Automatic line for manufacturing of foam concrete blocks of not-cured solidification ÏÁÇ-120À

Brief characteristics

The full output – up to 120 ì3 of aerated concrete mixes a day.
Finished product – walling and laster blocks with average density mark D500-D700 with compressive resistance Â1,5-Â2,5 (GOST 21520-89). Dimension of the block in a standard complete set is 188?300?588. Installation of other dimensions is possible.
Massif volume – 0.85 ì3
Time of one massif filling – about 11 minutes.
Release time of massif until cutting – 4-8 hours.
Release time of the cut massif before packing – 8-16 hours.
Warehouse stock of cement – 50 t.
Warehouse stock of filling – 50 t.
The established capacity of the equipment – 20 kW + 45 kW water heating.
Consumption of water – 30t of water a day.
Consumption of air – 2500 l/hour.
Maintenance staff – 6 person (without a warehouse site).
Conditions of allocation – premises of workshop type at absence of an atmospheric precipitation and temperature not less than +5° C.
Raw material

Portland cement – in accordance with GOST 10178 (not containing additives of Tripoli powder, trass, loam, molding boxes, ashes), the recommended brand – ÏÖ 500 Ä0, application of Portland blast-furnance cement ØÏÖ 500 and ØÏÖ 400 after additional testing is possible.
Siliceous components:
– Ashes ablation of cogeneration plant containing Si O2 not less than 45 %, ÑaO not more than 10 %, R2O not more than 3 %, SO3 not more than 3 %;
– Granulated blast-furnace slag – GOST 3476 – it is required a grinding up to a specific surface depending on the required average density.
It is allowed to apply eliminations from crushing the nonmetallic materials, providing reception of foam concrete with set physicotechnical characteristics.
– Sand – in accordance with GOST 8736, containing SiO2 not less than 90 % or quartz not less than 75 %, mica no more than 0,5 %, oozy and argillaceous admixture not more than 3 %.
The base complete set of line ÏÁÇ – 120À is not designed for use of sand. For manufacturing of foam concrete with sand as filling, it is necessary to carry out consultations of experts of Limited Company “IIC” about delivery of the additional equipment.
Water in accordance with GOST 23732.
Besides chemical agents are applied to acceleration the structurization of plastic durability, solidification, etc., and also foam former manufactured by Limited Company “IIC”.

The description of technological process

Preparation and warehousing of raw material
Cement and milled inert filling from cement carriers with compressor installation are loaded into silos. The silo of cement and the silo of filling are located in immediate proximity from ÄÑÊ (dosing unit amalgamator of components).
From silos cement and filling move to dosing units bunkers by means of horizontal or combined screw conveyors. Dosing of dry and liquid components is carried out by means of the industrial processor.
Water through the system of pipelines is filled in special tanks ÑÄÆÊ-3Ï before the shift beginning. In a tank for foam former aperture the concentrate of foam former, and in a tank for chemical agents necessary reagents are added. Liquid components (the concrete chemical agents) are mixed up, lead up to the set temperature and under the program are dosed out in the amalgamator. Thus the concentrate of foam former automatically mixes up with air in special foam generator up to the set frequency rate and as technological foam moves into the amalgamator. For maintenance of productivity and economy of the electric power it is recommended to fill in ÑÄÆÊ – 3Ï with warm water (not below 10-12° Ñ).

Mixing of components
Mixing of all dry and liquid components occurs in several stages. On the central control panel the factory makes the control, processing and management of all important functions of installation over all sites of preparation of aerated concrete mixes. The operator in the real time mode of traces all processes of operation of installation. In case of need the operator in a short period of time can correct or change the current structure, time of mixing, a temperature mode and other technological parameters on the electronic panel of the main board or by means of a computer. Also the operator can transfer the operation of installation in semi-automatic or manual control mode.

