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.
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.
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.
– 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).
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.
|Gas concrete mixture preparation area:
|combined screw feeder;
|water-preparation unit (ÑÄÆÊ – 3ï);
|preparation and dosing of gasifier unit;
|automatic control system;
frame constructions, stairs and barriers
|Mechanized area of inter-staged transport:
|positional transporters (4 pieces);
|pushing transporters (6 pieces);
|overpassing trolleys (3 pieces).
|Blocks cutting area:
|“ÐÈÔ”-1 (2 sets)
|Cutting machine for bottom part of a massif (2 sets)
|Mould for “ÐÈÔ–1”;
|handling dolly – 200 pieces.
|removable mould – 45 pieces.
|Supply tank for cement 50 t (2 pieces)
|Supply tank for filler 50 t (2 pieces)
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.
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.
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.
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