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Concrete Chiller- The Ulimate FAQ Guide by TopChiller

What is Concrete Chiller?

Concrete Chiller is used in the construction industry to provide proper flow of water with the required set-point of temperature.

It differs slightly from other kinds of chillers as it is manufactured for a specific purpose. Concrete Chiller serves the concrete manufacturing process from start to the finish.

It is utilized during the mixing of materials to the final curing of the concrete product.

What are the Characteristics of a Concrete Chiller?

Accurate and Precise

This one is the most important set of two interconnected characteristics that are important for concrete manufacturing. Concrete Chiller provides the most accurate and precisely managed temperature control to the refrigerants.

Used from Start to End

It is used as a mandatory manufacturing device during the whole concrete forming process. Concrete Chiller is used almost on every stage.

Energy Efficient

It comes with the outstanding characteristic that it is very energy efficient and will save a lot of cost in terms of energy over a long time.

What are the Advantages of a Concrete Chiller for your Applications?

Continuous Process with Optimum Efficiency

As it is used continuously for 21 to 15 days, efficiency consistency is always maintained. It is capable to work at optimum efficiency for a long time.

Durable and Flexible

Concrete Chiller is made with advanced technology and high-quality materials, making it a durable device. Its parameters can be customized to your required sets, hence very much flexible and can be used for various applications.

What are the Major Components of a Concrete Chiller?

Compressor

The function of a compressor is to manage the flow rate, temperature, and speed of refrigerant by the process of compression. It may be of screw-type, scroll type, or centrifugal type.

The Refrigeration Unit

The heat collection and lowering of the temperature of the refrigerant is performed by the refrigeration unit.

Control Panel

It is the brain of a Concrete Chiller, where you will get access to all the control functions by which you can fully control and customize it.

What are the Additional Components of a Concrete Chiller?

A Separate Water Tank

It can be added to the Concrete Chiller to increase its refrigerant capacity. It is very useful in case of emergencies where the main tank has failed to work.

Extra Set of Pumps

An extra set of pumps can be added to have 2 to 4 more pipes for a faster process. These can be used to make curing, mixing, and other stages of the process.

What is the Importance of Concrete Chiller for Hydration of Concrete?

The basic principle is that during the mixing and initial stages a concrete mixture is hydrated properly so that the proper mixture can be formed.

In the final stages, the extra moister and water content is eliminated from the hard and strengthened concrete product to finish the production.

Hydration is one of the first stages of concrete formation hence the most important one. A Concrete Chiller provides the water maintained at the required temperature and flow rate so that proper hydration can be achieved.

This controlled water temperature makes the hydration successful and concrete product a qualitative product.

How does a Concrete Chiller help in the Better Curing of Concrete Products?

Curing is the final stage of the concrete manufacturing process where it gets all its strength, hardness, and toughness. The strength of the concrete depends upon the way curing is done.

A Concrete Chiller efficiently does this function and a high-quality concrete product is achieved.

The temperature and flow rates are two important parameters for the curing and both parameters are accurately regulated by the Concrete Chiller.

It helps in better finishing and better quality in terms of hardness, tensile strength, and toughness of the concrete.

How does a Concrete Chiller Work?

Stage one: In this stage, all the parameters are customized and the Concrete Chiller is started. It might take 20 to 25 minutes to reach the set point of temperature.
Stage Two: When the refrigerant temperature is reached to the required degree it proceeds for the further process.
Stage Three: It undergoes refrigeration where it collects the heat of the water and lowers its temperature.
Stage Four: The chilled water moves to the pipe assembly while the refrigerant heat is eliminated from the system by the condensation process in the condenser.
Stage Five: The chilled water is supplied to the concrete process at fix flow rate and this cycle is repeated to provide a continuous flow of water to the process.

What is the Importance of Concrete Chiller for the Construction Industry?

Concrete industries highly depend upon the applications of temperature in all their manufacturing processes.

Either it’s concrete or concrete-based products the processing cycle requires a well-controlled application of temperature on various stages.

In the case of concrete, a Concrete Chiller is used from most initial stage to the last stage in its manufacturing.

It is used during the initial mixing stage of materials for concrete, then it is used for dehydration, and then finally it makes the curing process complete.

What are the Applications of a Concrete Chiller?

Concrete Manufacturing Process

It is the heart of concrete manufacturing processes where it is used at every stage. It’s mostly used in mixing, dehydration, water content perfection, curing, etc.

Concrete Based Products Manufacturing Industries

Concrete Chiller is used in various concrete-based industries. Tiles, concrete sheets, concrete walls, etc are the products where it is applied.