Formation, cutting, transportation
The ready mix through the bottom mouth of the amalgamator is unloaded into the metal form. The form of a file will consist of two parts – the pallet and a demountable curb. The pallet represents the carriage on four steel wheels with the wooden basis projecting above a metal skeleton. The demountable curb will consist of two parts the “ã” -shaped form and in assembled state forms four sides, forming the massif. Before filling with aerated concrete mixes, the demountable curb is assembled, lubricated with a special solution or laid by an oiled paper and put on the pallet. For maintenance of tightness, joints of the form are glued by a special sealant. In order to prevent damages during transportation, the sealant is delivered separately from forms and pasted by the Customer.
After filling with aerated concrete mix, the form by means of the positional conveyor, is delivered to a place of ensembling of stripping strength. Time of ensembling of stripping strength depends on many factors (concrete structure, brand of cement, temperature, etc.) and changes from 4 up to 8 hours.
For maintenance of highly strengthening characteristics of a material it is very important to provide a rigid temperature mode at the moment of strength ensembling. Depending on used materials it is necessary to maintain temperature of 40-50° C the section before massif cutting (4-8 hours) and 60-90° C the section after massif cutting (up to 16 hours). More exact temperature schedule is established by the Customer in an operating mode according to the results of control supervision. For providing of conditions of a mode heat and humidity processing, it is recommended to the Customer to organize hotbed designs or stationary tunnel chambers.
At the expiration of the strength ensembling period the demountable curb is disassembled, the pallet with the massif moves to a cutting section. The curb is cleaned, assembled, oiled, and installed on the free pallet and moves to filling under ÄÑÊ.
The massif, which has gained necessary plastic strength, is captured by the special positional conveyor and moves for cutting. At the first stage by means of screw milling cutter the top is sheared off the massif (up to 5 mm). At the second and third stage cross and longitudinal massif cutting occurs. After that the massif cut into blocks is rolled to a pushing conveyor for submission into chambers of heat and humidity processing. There is an experience of the tested variant of the arrangement of such chambers as “thermos” with use of exothermal effect of reaction of cement hydration.
If the Customer uses sand or large screening as fillers, there is a probability of pilling of material with subsidence of larger particles on the massif bottom that can result massif undercut. In this case in the wooden basis of the pallet technological flutes are slitted for passing of cutting strings up to the metal skeleton.

After the stage of heat and humidity processing, the cut massif is rolled out on the carriage on disassembly. Blocks are stacked on shipping pallets, pulled together with a fastening-tape and with the help of transporting mechanisms move to warehouse platform or to warehouse. The further curing period of finished blocks at positive temperature is determined by the Customer and makes from one to two weeks. The released pallet is cleaned, interlaid with layer or with oiled paper and brought into filling zone.

Specification

Total: price of the plant, without custom registration and chief mounting:,
assembled with ÓÐÊ-3Ì – 7.326.000 rubles.
assembled with “ÐÈÔ-1” – 7.713.500 rubles.

Commercial conditions
Pricing: from a warehouse in Russia, Kaluga, not including price of customs registration and installation.
Terms of shipment: about 4 months from the moment of receipt of advance payment and the solving of all technical questions.
Payment: advance payment at the rate of 80 %, the rest of 20 % at the moment of availability of the equipment for shipment.

Chief mounting and putting into operation

The result of chief mounting and putting of the equipment into operation is considered to be “dry” trial start, commissioning and training of the Customer’s staff, manufacture of a trial lot of products with volumetric density of 600 kg / m3.
The density of 500êã/m3 is mastered after the certain term of operation, at the achievement of necessary professional skills of the staff and optimization of a mix structure by the Customer in his premises.
The same is for density of 400êã/m3 if quality of used materials allows.
Before putting of the equipment into operation the Customer should provide necessary raw material on the industrial platform.
By the moment of experts arrival for carrying out of chief mounting and putting of the equipment into operation it is very important that all the foundations are ready and fit the set sizes. The supply of a current and water should be carried out. It is necessary to have load-lifting mechanisms. All works on preparation of the premises and installation of auxiliaries should be finished. Works on preparation of a premise, assembling and installation of railway lines, filling of foundation and other building work are not related to installation. Those parts of the equipment which are provided by the Customer are not related to installation as well.
The staff which will operate the installation, should be on a platform during all term of installation and start-up of the equipment. The customer should provide electricians, mechanics and auxiliary staff for carrying out the installation works.
The customer additionally pays residence costs for specialists of Limited Company “ICC” in hotel, meals on the building site, transportation from hotel up to a place of installation and back, and also transport charges from Kaluga to a place of installation and back.

