Polyethylene Concrete Mixer

OPERATIONS MANUAL OF S12-15

In Partial Fullfilment of the Requirements in Work Immersion

ABSTRACT
The profusion of plastic is one of the major issues in attaining a clean & green and sustainable
environment as plastic pollutes sea, land and atmosphere. However, despite plastic’s negative effects on
the environment, its versatile behavior—lightweight, flexible, strong, moisture-resistant, and cheap—
can be an alternative or aggregate to many existing composite materials like concrete. To address this
plight, the proponents present “Polyethylene Concrete Mixer” (PolyCon Mixer), an innovative project
which aims to attain the following Sustainable Development Goals (SDGs) by the United Nations: SDG #
3 (Good Health and Well-Being), SDG # 6 (Clean Water and Sanitation), and SDG # 13 (Climate Action).
The PolyCon Mixer is an innovated concrete mixer with shredder and pulverizer that will be responsible
in turning plastics to fine powder. This paper presents a comprehensive guide in handling the PolyCon
Mixer properly. It is divided into six sections. The Important Instructions for Safety and Environment is
discussed first, followed by the Components, Installation, Operations, Maintenance and Cleaning, and
lastly, Troubleshooting. Furthermore, this manual also provides guidance for members and employees
to perform their functions correctly, reasonably, and efficiently. It documents the approved standard
procedures for performing operations safely to produce goods and provide services.
Table of Contents

ABSTRACT ................................................................................................................................................................. I
CHAPTER 1
IMPORTANT INSTRUCTIONS FOR SAFETY AND ENVIRONMENT ...................................................... 1
1 PLANNING..................................................................................................................................................... 1
1.1 ASSESS POTENTIAL FIELD HAZARD ..................................................................................................................... 1
1.2 ASSEMBLE A WRITTEN FIELD SAFETY PLAN ................................................................................................. 2
1.3 CONSIDER TRANSPORTATION AND PRECAUTION ...................................................................................... 4
1.4 ENVIRONMENTAL MANAGEMENT PLAN........................................................................................................... 4
2 TRAINING ..................................................................................................................................................... 5
2.1 FIRST AID INITIAL RESPONSE ................................................................................................................................. 5
2.2 LEADERSHIP SKILLS ...................................................................................................................................................... 7
3 INCIDENCE RESPONSE AND REPORTING........................................................................................... 7
3.1 SEEKING MEDICAL CARE ............................................................................................................................................ 7
3.2 INCIDENT REPORT TO CAMPUS .............................................................................................................................. 8
3.3 REVIEWING LESSON LEARNED .............................................................................................................................. 8

CHAPTER 2 ............................................................................................................................................................... 9
4 COMPONENTS.................................................................................................................................................. 9

CHAPTER 3 .............................................................................................................................................................10
5 INSTALLATION ..............................................................................................................................................10
Type chapter title (level 3) ................................................................................................................................................... ?

CHAPTER 4 ................................................................................................................................................................ ?
6 OPERATIONS ..................................................................................................................................................................... 5

CHAPTER 5 ............................................................................................................................................................... ?
7 MAINTENANCE AND CLEANING ............................................................................................................................... ?

CHAPTER 6 ................................................................................................................................................................ ?
7 TROUOBLESHOOTING ................................................................................................................................................... ?
Important Instructions for Safety and Environment

This manual outlines the duties and responsibilities of the proponents and the users of the
product Polyethylene Concrete Mixer with respect to aviation safety oversight. This manual also
provides guidelines and resources to lead secure, successful field courses and ventures
optimizing safety through project management. The manual’s content confines itself to risk
management issues that are relevant for research expeditions and other outdoor excursions to
be done by students of S12-15 and residents of Brgy. San Carlos Lipa City.

Critical elements have been identified and organized into key sections mainly on planning,
training and incident response/ management which are essential parts of a safety oversight
system and must be considered for the effective implementation of a safety related policy and
associated procedures.

This operations manual serves as a comprehensive guide in handling the PolyCon Mixer
properly. One must understand the hazards of using this machine for awareness on how to
prevent and supervise any possible accidents that may occur upon operation. The utilization of
this product requires electric connection and so the user must unplug the machine when not in
use in order to save energy and minimize contribution to carbon footprint.

1. Planning
Planning, in every aspect, is foundational in accomplishing various agendas; these agendas
include the safety and the environment of the proponents and the users of the Polyethylene
Concrete Mixer. The enumerations below showcase instructions which are beneficial for the
involved personnel.