What are the Different Types of the Concrete Chiller?

Water Cooled Concrete Chiller

In this type of Concrete Chiller water is used as the primary refrigerant for cooling. It is most widely used in the concrete industries.

Air Cooled Concrete Chiller

Air-cooled is used for cooling purposes and it is sucked from the surrounding. It is mostly used as a central cooling chiller for concrete formation plants.

Portable Concrete Chiller

Portable Concrete Chiller is preferred in small-level concrete formation plants where random cooling is needed. You can carry it around and use it in many functions as it is portable, light in weight, and easy to relocate.

How a Concrete Chiller Improves Quality of the Concrete?

The quality of concrete depends upon the effectiveness of a Concrete Chiller. Every stage and step of the concrete manufacturing process is equally important for the final quality of the concrete.

A Concrete Chiller plays its function in the mixing, where it provides properly chilled water and well-accomplished mixing of materials is achieved.

Then it helps in dehydration, which improves the internal structure and strength of the concrete.

Finally, it helps in curing where it improves the quality by improving its strength, compression strength, hardness, surface finishing, and wear resistance.

What is Portable Concrete Chiller?

It is a type of Concrete Chiller that comes with several uniquely designed features, like portability, strength, small size, and footprints, etc.

It is selected for some specific applications of the concrete industries. In a small concrete industry where a big Concrete Chiller cannot be afforded, a Portable is used to get the temperature regulation job done.

It is much cheaper than the Concrete Chiller. It has an advanced control unit that precisely controls every parameter.

With built-in wheels in the bottom, you can easily carry it around and apply it to many places. It takes less space, hence solving the confined space problems of your industry.

How to Make Selection Between a Portable Concrete Chiller and Common Concrete Chiller?

When you need to make a proper selection between a portable and a common industrial Concrete Chiller, it can be done based on the following differences or factors.

• When your industry has a problem regarding space, you should select the portable one. It can be installed in small spaces.
• Budget is the second factor for selection. It comes at lower prices than a common Concrete Chiller.
• The selection also depends upon the nature of the application. It is applied for large-scale industries, where a Portable Concrete Chiller is used in small-scale industries.

How Ambient Temperature Affects the Efficiency of a Concrete Chiller?

Ambient temperature can be a crucial factor while it comes to the cooling capacity of the Concrete Chiller.

Either it too high or too low a temperature range in the environment will affect its performance.

The smart approach is one where you set the temperature of the Concrete Chiller considering the factor of ambient temperature.

The high range of temperature will cause the set-point temperature of the Concrete Chiller to decrease and it will not produce the optimum amount of cooling.

The very low temperature outside like in winter will also cause fluctuations for its efficiency and overall temperature control efficiency won’t be optimum.

It’s better to set a temperature on your Concrete Chiller that can also tackle the effect of ambient temperature.

What Factors Affects the Concrete Chiller Capacity?

Following are some of the major factors that cause inefficiency in the performance of a Concrete Chiller.

• Using dirty water as the refrigerant. It will cause several problems along with inefficiency in it.
• Improper maintenance or no maintenance at the proper time.
• Not replacing old and rusty parts. Replace the old parts with new and modern ones. It will increase the efficiency of the previous parts.
• Ambient temperatures can also cause a big efficiency problem for Concrete Chiller.

What is the Difference Between Common Industrial Chiller and Concrete Chiller?

Both of these differ in their applications in the first place. A common Industrial Chiller can be used for several processes, products, plants, etc.

While a Concrete Chiller is only used in construction industries for the manufacturing of concrete. The basic work working mechanism is mostly the same for both.

It consists of compression, refrigeration, and condensation. The structural design and number of components can be different to some extent.

A Concrete Chiller contains pipe assembly tubes while an industrial chiller does not always have them. Both of these also differ in cost, maintenance, and noise levels.

How to Select Suitable Concrete Chiller for your Industry?

The concrete industry has different kinds of requirements and factors for a Concrete Chiller.

Many considerations are somehow the same, but the following given considerations must be kept in mind while making a selection of a Concrete Chiller for your concrete industry.

• For concrete, the temperature, flow rate, and speed of water are the most important factors for a successful manufacturing process. select one which can provide all these efficiently.
• As a Concrete Chiller is used constantly for months, it should have the capability to run continuously without any kind of decrease inefficiency.
• It should be energy efficient. Energy efficiency will save a lot of cost for your process when it is used for a long time.
• In case of a continuous process, you cannot afford to stop it for any kind of repair or maintenance. So select a Concrete Chiller that required very less amount repair and maintenance for a long time.

What is the Cost of a Concrete Chiller?