Technological works carried out by specialists of Limited Company “ICC”
The purpose, tasks, and initial data for execution phase:

Development of the documentation, training and improvement of the “know-how” of walling blocks of non-steam cured manufacture on line ÏÁÇ – 120À

Stages:
1. Development of offers by way of preparation of raw material.
2. Development of the technological, industrial and auxiliary documentation.
3. Improvement of the walling blocks “know-how” of non-steam cured foam concrete with density mark: D500, D600, D700, training of the working staff on line ÏÁÇ – 120À and acceptance of the executed work.

The basic requirements to results:
Technological process should provide manufacture of walling blocks non-steam cured foam concrete with technical characteristics, satisfying requirements of GOST 21520-89 and GOST 25485-89 by indicators of average density mark and a class of strength compression.

The list of the documentation presented after completion of works:
1. Offers on technological ways of preparation of walling materials.
2. Production schedules for designing of fine walling blocks manufacture on line ÏÁÇ – 120À with application of local raw materials.
3. Chart of technological process of manufacture.
4. Industrial instructions on worksite (dosing specialist, the carver, mill specialist the packer).
5. Blank forms for journal conducting (the entrance inspection, the current inspection, the outgoing inspection, log-books at worksite of dosing specialist, the carver, the mill specialist).
6. Selection of GOST and building regulations activities.
7. List of the necessary equipment for laboratory with addresses of suppliers.
8. Samples of the passport on finished goods.
9. Samples of documents on carrying out of inspection of the enterprise for certification of production.
10. Samples of documents for reception of sanitary – hygienic conclusion concerning manufacture environment.
The documentation is transferred in a printed form or on the electronic carrier in one copy.
Requirements on security:
The documentation and the information received while “know-how” adjustment and training of the technologist cannot be transferred to unauthorized persons.

Wiring and putting the electric equipment into operation
By the moment of wiring all parts of the equipment should be correctly installed, cable channels are ready and cleaned. All distributive cases should be installed. Input of the electric equipment is possible only at above-zero temperature in workshop (more than +5° Ñ).
For the period of carrying out of installation works and start-up of electric equipment the Customer is obliged to provide the electrician serving the installation in future and technical support staff..

Specifications
The necessary recipe of aerated concrete mixes is defined by the Supplier while putting the equipment into operation not on a basis of the analysis of test samples of a material provided by the Customer. The Customer carries out optimization of a compounding of a mix independently during manufacture on the basis of laboratory analyses and supervision. Specialists of Limited Company ” ICC ” render the advisory technological assistance for all period of operation of the equipment.

General conditions

The present commercial offer is based on standard conditions of Limited Company “ICC” on delivery, shipment, chief mounting and acceptance of the equipment in operation.
Machines and parts of installations are produced according to the Russian standards and instructions of the legislation.
The parts of installations which are not included into standard deliveries of Limited Company “ICC”, but belonging to standard equipping of Limited Company “ICC”, should meet technical standards for maintenance of faultless following operation of all installation as a whole. The guarantee of the given company is not applied to integral, but not produced by Limited Company “ICC” components. Limited Company “ICC” does not guarantee technical characteristics of such components.
Building of all foundations is carried out by the Customer on the basis of the circuits of placing of the equipment coordinated with Limited Company “ICC”. For inadequate building of foundations Limited Company “ICC” does not bear the responsibility.
Noise insulations and acoustic protection devices, dustproof filters, etc. are not included into standard delivery if they are not declared in the specification additionally.
The equipment is delivered without the device of compressed air supply, the appropriate supply with the compressed air is provided with the Customer. All data concerning supply by the compressed air is provided by Limited Company “ICC” after placement of the order. The water heating devices delivered in standard complete set ÏÁÇ-120 À, are designed for maintenance of the set temperature. For maintenance of necessary productivity the temperature of supplied water should be not less than +10° C.
Any claims, in particular, connected with consumption of losses of any kind, including those, not connected with standard delivery volume or with the stipulated guarantee certificates are excluded. In particular, Limited Company “ICC” does not bear the responsibility for the missed benefit or the half-received profit.
Operation manuals are issued in Russian. All translations into other languages can be provided at additional expense.
The engineering data specified in the offer such as, for example, capacity, the charge of a current, air and water, are approximate, but not guaranteed and should be stipulated while placing the order.
Observance of all instructions concerning the safety precautions and other local normative documents is assigned to the Customer.
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