1.1 Assess Potential Field Hazards

In a working environment, accidents caused by different factors are inevitable, which is why
being aware of an area’s potential field hazards is necessary. While this will not completely
eradicate the chance of an accident, it can considerably lower the number of casualties and
even fatalities in the workplace. The chosen locale of the proponents is Barangay San Carlos,
Lipa City, a district facing multitudinous environmental difficulties due to improper waste
management, and garbage burning. As a result, the assessed field hazards of the community
are the following: Air pollution (from garbage burning and piled trash), Chemical hazards (from
garbage burning), and Bacterial infection (from piled trash and exposure to clogged drainages).
1.2 Assemble a written Field Safety Plan

Field Safety Plan:

Field Site Location: Barangay San Carlos, Lipa City, Batangas

Activity Description: Operating Polyethylene Concrete Mixer to create cement made from
plastics

Plan Created for: The proponents and the residents of Barangay San Carlos, Lipa
City, Batangas

SITE INFORMATION

Site Information: Flat terrain

Travel to Site: The proponents will travel to the site using a

rented jeepney provided by either De La Salle
Lipa or by the proponents themselves using
their CAPSTONE funds.

On the other hand, the residents of the

barangay will not have to use a vehicle for
transportation, as the machine is located in
their area.

Environmental Hazards: Air pollution from garbage burning and piled

trash; Chemical hazards from garbage
burning; and Bacterial infection from piled
trash and exposure to clogged drainages.

No Go Criteria: The activity shall be cancelled or postponed

during typhoons and life-threatening
situations such as earthquakes.

EMERGENCY SERVICES AND CONTACT INFORMATION

De La Salle Lipa (043) 981 0122

Nearest Emergency Department (ED) Mary Mediatrix Medical Center

Estimated transport time: 9 minutes
Contact Information: (043) 773 6800
PARTICIPANT INFORMATION

Physical Demands: Strength, Stamina and Flexibility

Mental Demands: Mental capacity to endure arduous work and

Sufficient knowledge on operating machines

EQUIPMENT AND ACTIVITIES

Activity Hazards Bacterial infection from exposure to unclean

plastics

Personal Protective Equipment Heavy-duty rubber gloves, Safety goggles,

Safety-toed footwear, Hard hats

Adapted from Berkeley EH&S Office of Environment, Health & Safety, “How do I create a field
safety plan?” https://ehs.berkeley.edu/field-safety/how-do-i-create-field-safety-plan. Retrieved
November 4, 2019.
1.3 Consider Transportation & Precautions
If De La Salle Lipa does not cover the transportation means of the proponents, they shall utilize
their CAPSTONE fund to rent a jeepney for transportation, which is cost-efficient compared to
other means of transportation.

Service Contact Number

Jeepney Service, Batangas City 09109760490

The following precautions must be followed during the travel:

● Establish a rule wherein the members cannot separate from the group
● Regularly do a headcount to know if a member is missing
● Give out the contact of the class president and the assigned in-charge school personnel
to the members

Person in-charge Contact number

Emmanuel Schumi Pinohermoso (Class 09666931940

President)

1.4 Environmental Management Plan

An environmental management plan depicts how an activity may affect the natural environment
wherein it takes place and sets out clear responsibilities to the individuals so they can avoid
negative impacts and promote love for the environment.

Environmental Management Plan for Operating Polyethylene Concrete Mixer to Create

Cement Made from Plastics

POTENTIAL IMPACTS MITIGATION

Depletion of natural resources needed to Resource productivity

manufacture cement

Production of new plastics in order to Vigorous campaign that the activity only
continue using the PolyCon Mixer accepts recycled plastics in order to operate
the machine
2. Training
Mentoring is essential to transfer knowledge and practical skills from experienced faculty, staff
and researchers to new researchers and students, and is often provided informally. Proponents
are expected for skills across many dimensions in order to maintain project momentum, spur
team engagement, manage change, overcome conflict, use judgement and decisiveness, and
ultimately brings projects across the finish line on budget on time and within scope.

2.1 First Aid / Initial Response

It’s impossible to discern all possible injuries or incidents that may occur when working in
uncontrolled environments, but first aid skills and having emergency plans in place will help
manage situations effectively and potentially mitigate negative consequences. First aid provides
the initial attention to a person suffering an injury or illness. First aid in the workplace has a
number of benefits including saving lives, preventing permanent disablement, providing
immediate support to the injured person, improving safety awareness and preventing injury and
illness in the workplace, and assist in the early return to work and rehabilitation.

