About Us
2. Production Process
CPD production process is a fully automated one. It starts at receiving and handling raw materials, batching, mixing, pressing, curing, packing then strapping. Following is an in-depth look at each step of the process.
2.1 Receiving and handling Raw Materials
All incoming raw material are from approved quarries. Said approval is guaranteed periodically to each supplier/quarry to insure consistent quality of aggregates. Different size aggregates are stored in separate areas each with dividing walls to control segregation. Aggregares are subject to strict laboratory tests specifically measuring salt and alkaline content. All aggregates used in our products are dolomite stone from Attaka Mountain and in accordance with ASTM C33. Other than aggregates the following ingredients are used:
Municipal portable water.
Ordinary portland cement in accordance with ASTM C150, manufactured by Egyptian Cement Company.
Inorganic pigments with assorted colours in accordance with ASTM C79.
Additives and admixtures upon request or as need be.
2.2 Mixing
Mixing starts by automatically batching and weighing all ingredients then adjusting the added water depending on the aggregates moisture content and ambient temperature. This is accomplished in accordance with a pre-programmed mix design guided by computer orders.
Dry ingredients are mixed first, then water and liquid additives are added in portions and mixed.
2.3 Pressing
As soon as proper mixing process is complete, the press machine automatically requests fresh concrete, where the systematic processes of filling, vibrating, and pressing take place.
2.4 Monitoring
Quality engineers and machine operators are continuously monitoring all mixing and pressing procedures, and only intervene when necessary.
2.5 Testing
Immediately after pressing, the wet product is inspected for compliance with the set/required standards such as; dimensions, surface texture, corners appearance, … etc. The Quality Control Department also carries out at times minor adjustments to the mix designs, known as tweaking, depending on prevailing climatic conditions.
2.6 Curing
When the pressing/testing processes are complete, products are automatically stacked on wooden pallets, and transferred mechanically to the curing chamber. Products are stacked on shelves to naturally cure for 24 hours or more depending on the product. The shelves are kept at a minimum distance of 40 cm from each other to insure proper curing.
2.7 Packing
After curing, products are automatically palletized, horizontally and vertically strapped with steel, fiber or nylon. The stacking system adopted by us is good for land and sea transportation.
2.8 Storing
Each type and size of product is stored in its designated, storage area and delivered on first produce first out basis. Further curing can occur in the stock yard depending on strength requirements.
2.9 Testing
Random samples from all finished products are tested periodically. Samples are taken from the center and/or the edge of random pallets. Laboratory tests are carried out for compressive strength, absorption limits, abrasion resistance, colour faiding and general appearance requirements to meet Egyptian and ASTM standards.
2.10 Loading
Only pallets tagged "QC Approved" are released to customers. Loading is done by forklift either on customer's or CPD trucks. Gate security officer on duty will double check truckloads for "QC Approved" tages.
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