ability to use local materials as well as non-specialized labor. These combined eliminate challenges posed by:
- Contractors & Landscapers
- Construction Companies
- Stonemasons
- Building & Garden Supply Centres
- Entrepreneurs Establishing Independent Business
- Recreational Facilities
- Leasing & Rental Companies
- Government & Non-governmental Organizations
- Isolated or Remote Communities
- Mining and Resource Companies
The DM-185 is designed to produce and work the widest range of concrete products possible on a mobile platform. With the ability to precision control the input of raw ingredients, add mixtures, dyes and others, the DM-185 can batch for virtually any project demand and meet or exceed building codes. Once the product requirements have been determined and the mix type selected there are literally hundreds of combinations and possibilities. Below are a few of the most commonly applied product types the DM-185 manufactures plus ways they can be worked. For job specific content, styles, or finishes not listed, Stonemaker’s technical support is available to help determine the most effective solution.
Dry Mix Products
Dry mix concrete products utilize less water and less portland cement. When formed under pressure this mixture produces superior grade products at a faster cure rate. Because it requires less portland it can greatly reduce product cost. This process is ideally suited for the inclusion of add mixtures that control cure cycles, workability and colour amongst others.
Pavers and Modulars
The DM-185 is factory equipped to produce a wide range of pavers in the most popular shapes and sizes. With the ability to include surface patterns and/or add mixtures (see below) it gives you production capabilities and performance features unmatched by even the largest concrete factories.
Interior/Exterior Veneer
Creates beautifully finished exterior/interior veneers and double sided stones that can be applied to walls, foundations, fireplaces, chimneys, columns, window casings & much more. Any of these are thickness adjustable from 1/2″ to 10″ permitting areas to be veneered that were previously not possible. The DM-185 comes equipped with natural stone appearance stamping plates and a wide range of custom plates are available upon request.
Blocks & Stones
What the DM-185 was designed to build, high quality, high volume production of blocks and stones produced for job specific demands.
Interlock
The DM-185′s compression chamber allows the production of interlock stones which are ideal for retaining & garden walls.
Bricks
Produces highly durable concrete bricks and like other DM-185 products, these bricks can be mass produced with customized content or colour.
Patio & Garden Tiles
The DM-185′s capabilities are ideally suited for manufacturing tile. Flexibility of size, shape & colour affords high volume, inexpensive production.
CEB/COB Stone (Optional)
A centuries old building process that is both inexpensive & fire resistant. The DM-185′s capabilities are made to order for producing CEB/COB walls, ovens & sculpted formations. CEB is considered environmentally sustainable and can be found in use throughout the world.
Hollow Block (Optional)
With the addition of an attachment, the DM-185 is able to produce thousands of hollow blocks per day. Standard production sizes included: 8″ x 8″ x 16″ 8″ x 10″ x 16″ 8″ x 4″ x 16″. Custom sizes are available upon request.
Sizes, Shapes & Thickness
The DM-185 comes equipped and ready to produce six of the most commonly applied sizes for all of the products listed above. Standard production sizes included are:
4″ x 4″ 4″ x 8″ 6″ x 6″ 8″ x 8″ 6″ x 12″ 12″ x 12″
Changing from one product size or shape to another is done on site and completed within 10 minutes.
Adjustable thickness from 1/2″ to 10″ takes seconds to change, can be switched from one piece to the next and is accurate every time.
Surfaces & Patterns
Stonemaker offers a wide assortment of stamping plates that allows you to custom finish the surface of stones, veneers or any product manufactured in the compression chamber. The DM-185 comes factory equipped with various surface patterns and changing from one pattern type to another is done in under 1 minute. Stonemaker offers customized stamping plates which allows you to replicate a pattern no longer available or offer one tailored to client demand. The DM-185 also has the unique ability to produce double faced stones in patterns of your choosing, a capability that is ideal for creating interior or exterior finishes that dramatically cuts installation costs. This patented process is the only one of it’s kind in the world.
Add Mixtures
Add mixtures such as plasticizers for bonding and dyes for colouring can be included into the batching process to produce a desired effect. Bonding agents can enhance the cure cycle or product strength while colouring with dye pigments allows uniqueness of finish, eliminates the need for paint and provides product durability.