First Aid kits will normally be installed in high risk work areas, exemplification in Brgy. San
Carlos where residents are known to be in the profession construction working leading to the
fact that sites can be seen. A risk assessment must be conducted for the relevant
locations/activities to ascertain if a first aid kit is required. The risk assessment is to be
conducted by the students in collaboration and help of their mentor. There is no adequate
substitute for getting this training. First Aid Initial Response establishes protocols for first aid
reference, but in no way is a replacement for maintaining current first aid certification. This
includes valuable hands-on practice that cannot be replicated in any other way.

For Life Threatening injuries

Call Lipa City Police Station (0977 744 9692) or Mary Mediatrix Medical Center (043 773 6800).
Always be informed about physical whereabouts/locations.

According to 2015 first aid procedures recommended by the Philippine Red Cross:

Possible Incidents Basic First Aid Procedure

Bleeding Cover the wound with gauze or a cloth
and apply direct pressure to stop the
blood flow. Don't remove the cloth. Add
more layers if needed. The cloth will help
clots form to stop the flow.

Burns ● Flush the burned area with cool

running water for several minutes.
Do not use ice.
● Apply a light gauze bandage.
● Do not apply ointments, butter, or
oily remedies to the burn.
● Take ibuprofen or acetaminophen
for pain relief if necessary.
● Do not break any blisters that may
have formed.

Blisters
Cover it to prevent continued rubbing and
pressure on it that can cause it to swell
and possibly burst on its own. If the blister
is large or painful—especially if the
activity isn’t finished (such as you are in
the middle of a hike)—follow steps to
drain and dress a blister.12 Use a
sterilized needle and make small
punctures at the edge of the blister and
express the fluid. Then apply an antibiotic
ointment and cover it to protect it from
further rubbing and pressure.

Fractures
● Don't try to straighten it.
● Stabilize the limb using a splint
and padding to keep it immobile.
● Put a cold pack on the injury,
avoiding placing ice directly on the
skin.
● Elevate the extremity.
● Give anti-inflammatory drugs like
ibuprofen or naproxen.

Sprains The symptoms of a sprain are almost

exactly the same as that of a broken
bone. When in doubt, first aid for sprains
should be the same as broken bones.
 Immobilize the limb, apply a cold pack,
elevate it, and take anti-inflammatory
drugs.15 See your doctor for further
diagnosis and treatment.

Nosebleeds
● Lean forward, not back.
● Pinch the nose just below the
bridge. Don't pinch the nostrils
closed by pinching lower.
● Check after five minutes to see if
bleeding has stopped. If not,
continue pinching and check after
another 10 minutes.
● You can also apply a cold pack to
the bridge of the nose while
pinching.

Adapted from Brouhard, R. (2019). “10 Basic First Aid Procedures”

https://www.verywellhealth.com/basic-first-aid-procedures-1298578 Retrieved November 4,
2019.

2.2 Leadership Skills

Given that the project is spearheaded by different committees inside the class, the success in
the completion of tasks is the primary responsibility and goal of the Project Manager, he/she is
obligated to lead teams, delegate tasks, set project milestones, and manage the overall
progress of a project from beginning to end along with the help of other groupmates.

3. Incident Response and Reporting

3. 1 Seeking Medical Care

In case of accident due to product malfunction, refer to troubleshooting. Handling of the
product can also lead to accidents if the operator is not properly skilled, equipped with
required gears, or prepped with user guidelines. Thus, first aid kits must be available all
the time and the operator/s must know at least the basic first aid procedures (refer to
Training 2.1). If the malfunction and mishandling caused harm to the operator, make
sure to execute first aid procedures. Take the patient to the nearest hospital if
necessary.

Nearest Emergency Department (ED) Mary Mediatrix Medical Center

Estimated transport time: 9 minutes
Contact Information: (043) 773 6800
Taken from 1.2 Assemble a written Field Safety Plan

3. 2 Incident Reporting to Campus

If any accident occurs, San Carlos must report the incident to De La Salle Lipa, since the
CAPSTONE project was endorsed by the school to the students.

De La Salle Lipa (043) 981 0122

Taken from 1.2 Assemble a written Field Safety Plan

3.3 Reviewing Lessons Learned

To ensure that there won’t be any problems before operating the PolyCon Mixer, and to control
the product smoothly, ensure that the procedures on operating the product and its proper
handling are read. If problems occur and incidents happen, refer to the guidelines given on
Operation.

