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MamaSays

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Burj Dubai Design

Not only is it tall, the design of the Burj Dubai is groundbreaking in many other ways. 64 floors of apartments makes it the first worlds tallest tower to offer residential space in centuries.

For the head architect, Adrian Smith at Skidmore, Owings and Merrill, challenging designs is nothing new. He’s been behind the Jin Mao in Shanghai, the United Gulf Bank building in Bahrain and most recently the the Trump International Hotel and Tower.

Trump in Chicago, 415 m (1362 ft).
Photo courtesy to: Skidmore Owings and Merrill LLP

For the Burj Dubai design Adrian Smith and SOM decided to use the bundled tube design, the same design SOM choosed for the Sears Tower and revolutionized the construction industry in the early 70s. Lead architect at that time were the famous Bruce Graham also from the Chicago office as Adrian Smith.

Bundled tubular design illustrated with a model of Sears tower, Chicago, also once
the tallest building in the world and built on the same principles as the Burj Dubai.
Picture Courtesy to Katoholieke Universiteit Leuven

The major advantage of using a bundled tubular as you might be able to tell from the picture are limiting the influence of shear lag. Shear lag is particularly an issue in skyscraper designs such as the Burj Dubai’s with it’s large side dimensions and what the Bundled tubular model do is simply making it possible. The Y shaped floor plan, inspired by the flower of Hymenocallis takes advantage of the bundled tube design of Burj Dubai and creates a variety of different spaces inside the building, all with a great view.

The Y-shaped floor plan.
Picture Courtesy to Emaar Properties PJSC.

Allied Bank Plaza, Houston.
Another example of bundled tube design.
Photo Courtesy to: Houston Architectural Info.

As for the Allied bank Plaza which shapes a dollar sign when viewed on from up abowe the lobes of the Burj Dubai design hide the shapes of a mosques onion domes, something which can be seen from certain angles close to the base if you look up the building.

In recent years Smith has become commited to energy efficient designs, for the approved Pearl River Tower project in Guangzhou, China, he worked together with former SOM architect Gordon Gill and together took sustainable designs to another level.

This was clearly shown on the Burj Dubai design as well, thermally insulated and with no horizontal surfaces to prevent dust to settle and keeping the energy efficient cladding clean are both major measures pointing in the same directions.

Looking at interior design the lobby will consist of two floors and as for the hotel and 160 of the apartments in the building the Giorgio Armani S.p.A. and EMAAR Hotels & Resorts LLC closed a deal in late 2004 to create the first Armani labled hotel in the Burj Dubai.

The Armani hotel will have a spa and five restaurants and the interior design of the apartments are Armani themselves responsible for. In total the complex will cover 40 000 m² of the floor space(in total 314,000 m²). Wa international, a Dubai based design company has been consulted on other part of the projects.

As for Adrian Smith, our beloved architect behind this project he and SOM decided to walk separate ways. Having said to be responsible for 70 to 80 percent of the Chicago office profit he left SOM october 2006 are now right in the middle of setting up his own practice with Gordon Gill, Adrian Smith + Gordon Gill Architecture. Turning 63 next year I still hope we have many groundbreaking designs to look forward to and recalling what Smith said himself recently: “I’m not planning to cut down before my 70:s birthday” I’d say chances are pretty good.

The tallest building in the world

Not even halfway through construction the Burj Dubai is already the 5 th tallest building in Dubai but staying it is another project. (As of 11/10/2006.)

Tallest title put in a perspective.
Which titles could the Burj Dubai really claim?
Approved or Proposed new Tallests.

Tallest Title Put in a Perspective.

A spokesman for the developer, Emaar, said in a interview “I don’t think Burj Dubai tower could claim the title in 10-15 years, it would surprise me.” Me to. The Empire State Building managed to keep it’s title in 42 years, quite an accomplishment and that also an record in it’s class. In recent year the competition has been closing in even more, the Petronas tower only managed to keep the tallest building in the world title for six years and the current holder Taipei 101 for less then five if Burj Dubais construction progress as expected.

Taipei 101, Current worlds tallest tower
with a rooftop height of 1470 ft (448 m),
most likely 200 m(670 ft)shorter then challenging Burj Dubai.

Although the final height of the Burj Dubai tower is keept a secret the aim is very clear, the tallest building in the world all categories. At least for a short period of time. This would guarantee a height of at least 630 m (2,067 ft) to beat Taipei 101, the CN tower in Toronto and the Fargo mast in North Dakota and most certinly will it be much taller then that.

CN tower, Toronto 553 m (1815 ft).

Back to top

Which titles could the Burj Dubai really claim?

The Council on Tall Buildings and Urban Habitat’s, one of the most respected sources when it comes to categorization define the following four measurements for the tallest building in the world(note buildings).

To Structural Top: Height to structural top of the building.
To Highest Occupied Floor: Height to the floor of the highest occupied floor of the tower.
To Top of Roof: Height to the top of the roof.
To Tip of Spire/Antenna: Height to the tip of spire, pinnacle, antenna, mast, or flag pole.”

The Burj Dubai will have all the abow titles but with it’s great height it will also claim the “tallest freestanding structure on land” and the “world’s tallest supported structure on land”, traditionally out of any buildings league and there has already been argued if the Burj actually could claim it no matter it’s height.

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Approved or Proposed new Tallests.