Its exact cost cannot be told as it varies based on its capacities and design.

A Portable Concrete Chiller comes at the lowest and cheapest price as compared to the other designs and models.

A Portable type comes at a cost range between 980 USD to 1300 USD. An average size Concrete Chiller comes in a cost range of around 20000 USD to 22000 USD.

What is the Difference Between Air Cooled Concrete Chiller and Water Cooled Concrete Chiller?

Primarily they both differ in the type of refrigerants they both use. Air cooled uses air while water cooled uses water.

In the case of Concrete Chiller, the type of use and work mechanism of both are the two major differences here.

Air cooled is generally used for central cooling in a concrete manufacturing plant.

This central cooling provides all the desired temperatures and conditions under which several concrete manufacturing processes are conducted.

While a Concrete Chiller is used in the process along with every stage of concrete manufacturing.

In terms of working mechanism, an Air cooled works by suction of air inside the compressor and creating required cooling. Water cooled works by the condensation and compression of liquid refrigerants.

What are The Benefits of Using Water Cooled Concrete Chiller as Compared to the Air Cooled Concrete Chiller?

• A Water Cooled Concrete Chiller is used directly in the manufacturing process, hence more accuracy and efficiency are guaranteed.
• An Air Cooled is used for central cooling, due to which it cannot handle the temperature more precisely as compared to a Water Cooled.
• Water Cooled can be used for a large number of functions during the concrete manufacturing process, while an Air Cooled cannot be used in this way.

How to Maintain your Concrete Chiller for Longer life?

• Keep details of the daily performance curves of your Concrete Chiller. If you see any kind of unusual performance go for maintenance.
• Grounding should be vibration-free and compact. It will keep your Concrete Chiller safe and maintained from the bottom.
• Proper lubrication should be done on time.
• Do not overuse or overload it for a long time.
• Monthly repairing and maintenance should be done.

What are the Safety Guidelines for a Concrete Chiller?

• In case of excessive noise, proper precautions must be taken. Excessive levels of noise can be dangerous for the workers working around.
• Reduce the noise level below the safe level from source or proper noise PPEs like earphones, etc should be made compulsory for every worker.
• Vibrations can damage the Concrete Chiller, ground, and other instruments and cause you huge loss of resources and money.
• Keep vibrations low to keep your industry safe along with the safety of workers.

How to Estimate the Cooling Load of your Concrete Chiller and Size?

• For cooling load, first of all, calculate the cooling power required per unit time. It can be calculated in tons of water processed per hour.
• Calculate the flow rate of water that your process needs. It is usually given in gallons or liters per min or ml/sec.
• Finally, calculate the Kcal of heat that will be discarded by the Concrete Chiller per unit time.

Based on these calculations, one can estimate the cooling load and size of the Concrete Chiller for the industry.

How to Optimize Performance of your Concrete Chiller?

The complete optimization of a Concrete Chiller is achieved by following the below guidelines.

• Maintenance should be done on time. Fix a monthly maintenance cycle. It should not be delayed for a long time.
• Old and inefficient parts should be replaced with new ones. You can replace them with more advanced ones and increase the efficiency of your Concrete Chiller.
• Customize it by proper parameters that are suitable for the process.

What are the Practices that Reduces the Efficiency of Concrete Chiller?

Improper Selection

Selection of the proper Concrete Chiller for your application is very necessary to get the desired efficiency. Improper selection will not provide that required efficiency.

Power Source Fluctuations:

Fluctuations in the power sources may cause Concrete Chiller to power on and off again. That will cause a huge disturbance for the performance efficiency.

Also, it can cause several unexpected failures.

Improper Flow Rate:

The improper flow will cause a decrease in inefficiency. It can be because of some kind of fault or failure of the compressor.

How to Install your Concrete Chiller?

Below given are the general guidelines for the proper installation of your Concrete Chiller.

1. Deliver the Concrete Chiller to your industry safely.
2. Select and prepare the proper location for it.
3. Prepare the ground and place it there.
4. Unpack it following the standard guidelines.
5. Read instructions and follow them to attach every part.
6. Install the pipes, tubes, water tank, and other components.
7. Customize the setting and start it.

How to Select the Best Location for your Concrete Chiller Installation?

The location should be most suitable so that it can perform efficiently. For a Concrete Chiller following guidelines are useful when selecting the proper location for it.

• Select a location where proper ventilation is available. A congested location can cause damage to the cooling efficiency of the Concrete Chiller.
• A proper location where it can cover all the concrete units. From which it can cover the maximum amount of the concrete units.
• Locate your Concrete Chiller where there is no excessive dust and moisture in the surroundings.
• Select a location where the ambient temperature is most suitable for the Concrete Chiller.