1. Evaluating the “Accident Potential”

To avoid future injuries, assess the possible hazards (eg. sharp objects, swallowing smaller
mechanical parts etc.), conduct inspection before using the product, and evaluate the probability
of a risk that can potentially be a source of an unwanted injury. Standard protocol must be
followed: refer to 1.2 "Assemble a written Field Safety Plan" and 2.1 "First Aid/Initial Response".

2. Facilitating Safe Group Decision-Making

In case of any problems that may arise, group discussion is recommended, wherein the
majority’s decision shall be agreed on. The group shall look for a “win-win” solution that is
acceptable to all—no decision will be made against the will of an individual or a minority. Instead
the group adapts to all its members' needs.
Components

Shredder Box - This part is where the shredding process will be done.
Parts Function

Metal sheets This material is used in creating the entire box fundamental for
providing space for the plastics to be accepted at the opening of
the box and shredding of plastics to begin with.

Shafting This device completely cut plastics into tiny pieces which acts as
the starting point of the whole phases involved in the whole
machine.

Shredding Plate (0.5) The purpose of this material is important as it is the step where
plastics will be shredded with the use of this material. This
material will be used to shred plastics with its sharp edges to
shred plastics into small pieces.

Mixer - Aused for combining shredded plastics, cement and water by keeping all the materials
required inside the drum or mixer then mixing it altogether to form a concrete mixture.
Parts Function

Mixing drum This material will be used as a location for the shredded plastics,
cement and water that would be mixed together.

Electric Drive - A form of machine equipment that is designed to convert electrical energy into a
mechanical energy and provide electrical control for the processes.
Parts Function

Electric Motor Through the use of electricity, this machine drives the product with
appropriateness and sufficient power. This machine converts
electrical energy to mechanical energy; hence it produces power
that will make the shredder blades as well as the mixer revolve.

Gears In this mechanical device, gears are used to transfer motion and
torque between machine components. This material will be
essential for the machine for it is responsible in changing the
direction of movement and increase the output speed/torque of
the machine.

Pulley and belt This system made of mild steel and rubber links the shredder and
the mixer in a rotational state of motion. Through the belt, the
pulleys transmit power between the axle of the shredder and the
 axle of the mixer, allowing the two systems to function
simultaneously.

Stand
PARTS FUNCTION

Rectangular pipe This material will serve as a support stand to the shredder box
where the plastic bottles will be located that will be shredded.

Installation (if kulang ang space po, pakiadjust na lang pages sa table
of contents na maapektuhan, tysm uwu)
INSTALLATION MORE SPACE HERE
Operations
A series of steps shall be followed in operating the PolyCon Mixer. To begin with, open
the lid located at the top of the machine. Next, load the shredder with clean plastics. Third, turn
on the motor by plugging in the electrical plug into an outlet to shred and pulverize the plastics.
Fourth, remove the electrical plug of the motor from the outlet to check the size of the plastics
by opening the pipe below the pulverizer. If the desired size is not yet achieved, repeat steps 1
to 4, however, if preferred size is achieved, proceed to fill the steel drum with Portland cement
and water. After filling, connect the pipe to the drum. Afterwards, remove the stopper of the pipe
to allow plastics to slide from the pipe to the drum then close the lid of the drum. Next, turn on
the motor by plugging in the electrical plug into an outlet to incorporate the elements inside the
mixer. After approximately 2-3 minutes, turn off the motor by removing its electrical plug from
the outlet and open the cover of the drum to check if the desired consistency is achieved
otherwise close the cover of the drum and turn on the motor again until preferred consistency is
attained. Lastly, carefully tilt the cover facing the ground to pour the concrete.

Maintenance and Cleaning

General Steps:
1. Open the metal sheet box
2. Remove excess waste debris or left overs
3. Carefully detach the screws of shredder and pulverizer
4. Remove the bent pipe

Cleaning the drum

1. Transfer the excess liquid on another container
2. Make sure the drum is empty
3. Remove the excess cement and brush to clean the drum
4. If necessary, change the drum itself

Cleaning the shredder and pulverizer

1. Brush the shredder and pulverizer to remove the excess waste particles
2. Wet both shredder and pulverizer
3. With water, thoroughly brush the shredder and pulverizer
4. Dry using rag
5. Then let dry those parts not reached by the rag

Cleaning the bent pipe

1. Water the pipe with water hose
2. Brush the pipe to remove the excess plastic particles
3. Dry with rag
4. Let dry those parts not reached by the rag
5. If damaged, change the bent pipe with the same size as the original