At any given time there is always dussens of projects aspiring on the worlds tallest tower title. A majority of them never raise abow the ground but remember, Burj Dubai was once also only a visionary tower which only a few really expected to get built. At the moment challengers to the title are almost exclusively visionary projects, no approved or proposed ones. However I have sorted out a few projects which seem more likely to get built then others but in the footsteps of Burj Dubai I’d also say it’s most likely I´ll have to update this list again very soon.
Tallest Tower list*
Building and location: Height:
Bionic Tower, Shanghai or HK. 1128 m(3,701 ft)
Sky City 1000, Tokyo. 1000 m(3,281 ft)
Enviro Mission Solar Tower, NSW, Australia. 1000 m(3,280 ft)
Millenium Tower, Tokyo. 840 m(2755 ft)
Al Burj, Dubai. Above 700 m(2296 ft)

*All types of structures and statuses listed.

The Solar Tower is an interesting challenger to Burj Dubai, it’s one of the two projects on the list that’s actually not only a vision, it’s proposed. what looks like a gigantic chimney make use of the wind to run a generator and also reflects the sun on thousands solar panels surrounding it on the ground. If beeing built this project could however only claim “the tallest free standing structure on land” -title, a title Burj Dubai most likely won’t be able to claim anyway but it’s still quite a spectacular project don’t you think?

Proposed Solar Tower in Buronga NSW, Australia.

Al Nakheel, the developer behind the other proposed building on the list, the Al Burj, has clearly stated it will rival the Burj Dubai tower when it’s expected to open in 2010.

Al Burj tower, Dubai Waterfront, Dubai.
Picture courtesy to Al Nakheel.

The next contender however are most likely to come from Asia or the middle-east but there’s projects in the west to of course, Fordham Spire in Chicago and Russia Tower in Moscow for example but with it’s current designs none of them are to rival the Burj Dubai. With the sudden changes the world experiences today almost nothing is for certain though and in a weeks time the situation might be a lat different so make sure to come back 🙂

Developer Emaar’s Burj Dubai Development

Developer Emaar’s Burj Dubai Development To Drive Company’s Participation At MIPIM 2005

Dubai, March 6, 2005: Emaar’s prestigious Burj Dubai Development and Dubai Marina will be among the several lifestyle properties offered to investors and homeowners at the 2005 MIPIM exhibition which will take place in Cannes, France, later this month.

The exhibition –now in its 16th year—runs from March 8 to 11 at Palais des Festivals and attracts the leading real estate developers from Europe, North America and Asia.

Emaar is making its second consecutive presence at the annual global property forum. The company, globally acknowledged as one of the world’s finest, will be led by a high-level delegation.

Robert Booth, Executive Director, Emaar: “The Burj Dubai development has become more than a wonderful property that houses the Burj Dubai and The Dubai Mall. It has become a signpost for everything that the city of Dubai stands for. The world has already acknowledged Dubai’s role in the Middle East as a prime mover of business, finance, leisure and lifestyle enterprises. Emaar’s appearance in Cannes with iconic properties like the Burj Dubai development and Dubai Marina will further raise Dubai’s stature as the Middle East’s city of the future.”

Visitors to the Emaar pavilion will get an opportunity to view the sheer size and magnitude of the five million square feet urban development featuring Burj Dubai, the world’s tallest residential tower, The Dubai Mall, the world’s largest entertainment and shopping mall, The Boulevard, The Old Town, man-made lakes and landscaped parks.

“With the Burj Dubai Development, we are creating a new architectural landmark for global property developers. In its daring vision and planning, the landmark project reflects the dynamic growth of Dubai’s real estate sector making it the favoured place to live, work and invest,” said Booth.

Reflecting the diversity of Emaar’s lifestyle offer will be the Dubai Marina, the company’s unique waterfront development regarded to be the French Riviera of the Middle East. The internationally acclaimed project comprises residential towers and luxurious villas that have been created around a 3.5km water channel. It is the region’s first ‘intelligent city’ that will eventually house 40,000 people in stunning surroundings that boast international restaurants, coffee shops and boutique-style retail shops.

“With its ever-expanding range of property developments, Emaar has altered the architectural landscape of Dubai. This exhibition provides us with a good opportunity to illustrate Dubai’s success as a lifestyle destination as well as connect with the key players in the real estate industry,” said Booth.

Emaar’s participation at MIPIM marks the end of a successful year for the property developer as it grew from strength to strength in size, value and product offerings. The company recently announced record annual
profits of AED 1.691 billion for the year ended December 31, 2004 corresponding to a net profit increase of AED 1.015 billion or 150 percent. This year alone, Emaar handed over more than 8,000 homes to its owners and launched nearly 40 developments, unprecedented for any developer anywhere in the world.

Courtesy to Burj Dubai developer Emaar Properties PJSC

Cement and inert aggregate silo

Our company produces cement and inert aggregate silos.

 

height of the frame
(without supporting frame)
up to 15 m
Silo diameter up to 3,5 m
Operating volume of one silo up to 80 m3

1. silo frame
2. supporting structure design
3. disk valve, rotary
4. pneumo-breaking-down circuit or vibrator
5. loading pipe

1. aspiration system
2. dancers with walk-site protection
3. top walk-site protection
4. levels sensors
5. automation unit for pneumo-breaking-down circuit
6. union flanges for screws (accordingly to customer’s Technical Specification)
7. horizontal, inclined, composite screws (accordingly to customer’s Technical Specification)

Q, т (cement) 20 30 40 50 60
D, mm 2400 2400 2400 2400 2400
H, mm 6600 8475 10350 11550 13475
H1, mm 8000 9700 11900 13000 15000
L, mm 1550 1550 1550 1550 1550
Q, т (cement) 70 80 90 100 120
D, mm 3000 3000 3000 3000 3000
H, mm 10890 11650 13200 14650 16890
H1, mm 12200 13000 14700 16000 17000
L, mm 1890 1890 1890 1890 1890


Regarding purchasing of equipment contact marketing department
ООО «Incorporated Industrial Company»
Russia, city Kaluga, Svetlaya St., 37

Tel. +7 4842 70 02 52,
+7 4842 70-04-92

Universal cutting system (УРК)

Application of the foam concrete cutting equipment (УРК)

УРК is used in manufacturing lines for producing autoclaved and non-autoclaved gas concrete for receipt of wall and partition blocks with geometrical imperfection from the specified size not more than ±2мм.
Blocks produced on УРК have smooth surface without oil film. Guaranteed cutting accuracy enables to lay blocks on a thin-layer or adhesive solutions.
УРК design allows to produce blocks with various standard sizes using only one kit of forms.
УРК mold is simple in production process. Cleaning, lubrication and assembly for one mold (0,9 m3) takes about 2-3 minutes.

