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Hydro WasHedPlaster sand & ConCrete sand

Our BackgroundBalaji Robo Sand is an established company with over 15 years of experience in mining activities in Warangal, Telangana. In addition to mining activities, the parent company is highly experienced and diversified in a variety of business activities including textile, logistics, entertainment, retail & sales, automobile and construction activities.

Balaji Robo Sand is now venturing into manufacturing of technologically advanced Sand with the Advanced Hydro Wash process at their state-of-the-art washing unit located in Warangal. This is the first unit to be established in the region.

The company’s fleet of trucks delivering their Advanced Hydro Washed Sand is an added advantage to their customers.

Balaji Robo Sand has a strong team of management and employees established at every stage of their business activities to ensure their customers get top quality raw material. We look forward to replacing river sand and providing a much more economical and sustainable solution to clients in the construction industry with our Advanced Hydro Washed Sand.

150μ below particles limited to <12% and 75μ below particles between 3-6% by weight

Delivered in SSD condition resulting in no additional correction for water absorption

Free water content at par with best available natural sand

Tested for High Performance Concrete (HPC) and Self Compacting Concrete (SCC)

Consistent gradation

TechnologicallySuperior Sand with Advanced Hydro Wash Process

Our GoalTo become a go to brand in the construction and infrastructure industry while building long lasting business relationships with clients.

Our VisionTo provide the highest quality Sand at economical prices to the growing construction industry.

Textile Logistics Entertainment Retail & Sales Automobile Construction

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3 Steps Washing Process

VSI dust is received in our hopper, which is fitted with belt feeder, for effectively feeding of to the circuit. It is provided with a VSD and a belt weigher system and thus feed to the system can be controlled and monitored continuously. The belt feeder transfers the VSI dust to the Feed Conveyor. The same can be done by a loader/truck.

Combo plant includes sizing cum dewatering screen system. The screen has spray jets which greatly improve overall screening efficiency; one part of the unit is designed for fine screening, and cuts the liberated particles at 2.5mm. This stage gives us our first product on to the stockpiler (4.75-0.075mm). Combo plant also consists of an integrated and compact fines washing unit including the required sump, heavy duty pump, and hydro cyclones. Secondary clays attrition is offered to the minus –2.5 mm material by the heavy duty slurry pump and high cyclone velocity. This first cyclone pass will remove a high percentage of the waste solids.The material is discharged to the second part of the screen which is used for dewatering, which ensures a low moisture content of the final product.

The combined slurry from the washing circuit (hydro cyclones overflow) will pass to water treatment tank to rapidly settle and control the tailings. Dense sludge of circa 450-550g/litre will be issued from the integrated heavy duty pump for discharge to a remote designated settlement area. Clean recycled water (thickener overflow) is immediately released from the system and piped to the water tank, ready for recycle to the washing system. The water treatment system is highly preferable to the majority of other mechanical settlement aids as there is virtually no agitation of the sludge bed and polyelectrolyte usage is kept to a minimum; circa 5 to 7 times less than some other well-known systems. Furthermore the ability of the system to pump waste solids to a remote area for final settlement means that valuable plant area is not taken up for sludge control.

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Crushing ProcessVSI Crusher Dust is produced by feeding hard stones of varying sizes to primary and secondary crushers (Jaw crusher and Cone crusher), for size reduction and these crushed stones are further crushed in Vertical Shaft Impact (VSI) crusher to reduce the particle size to that of sand. The VSI crusher by its unique design and action of attrition produces well shaped fine aggregate particles that are cubical and angular. The process of attrition also enables the reduction of surface roughness of the fine aggregate particles to some extent.

During the production processes, it is ensured that sand stockpiles are not contaminated with weathered/highly altered rock or with clay and other contaminants. Crushing of multiple source rocks into a single sand stockpile is also not be permitted unless it can be demonstrated that such a process is under blending control and produces a consistent product.

This product from VSI Crusher often contains high percentage of dust, not useful for construction, as they result in higher water demand leading to lack of control on workability / retention of workability as well as strength issues.

So to produce quality Sand out of VSI dust, we need to go for proper washing technique, by washing, the percentage of micro fines (passing 75 micron) is controlled. The washing facility also provides keeps the Manufactured Sand in wet or partially wet condition. This will help to reduce the water absorption rate by Manufactured Sand during concrete manufacturing and hence better workability and workability retention.

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Property Significance Natural River Sand Balaji Robo Sand

Grading Good grading is the most important quality of sand required for good quality of concrete.