Working Pre-cured
Producing locally lets you work the stones, blocks or any of the products before they have cured. The capability to custom cut or prep before installation with a putty knife or trowel affords greater precision, more variance and reduces the need for specialty labour or equipment. The DM-185 also eliminates waste as unwanted or rejected material can be re-processed in the batch mixer.
Wet/Ready Mix Capabilities
The DM-185 is capable of manufacturing and processing wet or ready mix concrete at a rate of up to 5 cu/yd per hour. Wet mix is used when pouring foundations, columns, filing moulds, casting or anywhere that necessitates concrete to flow into cavities or be pumped. Wet mix is able to include a larger aggregate size which yields higher strength. As with the dry mix three basic ingredients; aggregate, portland and water (plus add mixtures when required) are control batched and made ready for use. To switch from dry mix production to wet mix, you adjust the input of portland and water (ready mix requires more of each) and possibly the aggregate size.
Pouring
Each batch is channeled via the cement chute to the vibrating station to be moulded, casted or pumped, it can also poured into a wheel barrow or other container for transport.
Mortar
Batches and prepares mortar as quickly and efficiently as all other products. Raw materials inputs are adjusted via the control panel and batched within minutes.
Moulds
A wide assortment of PVC moulds are available; from basic construction to finishing elements. These moulds let you manufacture to your requirements and save both time and money.
Casting Station
A must have when using moulds. Heavy duty 10 sq/ft station vibrates moulded or casted concrete to eliminate air pockets, smooth surfaces and ensure strength.
Post Production
Testing
PSI/Mpa testing gauge permits testing of any and all products on site and verifies that they meet code without time consuming and costly submissions to the lab. The gauge is calibrated at Stonemaker’s factory and helps maintain minimum portland content while yielding maximum finished product strength.
Shearing
Powerful hydraulic shear gives you the ability to cut semi-cured or cured stones/blocks to specification. Ideal for all products and in particular, interlock.
Tumbling
The DM-185′s independently controlled tumbler gives the operator the ability to produce a weathered or aged look for any products. Cured pieces are placed in the 1 cu/yd tumbler for as little as two minutes and produces the desired effect without chiseling or manual labour. Remnants from the tumbled products can then be recycled.
The DM-185′s mobile capabilities permit it to go virtually anywhere and it’s compact dimensions and low weight allow it to be loaded into a container or onto the back of a truck for shipping long distances. Once in range of the job location, it’s manoeuvrability allows production from a semi or permanent site, hauled behind a truck or worked from a mobile platform such as a barge. It is able to go on site a few days prior to production being needed, produce exactly what the job specifications demand and then either move on to the next site or stay on, providing additional support and services. Once on the job site it is uncoupled from the tow vehicle, levelled on 4 hydraulically operated work pads, the cat walk is dropped down and is ready to begin production. In most cases, these operations require no more than 10 minutes to complete.
At the Job Site
The DM-185 is fully self contained and includes all equipment necessary for production and processing. Heavy duty 45 hp diesel engine ensures ample power for the hydraulic, electronic systems along with all other operational components. Centralized single operator command and control systems permit uninterrupted production with only one operator though various work centres allow more than one job to be done at a time. A fully integrated safety system overrides mechanical operations and protects both the operator and factory components. With the mobile factory set up on site and raw materials in place, the DM-185 is ready to go to work.
Mixing and Batching
As aggregate supply and need come in many forms the DM-185 is designed to process as wide a range as possible. The 1 cu yd aggregate bin includes variable size screening with adjustable sizes from sand particle to 5/8” stone as well as a vibrating sifter. These capabilities are ideally suited when use of local aggregate is the preferred or only option. The aggregates, portland cement and water are mechanically (backhoe, loader, bob cat, etc.) or manually loaded into individual storage compartments. Separate storage units for add mixtures and dyes are also incorporated and depending on job requirements, filled as needed.