Materials for foam concrete manufacturing

Cellular concrete with the uniformly-cellulated structure, manufactured according to GOST 25485-89 is used for cutting. Material. cured enough for steady cutting (4-12 hours after filling in the form). is used on УРК.

Technological process / foam concrete cutting

After being filled into moulds foam concrete becomes up to necessary strength (4-12 hours depending on the structure and producing technology) at 20-300°С. After that mold with cured massif is placed onto the transportation trolley of the УРК, the top of the metal mold (a cap) is removed, the operator pushes the START-UP button on the control panel and massif is cut into blocks of the specified size in automatic mode. During this procedure a thin layer of the top and edges of the massif are cut off.
After this the cut massif is removed with the pallet from the transportation trolley of the УРК and cures for another 4-8 hours, then blocks are laid on wooden pallets, packed with film and moved to the warehouse.

Control panel has speed of lowering of cutting cars control system, that allows to establish necessary frequency of the block surface finishing (from smooth up to deep wave).

The nomenclature of produced blocks

The minimal thickness of the block – 75мм.
The maximal thickness of the block – is limited by the linear dimensions of the massif.
Within the massif size it is acceptable to fix any necessary dimensions.

Brief technical characteristics of gas concrete blocks

УРК – 3М

Massif dimensions (l/w/h) – 1200/1200/600 mm.
Design capacity – 12 kW.
Maximum power consumption – 7,5 kW.
Design dimensions (l/w/h) – 12/3,1/3,3 m.
Output (actual) – 12 m3/hour.
Operating staff – one person
Continuous operating time is not limited
Operating modes – manual, automatic
Amount of simultaneously cut massifs – two

Regarding purchasing of equipment contact marketing department
ООО «Incorporated Industrial Company»
Russia, city Kaluga, Svetlaya St., 37

Tel. +7 4842 70 02 52,
+7 4842 70-04-92

Porous concrete massifs on the automated contour bend machine

Porous concrete massifs on the automated contour bend machine with electro-programming control “ÐÈÔ-1»

The main aim of production porous concrete items is production of quality products with maximally possible level of specified sizes. Concerning physical-mechanical characteristics of products, made of porous-concrete, it’s obvious that they’ve reached rather high level. But if to speak about geometry – dimensions accuracy and surface quality of wall blocks of majority of producers are usually lacking. Geometry and quality of blocks surface are determined by using technology of formation.

There are many different kind of mechanisms for getting foam concrete and gas concrete mixtures, but only four techniques of wall blocks forming are known at the time.

1. Pouring of foam concrete into bar moulds – the simplest and widespread technique. Working under this technique it’s possible to get blocks with accurate geometrical size using only expensive heavy-gage sheets metal moulds. At seeming simplicity of this technique it’s necessary to have great stock of difference size moulds, that unreasonably increases steel consumption and, consequently, equipment cost. While forming a foam concrete block a peelable cement film with hydrophobic properties is generated on the sides, contacting with metal mould walls. This film makes difficulties while plastering. That’s why it’s desirable to make cutting of side surfaces. Besides pouring of foam concrete into metal mould does not give to blocks accurate edges and right angles. This causes their worse positioning while laying and, consequently, degrades its quality.

2. At the present time the structural cutting on a certain stage of getting the plastic strength by cellular-concrete raw-massifs becomes widespread, but this technique possesses a number of considerable shortages.

Firstly, the dimensions accuracy of blocks is not enough because of string walking, especially in cases of its sliding on the side faces of blocks (so-called «barrel» defect), that prevents laying such blocks on clue and lowers the quality of laying on the mortar.

Secondly, short cutting of the middle bottom block part, which is caused by considerable length of the string and impossibility to provide its enough tension, by horizontal position of strings and rounding by string high-density inclusions – leads to breaking off of the corner pieces.

Thirdly, blocks cutting at a certain moment of technological cycle needs thoroughly technology observance and does not allow to accumulate massifs before cutting, that lowers technology flexibility.

Wavy sides surface after cutting can be estimated as advantage of string cutting technique. The products surface after cutting has small tracery, which promotes better adhesion between masonry mortar and mortar for plastering. Packed surface layer has variotrop structure, its peeling wasn’t observed.

3. Cutting with circular blade saw also has a number of considerable shortages:
– to cut 600 mm height monoblock it needs one disk with large diameter or two disks precisely matched in the cutting line. Either the first, or the second decisions are rather expensive. Disks wobbling leads to low-quality cutting.
– disk (disks) sharpening requires special equipment and is expensive procedure;
– coming in and out of the spinning disk into massif body results in extraction of foam concrete pieces – chippings on blocks are formed. To solve this problem the monoblock needs to harden more, but in this case much dust will be generated during gutting process and cutting saw teeth are abraded faster.