Natural river sand is not well graded. Some particle size as required by IS specifications are either missing or in excess.

This also results in wastage of material during oversize screening at site.

Can be produced to any desired grading. Consistent grading can be maintained uniformly as per original mix design.

Washed sand is properly graded and thus no screening is required at site.

Presence of very fine particle

Presence of very fine particles in controlled quantity positively influence workability, water demand and cement demand.

Very fine particles lower than 150 micron are not present. Even if they are, it is in the form of mud and clay.

Particles less than 150 micron are always present in desired quantity of 10-12% in form of sand. This results in reduced water demand, cement demand and also improves workability & strength.

Cleanliness Impacts concrete quality by way of reduction of strength, shrinkage, soundness, permeability, durability and resistance to corrosion.

Since it is dredged from river stream bed pits, it contains objectionable quantities of mud, clay, silt, shells, decayed organic particles. They are rarely clean.

Since it is produced from crushed rock fines, after thorough washing, it is very clean and can be produced to the desired grading.

Texture Smooth texture reduces water demand gives the workability but reduces bond strength.

Is smooth and helps in concrete making but too smooth surface reduces the bond strength.

Particles are not smooth and hence do not extend some of the desirable properties of natural sand but provide good bond strength.

Uncompacted void content in all-in-aggregate

Minimum void content in all-in-aggregate is an important parameter for good concrete.

It has been found by experiments that uncompacted voids in all-in-aggregate in natural sand is 36%.

In the same series of experiments it has been found that uncompacted voids in all-in-aggregate of Balaji Robo Sand produced by rock-on-rock technology is 34%.

Cost Cement savings Since it is not properly graded and the quality fluctuates the overall cement requirement is higher.

Proper grading and consistent quality ensures lower cost of concrete.

MortarProportion Flow (%)

Water-Cement Ratio Compressive Strength (MPa)

River Sand Balaji Robo SandRiver Sand Balaji Robo Sand

7 Days 28 Days 7 Days 28 Days

1:6

85 1.72 1.30 2.10 4.03 5.15 8.53

100 1.75 1.34 1.96 3.82 4.88 8.19

1:4

85 1.13 0.84 2.84 7.35 12.89 15.96

100 1.18 0.88 2.77 6.04 11.89 15.50

Comparitive Analysis of Natural River Sand vs. Balaji Robo Sand

Advantages of Balaji Robo Sand vs. Natural River Sand

Crazing: The development of a series of hair cracks on the finished plaster surface is known as ‘map crazing’. It forms a haphazard pattern over the wall surface affected because of excess of ultra-fines in plaster sand. Balaji Robo Sand is well graded and maintained as per IS Std.

Grinning: The appearance on the surface of the plaster of the pattern of joints or similar breaks in the continuity of the surface characteristics of the background because of improper plastering, Mix Design & using Dry Sand. Balaji Robo Sand maintains the desired amount of moisture, which also saves water.

Peeling: The removal of substantial areas of plaster work from the background. It’s because of absorption of water from wall, which you can avoid by using water washed Balaji Robo Plaster Sand.

Efflorescence: A deposit of soluble salts on the surface of the plaster or background because of using salt water for mix design & presence of soluble salts in river sand. Balaji Robo Sand usage pure quality water (PH Level tested).

Cracking: The development of one or more fissures not assignable to structural cause is due to bad quality sand containing unwanted Ultra Fines. Balaji Robo Sand is properly washed & graded.

Blistering: The development of one or more local swellings on the finished plaster surface, caused due to poor workmanship. Less heat & moisture content in Balaji Robo Sand.

Compressive Strength of the mortar made with Balaji Robo Sand is twice that of mortar made with River Sand.

Compressive Strength of Mortars

Why is Balaji Robo Sandsuperior than others?1. Balaji Robo Sand exactly matches Zone-II (Concrete Sand) and

Zone-III (Plaster Sand), having 150-600 microns as per IS Std. In other sands, fractions between 150:600 microns are less, sand is coarse and do not meet specification.

2. Every day we are testing our products, ensuring consistent quality.

3. We use good quality VSI material for washing and use less than 3.5mm material to produce quality plaster by recrushing & screening.It helps us to achieve good shape and gradation as per IS Standard, which is comparable with river sand.

4. Bulk density and specific gravity of Balaji Robo Sand is comparable to that of river sand, which other sands can’t match.

5. We have conducted several tests on Balaji Robo Sand (For Concrete & Plaster Sand) against river sand and found that it is suitable to replace river sand. Other sands do not satisfy these tests due to usage of poor quality feed material, no cubicle shape, no gradation and high percentage of silt.