Maintaining PolyCon
1. Avoid putting other kinds of plastics except for High-Density Polyethylene (HPDE)
2. Let the machine rest for 10 minutes for every 30 minutes use
3. Do not use the product on natural catastrophes or unpleasant weathers/climates
4. Turn off the machine when not in use
5. Do not leave the product unattended when in use
6. Only detach screws with its corresponding screwdriver
7. Never let a child age 7 and below to use the product unless guided by an adult
8. Clean the product immediately after every use
9. Strictly follow the aforementioned methods in cleaning the product, and only use the
mentioned materials for cleaning

Troubleshooting
This troubleshooting guide is intended to cater assistance for the users of the Polyethylene
Concrete Mixer to detect and correct the issues which can emanate from the usage of the
product, either brought by human or mechanical error.

RESOLVING KNOWN ERRORS

7 Tight or stuck metal chains

Term Detail

Problem Lever is hard to revolve because it is tight or stuck, which consumes more
time for concrete production.

Cause Dirty and dry chains brought by environmental conditions or frequent usage.

Solution Clean the metal chains by wrapping it with a clean, lint-free cloth, and then
backpedaling the drivetrain through it to wipe off the exterior muck. After this
process, oil-based lubricants should be used in order to help float
contaminants to the surface of the chain and make cleaning easier, while at
the same time, prevent rubbing of rollers and plates between each other.
Repeat this process after every use in order to prevent chains to get dry and
break.

7.1 Blunt and Clogged Shredder

Term Detail

Problem The shredder fails to shred the materials.

Cause Pieces of plastic clogs the shredder and blunt shredding blades

Solution Unscrew the side of the shredder box and remove the clogged materials. If
the blades are blunt, disassemble the shredder and use a grinding wheel to
sharpen it.

7.3 Mechanical gaps

Term Detail

Problem Unsettling imbalances and instability of the machine ensemble with loosened
and/or detached gears that may not effectively perform their respective
functions.

Cause The screws and bolts which primarily adjoin the mechanical components
become under-tightened and loses their clamp forces due to various
environmental or systematic malfunctions.

Solution Since the PolyCon is a complex entirety, there is a need to use a drilling
machine instead of a regular screwdriver in re-tightening it. Moreover,
castellated or jam nuts could also be further applied as an additional
protection to the security of the screw adhesion.

7.4 Noise nuisance

Term Detail

Problem Noise is normally generated with a machine’s functionality. However, it starts

to become a nuisance to its environment when such a noise develops into a
boisterous and unceasing one, which is far different from the usual sound.

Cause The noise may indicate that a part of a component that is apportioned to a
function of spinning or mixing was loosened or worn out. Additionally, other
possible errors such as broken parts or stuck objects in the mixer might also
result to the generation of disturbing noises.

Solution Upon checking, if the cause was simply a stuck object, it should therefore be
immediately removed and should also be further assessed if it caused other
physical damages to the mixer. Moreover, in the case of loosened
components, the solution in Section 3.3 may be applied. In more extreme
cases that the component was totally broken apart, it should immediately be
replaced and duplicated.

7.5 Rusting of machine elements

Term Detail

Problem Building up of rust in the motor and other metal plated parts of the machine
that can cause the shredder to be inoperable.

Cause Overheating of the motor that can chemically affect untreated metal
components and from the oxygen coming from the air that will lead to the
formation of rust.

Solution Application of paste wax throughout the possibly affected materials, apply
durable acrylic paint, and use stainless steel instead of normal cast iron.

7.6 Shredder stops working in the middle shredding

Term Detail

Problem Shredder suddenly stops working or turns off in the middle of pulverizing
plastic waste.

Cause Shredding excessive amount of plastic waste beyond the capacity of the
product to shred; overheating caused by going beyond the maximum run-time
of the product.

Solution Check if the product is jammed, if it is, refer to 2.2 of the operation manual. If
not jammed, the product probably is overheating. Turn the motor off and
unplug it, wait for 30 minutes until it cools down; then plug it once again and
turn it on. If it still does not turn on, contacting the product's manufacturer for
help is the best solution.

DISTRIBUTION OF TASKS:
CHAPTER 1 – ADVERTISING GROUP
CHAPTER 2 – LOGISTICS GROUP
CHAPTER 3 – RESEARCH GROUP
CHAPTER 4 – PROJECT DEVELOPMENT GROUP
CHAPTER 5 – FINANCE GROUP
CHAPTER 6 – RESEARCH GROUP