4. Cutting of massifs with closed chain and belt saws has recently acquired more and more adherents. Different Russian manufacturers developed several types of cutting lines and machines. The specific feature of cutting technology on such lines is the necessity to separate massif from the pallet and further multiple tipping of sawn half-finished blocks on several sequentially set contour bend saws during cutting process. The massif should have enough mechanical strength (1.0 MPa and higher up to final strength of the type). This implies the necessity the prolongation of the process of porous concrete mixture curing in metal mould, that reduces to lowering of their turnover, increasing of metal moulds stocks, increasing of volume and area of heat-humidity treatment chambers. Besides, tipping process need additional equipment installation and because of heightened strength of cutting massifs it’s necessary to use expensive belt saws with special carbide teeth, which abraded too fast and this causes abrupt increase of the prime cost of the cutting process.

Besides heightened energy consumption this technique has one more disadvantage – dusting.
In spite of shown disadvantages, in existing value system, when the quality of the product is the first importance fact and becomes the main competitive advantage, producing wall blocks made of porous concrete using mechanical technique comes to the foreground.

On the basis of analysis of the wall blocks production on various famous Russian equipment using belt saw, OOO “IIC” specialists came to the conclusion that majority of abovementioned disadvantages can be eliminated if massifs are sawn after stage of gaining plastic strength within the stage of hardening beginning, when the string cutting technique can not be used by this time.

Firstly, massifs can be cut on the bottom part of the ôîðìîîñíîñòêè, thereby exclude operations of separating and tipping of monoblock and semiblocks.

Secondly, the necessity to use expensive imported carbine saw falls away, cutting process is carried out by cheap Russian belt metal saw in standard model, without carbine teeth.

Thirdly, only one saw is used for cutting.

Fourthly, there is no dusting, because cellular-concrete mixture has certain humidity at cutting moment.

Besides this, it’s important that time period for cutting fulfilment is considerably longer if to compare with string cutting and it’s possible to accumulate dismantled massifs before cutting.
Starting developing of a new contour band machine OOO “IIC” specialist used their own long experience of developing and manufacturing string cutting machines (“ÓÐÊ-2”, “ÓÐÊ-2ì”, “ÓÐÊ-3”). There were produced more then 70 such machines since 2002 up to 2007. At the same time permanent experimental-designing works and researches of new in essence technique of porous concrete raw-massifs cutting using different types of belt saws took place. After prolonged and numerous tests they were managed to find the optimal parameters of cutting mode and choose the most multipurpose type of belt saw. At the end of 2006 as the result of done work the unique cutting equipment of a new generation was created – automated bandsaw cutting machine with electronic-programmed control «Ðèô-1» for cutting large, 1240?12400?610 mm sized, cellular-concrete massifs.

The machine set includes unit for cutting the top side of the massif, one horizontal contour band module and è coordinating-transporting unit. All the mechanisms variable-frequency electric drive. «Ðèô-1» is equipped with convenient and easy-to-work control panel. Necessary dimensions of cut (block dimensions) are set on electric panel of operator. None of additional operations for machine changeover for new sizes are necessary. Besides, the display on the operator panel shows the analysis of machine work in real-time mode. Manual control is provided for adjustment the machine or for working in semiautomatic mode. Positioning and transporting of the cutting massif takes place on the coordinating table of the machine.

The machine works like that: pallet-trolley with massif, hardened enough, is taken by special positioning transporter and goes to cutting machine «ÐÈÔ-1». At the first stage the top side of the massive is cut off by screw cutter (up to 30 mm) and block length is formed (600 mm). The bottom side of the massif has strictly horizontal surface due to usage of rigid thick-walled bakelized veneer sheet in the pallet. At the second stage cross and length cutting of the massif by horizontal saw with sequential number of cycles of cutting module lifting and lowering takes place; cutting step and width and height dimensions are fixed by the coordinating table operation. After this parted into blocks massif is rolled on the overpassing trolley to the pushing transporter to be places into tunnel thermos chambers for heat and humidity treatment.

Besides this, «Ðèô-1» can be equipped with a belt knife for calibration of top and bottom sides of massif under special order.

Machine can operate with saws of two types:
– cutting massifs with gained plastic strength;
– cutting massifs with gained designed strength.

Specification for «ÐÈÔ-1»

Capacity (regarding final products), ì3/÷ ………………………………………………………… up to 5
Design capacity, kWt…………………………………………………………………………………………… 4,5
Floor-level space of the machine with coordinating-transporting unit, mm………4,6? 4,5
Weight, kg …………………………………………………………………………………………………………… 3500
Cutting accuracy, mm……………………………………………………………………………………………±1
Cutting elements…………………………………………………………………………screw cutting and belt saw (horizontally located)
Quantity of saws……………………………………………………………………………………………………1
Width of kerf, mm …………………………………………………………………………………………………from 1,1 till 1,5
Maximum height of cut, mm …………………………………………………………………………………600
Dimensions of mould for producing foam concrete massifs, mm…………………………1240 ? 1240 ? 600
Block dimensions, main standard size, mm ……………………………………………………………198 ? 300 ? 598
Finished products outcome from one massif, m3 …………………………………………………0,86
Quantity of cut sides in block ……………………………………………………………………………… 5 (6)
Time for one massif cutting in automatic mode, min ……………………………………………9,5.
Time for machine changeover for a new size, min ………………………………………………… 1
Time for belt saw exchange, min …………………………………………………………………………… 5
Lifting mechanism drive ……………………………………………………………………………………… electromechanical
Operating modes ………………………………………………………………………………………………… automatic, semiautomatic, manual
Permissible strength, kg/sm3 ……………………………………………………………………………… from 2 till 45

One operator is enough to operate the machine. The control can be handled manually or in automatic mode.
The main advantage of the present cutting technology can be named the possibility of the short equipment changeover to produce blocks of any size. Among other advantages are: accuracy and quality of wall blocks surface. Such blocks allow to make masonwork using special thin-layer mortar clue.
More then 10 production samples of “ÐÈÔ-1”were installed to the beginning of the 2008 we are planning to produce at our enterprise not less the 30 such machineries in 2008.

