INDUSTRIAL PROCESS HEATING FOR
Traditional mould heating methods are inefficient and use a high amount of energy which lead to high running costs and a high carbon footprint.
ZECK FAST-CURE Accelerated Concrete Curing uses digital, solid-state technology with enhanced performance and low energy costs.
concrete mould heating?
ZECK's thermal developers, working in the industry, wanted to find a more controllable and efficient way to increase early strength in moulds. It was recognised that traditional water heating, steam heating and gas blowers with tarpaulins were feeble and costly to run.
Little control, no mould-bed feedback, heat being thrown into the building, sometimes more than into the mould, all lead to a poor performing system that will cost you money in the long term.
Using patented technology from their existing products, ZECK maximise efficiency using key techniques.
Heat of Hydration is cleverly utilised in the control system and insulation is used to full advantage.
Most thermal curing systems in use today use a warm air technique to attempt to heat the mould. Blowing warm air over a large steel mould full of concrete is just hoping for the best.
ZECK switched the heating method from convection to conduction as they understood the art of heat transfer.
Switching the heating method was the key to enabling increased efficiencies and digitisation. Moulds could be insulated, stopping all that wasted heat from going into the atmosphere. This further enhanced what was achievable using digital controls. With ZECK's solid-state heating method, a high level of ability and ramp rate control could be achieved..
Heat of Hydration
Here comes the pièce de résistance.
It is well known that heat of hydration occurs in cement-based concrete mixes, but does a traditional heating system account for this?
The answer is an emphatic NO.
Why keep pumping out heat into the mould (or is it into the room?) when the heat of hydration (H of H) kicks in. The main aim of the heating is to kick start the heat of hydration, so why not hold back the power when this occurs?
To ZECK, it was plain and simple: use the digital technology to work in harmony with the workpiece, as the H of H increases, reduce the amount of power going in, until no more is needed.
Clean efficient use of the process. No other technology can do this, ZECK FAST-CURE reduces running costs and gives you a quality, superior end result.
Using Software to Advantage
For a more advanced system, we offer
CONCRETE PRO software which has been developed to offer cycle cost monitoring, energy usage, password protection, better cycle control, display screen adjustment of all parameters and can link to your data systems if required. We can also offer text messaging to plant operators at key event times.
Solid State Reliability
We only use tried and trusted technology, Solid State switchgear and heating devices that have a very long lifetime and are fully encapsulated.
We don't use trace heating as it just wouldn't be up to the job. We don't use fragile ceramic heaters and our power control is rated to take 800% of its maximum current, just to ensure the system has a very long lifetime. We are British made and proud of it and believe our curing system is world-beating. If you don't believe us, come and have a look.
The Switch to
GGBS has been around for many years, but recent years have shown a keener interest. Having a cement-free concrete using by-product materials is obviously something to consider.
One of the issues though is that the concrete will take longer to reach early strength than cement-based products, even though later strength is higher.
The ZECK FAST-CURE system is set right for GGBS and will assist you, economically and controllably, to get the right production output.
Increased Production Output
In some cases, you can double your output using the same mould floorspace.
Assurity of quality. Mould tolerances such as flatness & levelness will be more tightly controlled.
No steam burns, no risk of fire with gas burners
Utilises Heat of Hydration. No high ambient losses. Heats the mould directly, not into the air.
Allows you to use green energy to bring down your carbon footprint.
Reduces energy as heat of hydration kicks in and also in warmer months when less heat is needed