6. We are using the latest European mineral processing techniques to produce high quality sand as per clients requirement.

7. Water Retentivity: Water retentivity values for 1:6 cement mortar using river sand and Balaji Robo Sand were 27.3% and 28.5% respectively. For 1:4 cement mortar it was 25.6% and 35.6% for river sand and Balaji Robo Sand respectively. Thus, water retentivity of mortar was found to improve with the use of Balaji Robo Sand. Better water retentivity results in better strength and bond development.

8. Brick-Mortar Bond Strength: The flexure bond strength of masonry using 1:6 cement mortar (with 85% flow) was 0.06 MPa and 0.15 MPa for river sand and Balaji Robo Sand mortars respectively. The flexure bond strength of masonry prism improved by 150% when Balaji Robo Sand was used instead of river sand in the 1:6 cement mortar.

Mortars with Balaji Robo Sand exhibited better flow characteristics.

30% increase in masonry strength was observed in mortar made with Balaji Robo Sand vs River Sand.

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Is Sieves Wt Retained

Cum. Wt Retained

% Wt Retained % Passing Zone II

10 0.0 0.0 0.00 100.00 100 100

4.75 0.7 0.74 0.94 99.06 100 90

2.36 18.6 19.38 24.54 75.46 100 75

1.18 11.8 31.1645 39.47 60.53 90 55

0.6 17.5 48.6528 61.61 38.39 59 35

0.3 12.4 61.10015 77.37 22.63 30 8

0.15 9.5 70.61165 89.42 10.58 15 0

0.075 6.7 77.26715 97.85 2.15 3 0

Pan 1.7 78.96715 100.00 0.00 0 0

Total 78.97 FM 2.93 - - -

Is Sieves Wt Retained

Cum. Wt Retained

% Wt Retained % Passing Zone III

10 0.0 0.0 0.00 100.00 100 100

4.75 0.0 0.00 0.00 100.00 100 90

2.36 0.0 0 0.00 100.00 100 85

1.18 6.4 6.37 11.79 88.21 100 75

0.6 13.7 20.048 37.11 62.89 79 60

0.3 13.0 32.999 61.09 38.91 40 12

0.15 11.2 44.189 81.80 18.20 20 0

0.075 7.8 52.019 96.30 3.70 - -

Pan 2.0 54.019 100.00 0.00 - -

Total 54.02 FM 1.92 - - -

Gradation of MaterialsConcrete Sand

Plaster Sand

Advantages of Balaji Robo Sand Vs. Natural River Sand

Recoiling Capacity: Overall super structure weight is lesser and it is lesser in weight than natural sand. Recoil of 20% ensures lesser wastage.

Cost: Cost of Balaji Robo Sand is cheaper than Natural Sand, proper graded and reduces overall material cost.

Clay Content: Balaji Robo Sand is free from clay content since its properly washed and graded, which will reduce water absorption and avoid cracks.

Cement Consumption: Good workability and less cement consumption.

Curing: Less curing days.

Properties of Good Plastering: Balaji Robo Sand is tested to avoid: Debonding, Cracking, Crazing, Lack of Hardness, Grinning.

Particle Shape: Particles are not smooth and hence do not extend some of the desirable properties of natural sand but provide good bond strength.

Clean: It is produced after thorough washing, is very clean and can be produced to the desired grading.

Fineness Modulus: Fineness modulus of sand is as per standard.

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For orderS pleaSe ContaCt

9652 82 82 82 / 9121 28 28 28

Site Address:

Svy No: 636, Govindhapur Village Shayampet Mandal, Warangal Rural Dist

Email: info@balajirobosand.com Website: www.balajirobosand.com

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Balaji Robo Sand uses CDE’s pollution-free Green Technology for sand production that has following features:

We Use Pollution-FreeEuropean Technology

1. It is a Zero discharge system - no liquid or effluent is discharged to atmosphere.

2. It is a Zero waste system: Brick and blocks produced from sludge. All fractions of natural resources are converted into products.

3. We recover & recirculate 95% of the water. Water loss due to evaporation is minimal.

4. Sand product is delivered with low moisture to make it Concrete ready.

5. Clean power is used with low energy requirement per ton of feed.

6. Land requirement is small.

7. It is a dust free system.

8. Low noise (<80db).

Quieter than your dishwasher

ZERODUSTNo dust pollution No wastewater release to atmosphere

Zero Liquid Discharge Technology

Sludge turned into bricks and blocks

ZEROWWW WW STE