All the experience of machineries usage in production conditions showed the high reliability of all actuating mechanisms, extremely low level of expenses for raw materials (for 1 m3 ãof final products from 10 till 15 rubles, dependently on the filler used).

Regarding purchasing of equipment contact marketing department
ÎÎÎ «Incorporated Industrial Company»
Russia, city Kaluga, Svetlaya St., 37

Tel. +7 4842 70 02 52,
+7 4842 70-04-92

Wall blocks, produced of not-cured gas concrete using progressing vibroimpact technology

This is the first time in world-wide practice of production of porous concrete, when the technological production scheme, which provides integration of best Russian technological achievements in the sphere of porous concrete mixture forming on the basic of impact technology and technology of raw massifs cutting out on contour band machine of a new generation with quickly programming adjustment for getting practically any set size wall blocks, which does not have any analogs among world practices, are integrated.
Due to using impact technology this technological production scheme provides reducing of cement consumption up to 150 – 200 kg / 1 m3 of final product (if ash of power station and blast-furnace slag are used), reducing of the final concrete humidity and shortening of massif hardening period before cutting it into products of the set size – this in turn reduce considerably metal consumption for necessary board equipment. Besides this, implementation of impact technology and automating control system of the concrete mixture dosing allows to produce porous-concrete products with bulk density 350-700 kg / m3 with high physical-technical characteristics of final products up to domestic and world standards. Cutting machine “ÐÈÔ-1” with further massifs cutting into products of the set size with accurate within ± 1- 1,5 mm allows to produce blocks, using which it becomes possible to make masonwork on the building clue not more then 3 mm throat thickness. Besides this the nomenclature of block dimension types will increase from 27 to 340 that will require various demands of clients. Effective usage of domestic and high-reliability imported equipment lets considerably reduce labour-intensiveness of technological operations and provide energy saving.

Brief characteristics

Maximum capacity – up to 170 m3 of final products per 24-hours or 50 thousand m3 per year.
Annual output – wall and partition blocks with average density type D500-D700 with compressive resistance Â1,5-Â3,5 (GOST 21520-89). Blocks size in standard set is 198x295x598. It’s possible to set other dimensions.
Massif volume – 0,85 m3.
Time for pouring of one massif – about 6 minutes.
Time of concrete curing before cutting – 3 – 4 hours.
Time of cut massif curing till packaging – 19-20 hours.
Cement stockholding – 50 t.
Filler stockholding – 50 t.
Designed equipment power- 20 kW + 45 kW for water heating.
Water consumption – 50 t of water per 24-hours
Maintenance stuff – 6 persons (without storage area).
Placement conditions – should be placed in a building of workshop type, protected from atmospheric precipitations and temperature level not less the +5°Ñ. Workshop space should be not less then 2200 m2. Building height in pouring zone should be 7,5 m. Height of the ret part of the building should be not less then 3,5 m.
RAW MATERIALS

Portland cement – accordingly to GOST 10178 (it should not contain any additives of tripoli powder, clunch, silca clay and other pozzolanic admixtures, ashes), recommended type – PC 500 ÄÎ, it’s also possible to use portland-slag cement 500 and portland-slag cement 400 after additional check.

Siliceous components:
– ash-loss from power station, containing not less SiO2 not less then 45%, ÑaO not more then 10%, R2O not more then 3%, SO3 not more then 3%;
– granulated blast-furnace slag – accordingly to GOST 3476 – it’s necessary to make grinding till specific surface subject to required average density.
It’s allowed to use siftings, which were received after non-metallic materials shattering, which provide producing of the foam concrete with set physical-technical characteristics.
– sand – accordingly to GOST 8736, containing SiO2 not less then 90% or silica not less then 75%, mica not more then 0,5%, oozy or argillaceous admixtures not more then 3%.

Thebasic set is not meant for sand usage. To produce gas concrete with sand as filler it’s necessary to take a consultation with OOO “IIC” specialists regarding additional equipment delivery.

Water accordingly to GOST 23732.
The specific surface of used materials is accepted in accordance with technical documents dependently on required average density and heat-and-humidity treatment.

Gasifier: aluminium powder of ÏÀÏ-1 and ÏÀÏ-2 types in accordance to GOST 5494.
Regulators of structure-formation, plastic strength increasing, early-strength admixture and plasticizing agents:
plaster and angidrit CaSO4 stone in accordance to GOST 4013;
potassium carbonate in accordance to GOST 4221;
technical soda-ash in accordance to GOST 5100;
liquid soda glass in accordance to GOST 13078;
thriethanolamine in accordance to TR (technical requirements)6-09-2448;
thrienatriyphosphate in accordance to GOST 201;
super-plasticizer Ñ-3 in accordance to TR (6-14-625;
caustic technical soda in accordance to GOST 2263.
Besides this other chemical additives can be used to hasten processes of structure-forming, plastic strength, hardening and so on as well as stabilizer for gas porosities of OOO OPK production.

Technological process description

Preparation and raw materials storage
Cement and è fine-dispersed filler from cement trucks or near-railroad discharge device with the help of compressor system of pneumatic transport are fed into silos. Cement silo and filler silo are placed in immediate proximity to components dosing-mixing unit (CDMU).