The batch type (dry, wet mix or mortar) is selected on the control panel and the aggregates, along with portland cement are each measured and emptied into the batch mixer. Meter controlled water is then pumped into the batching unit. Add mixtures, dyes, or other inputs are added via metered measurement to required specification. All ingredients are then blended in the batch mixer producing evenly from one batch to the next. Each dry mix batch is approximately 9 cu ft and requires approximately 3-4 minutes to be thoroughly blended. Wet mix batches are roughly 18 cu ft and requires slightly more time to blend. The batching of either dry or wet mixes takes place independently of all other operations, allowing continuous, uninterrupted production.
Dry Mix
Once the operator has chosen the type and thickness to be produced and is ready to begin manufacturing, he selects either single mode, to produce one piece at a time, or full automatic mode for continuous manufacturing. The production cycle begins with the dry mix batch being emptied into the mix dispenser located between the batch mixer and the compression chamber. In automatic mode, the mix dispenser deposits the mix into the compression chamber, where it is vibrated to ensure compactness, the chamber is sealed and the mix is hydraulically pressed to form the product specified, it is then discharged from the chamber and the cycle is ready to repeat, all in as little as 15 seconds. In single mode the process works the same, only the operator controls each step of the production via the control panel. The entire stone/block production cycle works independently of the batch mixing process to provide an uninterrupted manufacturing cycle. Each and every stone/block manufactured can meet or exceed ASTM or other standards and specification.
For wet mix production the batch mixing cycle remains the same as the dry mix process, with more water and/or portland cement being added. Once the batch is mixed, a 10′ long sectional cement chute is bolted on over top of the dry mix batch dispenser, hydraulic rams extend the batch mixer into the air and the batch is off-loaded into the chute and channeled to the forward work area. With the mix in the chute the operator has numerous working options at his command. The DM-185 contains a forward vibrating station to allow pouring for castes or moulds. Raising the vibrating station into it’s transport position gives unhindered access so the chute can discharge into a wheel barrow or poured on demand. To control concrete flow, the chute is raised or lowered by a remotely operated electric winch.
Mortar on Demand
In addition to wet or dry mix concrete, the DM-185′s mix and batch capabilities produce up to 4 cu/yd per hour of mortar for use in laying brick, siding, etc. The production process is similar to the above, with raw material content being adjusted to consistency requirements.
Production
Once the mix type has been selected and the batch produced the DM-185 is the most versatile and all inclusive production system ever found on a mobile platform. The features begin with access and control and follow through to the finishing of products ready for installation.
Compression Chamber
The compression chamber is designed for the industrial grade manufacturing of all manner of pressurized concrete products. It’s flexibility allows; interchangeable steel divider insertion to produce variable sizes, adjustable thickness, inclusion of stamps for surface finishing (either single or double sided) and scribing for shearing of cured products. Each chamber has been precision engineered and built with operator safety and longevity of use in mind. Our compression chamber is fed by the mix dispenser, contains a shock mounted vibration system and works independently of all other production processes.
Vibrating Station
At the front end of the factory and directly in line with the batch mixer is a 10 sq/ft vibrating table. This is an industrial grade work platform, designed to process loads of up to 1,000 lbs. It is hinge controlled and lowered into the work position by remote control electric winch. It is fed directly from the batch mixer via concrete chute fed, has it’s own independently controlled vibrator, is raised up and out of the way by the electric winch for access by wheel barrow or for travel mode. This station is a must for working castes or moulds as it removes unwanted air pockets, ensures evenness of flow and ensures product strength.
Quality Assurance
Each and every product the DM-185 produces is capable of being tested for quality assurance. A calibrated strength testing gauge that is installed at the Stonemaker factory lets the operator see the shear strength and determine if production meets the standards required for the job. This invaluable device saves time and money as finished products no longer need to be sent to the lab for analysis.
Production Control
The main control centre is located directly beside the compression chamber at the main body of the DM-185. This control panel houses all monitoring and management including; the diesel engine, hydraulic systems, input controls, manual over rides and safety systems. Three other localized operator stations are built in at various points of the factory to control job specific applications.These include one station each to control: mix and batch production, concrete chute and vibrating station, as well as the stabilizing pads, tumbler and unwanted material discharge.