How to Prepare Ground for Installation of your Concrete Chiller?

Installation of it on improper and unsuitable groundings is not good for the health and durability of your Concrete Chiller.

For proper preparation of the ground following instructions should be followed.

1. First of all, the ground of installation should be compact and hard enough to sustain the load of the Concrete Chiller for a long time. If not, then make it hard by processing.
2. The ground should be vibration-proof so that it can sustain the vibrations created by the Concrete Chiller during the running.
3. Apply vibration absorbent materials like pads, foam sheets, etc on the ground to make it vibration-free.

How to Refill the Refrigerant Properly in your Concrete Chiller?

Refilling refrigerants may be a tricky job and require expertise. Although it can be done smoothly by following carefully below steps.

Step 1: Empty the old refrigerant properly. It may take time but it should be cleaned properly so that a new one can be refilled.

Step 1: Estimate the suitable levels of liquid refrigerant and mark them.

Step 1: Before refilling make sure to clean the tank properly.

Step 1: Refill the new refrigerant properly up to the marked levels.

Step 1: Again check the levels of refrigerant. When you are sure then start your Concrete Chiller.

What is the Difference Between the Maintenance of a Portable Concrete Chiller and a Common Concrete Chiller?

A Portable is different from a Concrete Chiller based on many factors. It is much smaller and easier to handle as compared to a Concrete Chiller.

The maintenance difference is given as below.

1. Portable are smaller in size and light in weight. Small size requires less amount of maintenance.
2. Maintenance becomes easy and quick because of the customized light design of a Portable Concrete Chiller.
3. It has less probability of failures so does not require major maintenances or repairs for a long time as compared to Concrete Chiller.

What is the Optimum Flow Rate of Water for a Concrete Chiller?

The flow rate of a Concrete Chiller may change depending upon various factors. There is n no fixed number for the optimum flow rate.

First of all, it depends upon the need for the concrete manufacturing process, that what flow rate will be optimum.

Mostly, a flow rate of 30 ml/sec is assumed as the most optimum flow rate for concrete curing and other applications.

This flow rate is no too slow, not too fast. It is average and can provide a smooth supply of chilled water to the concrete and other construction products.

What is the Consideration of Water Used in a Concrete Chiller?

The water and its characteristics, you are using in it are of great importance.  It not only affects the Concrete Chiller but also affects the concrete and another type of products you are manufacturing.

Following are some of the major considerations regarding water in a Concrete Chiller.

1. Use clean water, as contaminated water can cause damages to the concrete products. The final quality of the product will be compromised.
2. Dirty water is also a threat to the Concrete Chiller itself. It can cause corrosion in different components.
3. Water with TDS and TSS, can cause blockage and clog in pipelines.
4. TDS and other materials in water can accumulate in the different components of the Concrete Chiller and create big problems in a long time.

What are the Considerations for the Thermal Expansion Valve Unit of a Concrete Chiller?

The thermal expansion valve unit is a necessary component. It is responsible to handle all kinds of thermal shocks, expansions so that the Concrete Chiller can be safe and perform properly.

First of all, it should be made of quality materials. Many thermal expansion units are made of copper, steel, and titanium.

The titanium-based units have the best thermal expansion capacity and can handle a huge range of thermal treatments.

Secondly, it should be maintained properly. Its maintenance includes daily inspection, regular cleaning, and proper care.

How to Make your Concrete Chiller Less Noisy?

Lubricate Every Part Properly

Proper lubrication of every component of the Concrete Chiller will make their movements smooth and noiseless. Select a proper lubrication oil and lubricate them on weekly basis.

Maintain the Fans

Rusty or old fans make a huge amount of noise. Keep the fans properly maintained and cleaned to decrease the noise level to a minimum.

Fix the Bottom Properly

Loosen footprints of a Concrete Chiller can make vibrations and noise while operating. Fix the bottom properly with the ground. Keep noise-proof materials between the bottom and ground.

What are the Troubleshooting Guidelines for your Concrete Chiller?

When it is not Resulting in Optimum Curing of Concrete

Proper curing of the concrete depends upon the temperature level. If the temperature of the water is not enough, it will cause faulty curing and concrete won’t be properly manufactured.

Always keep water temperature to accurate for curing time.

Concrete Chiller is Causing Brittleness in the Concrete

When the flow rate of water is not proper and temperature fluctuations are high in number, concrete may become brittle.

It will not have enough strength and easily broken on small forces. Keep the flow rate and temperature to the optimum to solve this problem.