Cement and filler go from silos to the measuring hopper along horizontal or combined lifting screw. Dry and liquid components dosing is made with the help of industrial processor.
At the beginning of each shift water is poured into special tanks of dosing unit for liquid components “3ï” through piping system. Aluminium suspension is prepared in the mixer (unit for suspension preparation) from aluminium powder, surface-active materials and water. Water, aluminium powder and surface-active materials, which are continuously mixed, enter the mixer through the dosing unit. For permissibility the mixture has ventilation, double coating for water cooling and emergency sewer. The mixture also has thermal reley which switch on automatically all emergency equipment if the temperature level becomes higher the 20°Ñ. Portion of suspension, volume accordingly to receipt, is sent by pump to special tank for weighting in mixing compartment.

The powder and surface active materials solution are added into the tank with mixing unit or preparation of aluminium suspension. All necessary reagents are added into the tank for chemical admixtures solution. Liquid components (aluminium suspension solution and chemical admixtures solution) are mixed, brought up to the set temperature and are dosing into the mixer in accordance with the program. To keep efficiency and energy saving it’s recommended to pour into the ÑÄÆÊ (dosing unit for liquid components) – “3ï” warm water (not less then 10-12°Ñ).
Components mixing.
Mixing of all dry and liquid components has several stages. Control, processing and managing of all important functions takes place on the central control panel of the plant at all stages of gas concrete mixture preparation. The preparation of porous-concrete process in whole is managing from the control panel, located under the mixing tower and near the post of pouring mixture into moulds. Components dosing and process of porous-concrete mixture blending go on fully-automatically and are controlled by managing computer, where all receipts programs for producing of porous concrete of requested quality.

Operator in the real-time mode keeps track for all processes on the machine. In case of need the operator will be able to modify or change for a short time current composition, mixing time, temperature mode and other technological parameters on the main electronic control panel or using PC. Besides this the operator can change the operating mode to semiautomatic or manual control mode.

Massifs formation, cutting and transportation
Ready mixture is unloaded into metal mould through the bottom orifice of the mixture. The massif mould consists of two parts: a pallet and removable mould. The pallet is a kind of trolley with four steel wheels with basic made of bakelized plywood, which juts out over metal frame. The removable mould consists of two “Ã-shape” parts, which form four sides of massive when they are assembled. Before pouring of gas concrete mixture the removable mould is assembling, lubricated by special lubricant or is interlaid with oiled paper and set to the mould.

Moulds are sized with special sealant to provide tight connection. To prevent damages
during transportation the sealant is delivered separately from moulds and is sized himself by the Client.

After vibroimpact treatment the mould. Filled with gas concrete mixture with the help of positional conveyor is transferred to the place, where it gets stripping strength. Time for gaining the stripping strength depends on many factors (specific composition, cement type, temperature, filler type and so on) and varies from 4 till 8 hours. To provide high level of strength characteristics of material it’s very important to keep rigid thermal mode. Dependently on used materials it’s necessary to keep temperature on the level 40-50°Ñ on the side before massif cutting (3-4 hours) and 90°Ñ n the side after massif cutting (up to 20 hours). More precise thermal mode the Client set accordance with results of control check-up. When the time for gaining stripping strength runs out the removable mould is disassembled and massif on the pallet is sent to the cutting place. The mould is taken off and assembled again, set on a free pallet and sent for pouring under ÄÑÊ (dosing-mixing unit).

When the massif gains necessary plastic strength it’s taken by special position transporter and taken to cutting machine. The top part of a massif (till 5 mm) is cut off via screw cutting or belt saw at the first stage. The horizontal cutting of the bottom massif part on the special contour band machine is made on the second stage. Length and cross cutting of the massif on the cutting machine “ÐÈÔ-1” occurs at the third stage. After these operations parted massif is transported to the pushing transporter on a overpassing trolley to be sent to chambers of heat and humidity treatment. To keep thermal node of heat and humidity treatment the Client is recommended to build air-tight tunnel chambers with heat insulation of all surfaces. Due to thermal treatment in thermos mode heat energy and steam, which exude during exothermal reaction of cement hydration, are used maximally. We have such rested experience to install such “thermos”-type chambers to use exothermal effect of reaction of cement hydration. After stage of heat and humidity treatment parted massif on the trolley is rolled out for disassembling. Blocks are laid on transportation pallets, tighten with binder tape and are taken to the storage platform or storage room by loaders. Further maturing time for ready blocks at positive temperature is set by the Client and varies from 1 till two weeks. Free pallet is cleared, covered by polyethylene film or oiled paper and is taken to the pouring zone.

SPECIFICATION

¹ Name Price rub.
(incl. VAT)
Image
1 Gas concrete mixture preparation area: 0
insrease
insrease
combined screw feeder; 0
dosing unit; 0
mixture unit; 0
water-preparation unit (ÑÄÆÊ – 3ï); 0
insrease
insrease
preparation and dosing of gasifier unit; 0
vibroimpackt platform; 0
automatic control system;
frame constructions, stairs and barriers
6208000
2 Mechanized area of inter-staged transport: 0
insrease
insrease
positional transporters (4 pieces); 0
pushing transporters (6 pieces); 0
overpassing trolleys (3 pieces). 1520640
3 Blocks cutting area: 0
insrease
insrease
“ÐÈÔ”-1 (2 sets) 2400000
Cutting machine for bottom part of a massif (2 sets) 840000
4 Mould for “ÐÈÔ1”; 0
insrease
insrease
handling dolly – 200 pieces. 2040000
removable mould – 45 pieces. 324000
5 Supply tank for cement 50 t (2 pieces) 840000
6 Supply tank for filler 50 t (2 pieces) 840000
Èòîãî: 15012640

 

Position ¹ 2,4,5,6 the Client can produce himself or buy from other suppliers. Equipment, received from outside, should suit quality specifications, accepted by OOO “IIC”. Otherwise OOO “IIC” can not guarantee the final product quality.