Operator Access
Because the DM-185 was designed for portability, work platforms and stations have been created to allow ease of access and maximize efficiency. Like all other stations, the main operator control centre has been designed for the most effective production while at the same time maintaining single operator production capabilities. Along the batch mixing side of the DM-185, runs a 12′ x 2 1/2′ catwalk providing access to all points of batching, wet or dry mix production and flow. The catwalk has it’s own levelling jacks and is hinged allowing it to be to swung up 90º and locked in for transportation. It allows the operator to administer the mixing and batching process, switch from one batch type to another plus free unimpeded movement to the most important facilities. Additional access points and work stations include one each for the tumbling station, vibrating station, block shearing and strength testing centre.
Block Shear
The DM-185 allows production personnel to shear cured or semi-cured stones up to 1 sq ft. Stones or blocks are loaded on the shear platform, positioned at the break point where it is then hydraulically sheared.
Tumbler
The DM-185 has an independently controlled tumbler giving the operator the ability to produce an old or weathered appearance. Cured stones are placed inside the 1 cu yd tumbler which wears edges and produces the desired look without chiseling or manual labour. Remnants from the tumbler can be reclaimed and recycled in the batch mixing process. The tumbler is also an excellent system for landscapers to blend earth and soil mixtures. Tumbler may also be converted to break down rubble for reprocessing.
Pressurized Hot/Cold Water
On board hot and cold water supply for use within the manufacturing stage and for clean up. Can also be utilized as needed anywhere on the job site
Electrical Power Supply
1500 watts of 120 volt AC current and outdoor socket to power work lights, power tools such as drills, saws, etc.
Air Compressor
Ideal for surface prep, cleaning unwanted debris from work areas, clean up and as a source for other job site applications
Unused Material Discharge
Unwanted debris or oversized stone and rock is removed from the DM-185 mechanically. The funnel shaped upper half of the aggregate bin where the sifting takes place is hinged and contains a hydraulic ram. The ram tips the upper half of the bin out away from the factory unloading materials left inside, it is then lowered down into it’s work position and ready to receive another load of aggregate.
Hollow Block Production (Optional)
The DM-185′s hydraulic power supply and work platform are designed to accommodate and optional hollow block production unit. This attachment give the operator to manufacture concrete hollow blocks at a rate of approximately 1000 pcs. per day or high volume concrete brick production of approximately 10,000 pcs. per day. Production utilizes the dry mix process where the mix is channeled via the concrete chute to the forward work station, from there it is manually loaded into the machine, vibrated and depending on product specification, produces 3-4 blocks or as many as 22 bricks at a time. Moulds for producing hollow blocks of: 8″ x 8″ 16″ 8″ x 10″ x 16″ 8″ x 4″ x 16″ and for solid bricks: 4″ x 2″ x 8″ are all stocked by Stonemaker.
Clean Up & Tear Down
Once the DM-185 has finished on site production, the concrete chute is bolted in, the mix batcher is extended fully into the air and sprayed with water to remove unwanted remnants. All other components involved in production are cleaned up and made ready for transport. It’s access points and work stations are folded back into transport position and the hydraulic stabilizers are retracted it is ready to move on to the next site. This is accomplished in 10-15 and leaves behind no unwanted stone cuttings or on-site mess to be cleaned up. Safe, accurate, volume production for all your on-site concrete needs.
| Operational | Local Transport | Shipping | ||
|---|---|---|---|---|
| Dry Weight 10,800 lbs | ||||
| Length | 324 in. | 324 in. | 296 in. | |
| Width | 126 in. | 94 in. | 92 in. | |
| Height | 145 in. | 108 in. | 91 in. | |
Features
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- HMI computer controlled, 8″ color touch screen operation, displays and monitors complete factory operation including on board self- diagnostics
- Optional: satellite or cellular diagnostics, monitoring and repair available
- Optional: One hydraulically and electronically controlled hollow block forming device, equipped with three industrial hydraulic vibrators with heavy duty Timkin roller bearings
- One male and female, 4″ x 16″ forming dye, 8″ x 16″ forming dye, 10″ x 16″ forming dye
- Linear Height Adjustment