Prices are actual till 01 March 2008.

Chief-mounting and putting equipment into operation specifies in each case individually dependently on the object remoteness.
Commercial terms

Price formation: from storage in Russia, Kaluga city, without customs costs and mounting.
Time of shipment: 3-4 months after the date when advanced payment is received and all questions are decided ñ
Paytment: advanced payment at the rate 80%, other 20% – at the moment when equipment is ready to shipment.

Chief-mounting and putting equipment into operation

The “clean” trial run, putting equipment into operation and training of maintenance stuff of the Client and producing of a trial batch of products with volume density 600 kg/m3 are considered to be the result of chief-mounting and putting equipment into operation.
500 kg/m3 density is developed after certain operation life, when appropriate professional skills of the maintenance stuff and mixture content optimization by the Client on the site are reached.

For the density 400 kg/m3 the situation is the same in the case if quality of used materials allows this.

Before putting equipment into operations the Client should provide necessary raw materials availability on the site.

it’s very important, that all foundations were ready and conformed the specified dimensions by the time of specialists arriving to provide chief-mounting and putting equipment into operations.
Current and water inlet should be provided. Load lifting mechanisms presence is obligatory. All works for preparation of the building for the additional mounting should be finished. Either works, regarding building preparation, installation of rail track, foundation pouring and other civil works or that parts of equipment, which are provided by the Client are also irrelevant to the mounting.
Maintenance stuff, which will operate equipment, should be on the site during all the time of mounting and starting-up of equipment. The Client should provide electrical and mechanical technicians and auxiliary personnel to execute mounting works.

The Client books accommodation for OOO “IIC” specialists, transfer them from the hotel to the mounting place and back during the whole time of works execution. Chief-mountings and starting-up works need 1 month.

Electrical mounting and putting equipment into operations.
All equipment parts should be installed in a proper way, cable raceways should be prepared and cleaned out. All distributional boxes should be installed. Putting equipment into operations is possible only at above-zero temperature inside the building (more then +5°Ñ).

for the period of electrical mounting works the Client should proved an electrical technician, who will operate the machine in the future and auxiliary personnel.

Technical requirements
Necessary receipt of the gas concrete mixture is specified by the Supplier while putting equipment into operations on the basic of materials samples, provided by the Client, testing.
OOO “IIC” performs following works:
– development of suggestions regarding ways of raw materials preparation;
– development of technological, production and additional documentation;
– development of production technology for wall blocks made of non-cured gas concrete with density types D500, D600, D700; training operational stuff of the Client.

List of documents, given to the Client, when all works are done:
1 Suggestions bout technological ways of wall materials preparation.
2 Technological regulations to design producing of small blocks, using local raw materials.
3 Production flowsheet.
4 Technological manuals for operating places (people for dosing, cutting, grinding packing processes).
5 Report forms to keep register (incoming control, outgoing control, current monitoring, shift registers for workplaces on dosing, cutting and grinding processes).
6 Selecting of GOSTs and construction regulations for daily proceeding.
7 List of necessary equipment for laboratory with suppliers addresses.
8 Samples of passports for final products.
9 Samples of documents for keeping enterprise checking-up for product certification.
10 Samples of documents for receiving hygiene and sanitary resolution regarding production conditions.

One copy of all documents is given in printed or in digital form.
Optimization of mixture receipt the Client makes himself during production process on the basic of laboratory analyses and observation. OOO “IIC” specialists provide consulting on technical questions within the operating period of the equipment.

General conditions
Present commercial offer is based on standard OOO “IIC” conditions regarding delivery, shipment, chief-mounting and acceptance equipment into operations.
Machines and parts of equipment are manufactured in accordance with standards and directions of Russian legislation.
Parts of equipment, which are not included into volume of delivery from OOO “IIC”, but are the part of standard tooling of OOO “IIC”, should fit technical regulations to provide perfect operation of equipment as a whole in future. Built-in details, which are not produced by OOO “IIC”, are not covered by this firm guarantee. OOO “IIC” also does not guarantee the technical characteristics of such details.
Erection of all foundations is carried out by the Client on the basic of agreed with OOO “IIC” of equipment layout. Basic equipment layout and foundation erection is developed by OOO “IIC” specialists, these works cost is included into main equipment cost and does not request additional costs from the Client. OOO “IIC” is not responsible for the improper foundation erection.

Noise-insulating and noise-protective mechanisms, dust-protective filters and so on – do not included into volume of delivery if it’s not mentioned in Specification.
Equipment is supplied without compressed air feeder, appropriate air supply is provided by the Client. All data regarding compressed air feeding are given by OOO “IIC” to the Client after order placing. Water heating equipment, included into standard set of ÏÁÇ-120À, are designed for keeping specified temperature. To provide necessary capacity the temperature of input water should be not lower then +10°Ñ.

Any claims, especially concerning compensations of any kind, including those, which are not connected with the volume of delivery or agreed guarantee obligations, are excepted. OOO “IIC”, particularly, is not responsible for the lost or for the less-receiving of profit.

Maintenance manuals are published in Russian. Translation of all documents can be done for additional payment.
Technical data, specified in the offer, such as power, current, water and air consumption, are approximate, but not guaranteed and should be specified while order placing.
The Client should comply with all safety techniques instructions and other local legislations.

Regarding purchasing of equipment contact marketing department
ÎÎÎ «Incorporated Industrial Company»
Russia, city Kaluga, Svetlaya St., 37

Tel. +7 4842 70 02 52,
+7 4842 70-04-92

Earth Block Compressed Interlocking Soil Stabilized Enviro-Bricks are Fireproof

Earth Block Compressed Interlocking Soil Stabilized Enviro-Bricks are Fireproof, Waterproof, Insect Proof, Sound Proof, Hurricane and Earthquake Resistant Utilizing Recycled Stabilized

Soil Earth Block Green Home Construction Technologies

Energy Efficient, Environmentally Friendly, Mother Nature Built, Sustainable Construction

Environmentally Friendly Enviro-Bricks and Earth-Brick Homes are your affordable option. The American dream of a brand new custom home is now within reach for the average home buyer. If you would like to have a home built, please consider our recyled environmental “Green” homes. As we enter the 21st century we are at the dawn of a New Environmental Revolution. Our mission is crystal clear: preserve our environment; mass recycling; reducing deforestation; energy conservation and ending pollution of our planet. Through a focused grass roots effort of word of mouth education, we can all help Mother Earth more effectively than has been done to date.

There are many environmentally focused businesses in the world, but few that offer what Enviro-Bricks does. With a totally recycled building system, “Green” has never been “Enviro-Brick Green”. One of the most severe situations in the world is affordable housing. Sadly, this is a worldwide problem and the U.S. is no exception in having an economical solution. Enviro-Bricks has the most advanced solution yet!

It was recently reported that only three in ten families can afford to live in California. This same sad scenario is true across the country, so what is the answer? Enviro-Bricks are an economical solution as we use low cost mobile manufacturing units which recycle fly ash and wood waste along with stabilized soil and convert it into a superior building brick called Enviro-Bricks. We also manufacture hardscape earth bricks for walls, landscaping, sound abatement and fire wall protection.

As most of us realize, the lowest mortgage rates in over forty years has helped, but it is not the only answer witnessed by the current low affordability factors nationwide. Most people are living paycheck to paycheck with little or nothing left at the end of a month to go towards saving for a down payment on a home. With the additional factor of new home prices rising up to 30% or more last year in some areas, what is a family to do?

We are an Environmental Construction Solutions Technologies company specializing in low cost road remediation and residential and commercial construction utilizing our low cost high quality Enviro-Bricks construction system. With millions of miles of roads crumbling in disrepair, combined with the need for affordable housing due to the ever increasing costs of cement and lumber, ECTS has the answer. Lumber prices have more than doubled in the past six months, so the need for affordable alternatives is growing daily.

Imagine converting any dirt road into a superior strength road surface at a fraction of the cost of cement or asphalt? Imagine recycling fly ash into new roads with our RP soil stabilization which will save millions on road remediation and construction for every municipality in every state nationwide? Combined with our breakthrough in recycled building and construction bricks that look like high quality fired bricks, we have the only viable environmental and economical solution available.

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With all these Enviro-Brick advantages, plus energy savings of up to 50% on heating and cooling, lower insurance costs with a fireproof and waterproof home, your overall savings can be significant. If these are not enough reasons to consider building with Enviro-Bricks, then think about stopping deforestation and cement manufacturing pollution worldwide. When you consider a “Green” home, why spend up to 20% more when you can save your hard earned “Green” with ECT.

The Principal Facts on The “R” Factor of Insulation as Applied in Earthen Construction Utilizing Compressed Stabilised Earth-Bricks as Energy Efficient Alternative

It has long been a documented that Adobe is a very good insulator in the form of housing bricks, this however is not in the technical sense of the word insulation. The actual insulating value of any material is based on the resistance to the transmission of heat or cold applied to one side of the wall to the other side. Heat always moves to cold, hence, mass has an impact on this rating system, but there is no factor used to calculate mass ratings and variables.

On the other hand, earth walls have a good heat storage capacity, which means when warm, they will stay warm for a considerable length of time. This is called the “flywheel” effect. In a real building application the interior temperature will usually be at an average of the high and low temperatures outside from several days earlier. This is termed the “thermal lag” effect. While the outdoor temperature may vary from 30NF to 40NF in a 24 hour period, the inside changes will vary only a few degrees. Thus, the temperature might be 90NF in the day and 60NF at night for several days. The inside of the buildings will approximate the average temperature of 75NF. This feels cool compared to the daytime 90NF. and warm to the night time 60NF. The comfort factor is high because this dampens the wide variations in the exterior temperatures.

As you can see, there is far more that can and does impact insulation factors other than just the R-Value. Unfortunately, there are no standardized tests to establish thermal mass factors to date, so one must understand this before they choose a material for their home solely on R-Values. Many factors must be considered, and one is the above average mean temperature from night to day. In extremes, this will be a major factor, in the above example it will indicate the value of mass.

As the material used in the manufacturing of Enviro-Bricks is variable depending on where, and what plans the bricks will be used for, the R-Value will be customized to areas needs and/or the codes. We use fly ash and cenospheres in combination with soils which produces a rather high insulation factor due to the fact that fly ash is a very fine particle size and fills the voids around soil to produce a very high density brick when compressed. Cenespheres are essentially ceramic vacuum air filled bubbles. As a vacuum is the best insulator, we can achieve very high R-Values, and combined with mass, and density, there is little concern about lack of insulation. We have also added sawdust to also raise the R-Value when available in place of, or in combination with our cenosphere additive. When you have high density using unlike materials of different thermal qualities, this reduces the thermal transfer time, which thereby equates to better energy efficiency. We also use cenospheres mixed with paint when additional insulation values are required under extremes.

The industry is finally accepting the influence thermal mass factor has on the R-Value, so we will soon see a new rating system, which will factor in these new scientific findings. It is my opinion that we will soon see a new rating system, which will prove that thermal mass is as important, if not more important than then R-Values. Earthen construction has higher thermal factors, and less insulation value, while stick and frame has no thermal value and a higher R-Value. It has been clearly demonstrated that the energy efficiency factors are similar with both building construction methods given the same weather factors and test conditions.

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