About the company

In 1998 the OOO «Incorporated Industrial Company ” (OOO “IIC” for short)  was established in Kaluga city. Originally the enterprise specialized in developing and producing of non-standard equipment for food industry, in particular – automated lines, among them – batchers, mixers and drying lines for producing different food products. During its development OOO “IIC” made wider its development sphere. In 2002 the design-and-experimental department and laboratory were established to have possibility for starting scientific-and-production researches in porous concrete producing sphere on its own experimental-designing base.
OOO “IIC” specialists have done a great volume of investigative, designing and scientific-and-experimental work regarding creation modern technological lines and project of a  plant for producing different types of porous concrete. In the process. The were two main tendencies – creation of a plant with high capacity (up to 150 thousand m3  of products per year) with widened nomenclature of manufactured products and creation of specialized plants with low capacity (up to 30 thousand m3  of products per year). purposed for production of small wall blocks.
At the start period in 2002-2004 OOO “IIC” executed works in improving and automation of the technological process of porous concrete massifs (originally – foam concrete massifs) cutting. Serial production of automated cutting machines, which use cutting scheme wired strips (cutting machines ÓÐÊ-1, ÓÐÊ-2m, ÓÐÊ-3) was developed and adopted. These machines used new kinematic scheme for the drive of cutting modules lift-and-lower mechanism on the base of polyspasts for the first time in Russian practice. Before this case for analogous foreign and domestic equipment was commonly used and is used nowadays scheme with usage of more expensive and complicated in operation hydraulic drive, which needs hydraulic cylinders.
During following years permanent experimental-designing works took place as well as researches about conceptually new method of porous concrete raw-massifs cutting with usage of belt-saws of different types. After numerous  and extended experiments it became possible to find out optimal parameters of cutting mode and choose the most universal type of the belt-saw. As a result of great volume of executed works till the end of 2006 the unique cutting machine of a new generation was created for the first time ever in the world – automated belt-cutting  machine for porous concrete with electro-programming control – “ÐÈÔ-1”.
During 2004 OOO “IIC” specialists  created test samples of dozing-mixing modules for producing foam-concrete mixture$ these modules were tested on several enterprises of Russian Federation. After summation researches results principal changes in design of main units and equipment were brought in, the pilot project of a factory producing wall blocks with capacity 15 thousand m3 of products per year was worked out. As a result a new modern factory producing foam-concrete blocks was built in a small town Tovarkovo in Kaluga region. Development of equipment, technology? Automatization of technological process. Mounting and start-up of the factory were executed by OOO “IIC” specialists. Foreign firms were not involved into equipment supply. There was no necessity – as the cutting machine itself, dozing, forming and mixing equipment was designed by OOO “IIC”. Thanks to this approach the factory appeared to be much cheaper then foreign analogs, though the quality of manufactured products and technical and economic rates were not worse. The analogous factory was built started-up in the city Tuimazy in Bashkortostan Republic at the end of 2005.
After series of modifications a project of a factory with doubled capacity 30 thousand m3 of products per year was created in 2006. During that year the same factories was built in following cities: Ulan-Ude, Br’yansk and Safonovo. Due to successfully applied complex of technological decisions and chosen technological scheme of production process this project was in great demand among enterprises of building industry. In 2007 such factories were ordered to and installed in following cities: Apatity, Dolgoprudniy, Orenburg, Urkutsk, Penza, Minsk. Number of foreign companies also took interest in this factory project. Preproject works of supplying and installing factories to India are being carried out at the present time.
For a factory with capacity up to 30 thousand m3 of products per year about 0.4 hectare is enough to be located to. The factory is oriented for producing 26 thousand m3 of products out of not-cured foam concrete per year with three-shift work during 260 days. If increase the number of working days up to 300 – the factory productivity will be 30 thousand m3 of products per year. Technological scheme of the factory can be easily changed despondingly on type of used raw materials. The automated line for producing of not-cured massifs out of foam concrete ÏÁÇ-120À (PBZ-120A) is the factory basic.

The technological scheme of the foam-concrete mixture, which was developed by OOO “IIC” specialists, supposes, in the first place, applying of ready to usage of fine-dust filling materials, such as: limestone or marble powder, dust-loss from the power station, marshalite sands and so on. If to speak about usage of common natural mortar sands, our experience has shown their unfitness for producing foam concrete with reduced density (density type lower then D700) in majority of cases.

However, the main specific feature of developed technology is obligatory usage of certain set of  chemical substances and especially designed foaming agent, that allows to solve series of technological problems:

  1. exclude formation of foam concrete mixture fallouts;
  2. producing of  “hot” mixtures;
  3. reducing of time for getting necessary plastic strength of the moulded massifs;
  4. reducing of removable board equipment turnover cycle time;
  5. increasing of the strength characteristics of the final products
  6. cement saving.

A question about cement saving has recently arisen very sharply in close connection with breakthrough for cement. While progress in researches works, OOO “IIC” specialists  also searched of new low-power-consumption technologies of porous concrete production, using which it’s possible to reduce cement discharge till acceptable from economic point of view level – 150200 kg/m3. During searching works  the vibroimpact technology for producing not-cured gas concrete was chosen. After multiple laboratory experiments perspective types of raw materials were sorted out, ways of their preparation were specified, optimization of parameters and modes at different stages of raw materials preparation and making-up of gas concrete mixture was made. Simultaneously samples of necessary nonstandard equipment were manufactured. The principle of controlling vibroimpact with programming parameters of amplitude and frequency  was  assumed as a basis while designing vibroimpact foundation.
During second half-year 2007 experimental-industrial tests of a new technology were carried out in conditions of actually working production in the city Dolgoprudniy, Moscow region. Several pilot batches of small wall blocks made of not-cured gas-ashconcrete were produced. While they were preparing different parameters of mixture preparation were changed, complex of chemical and aerogenic additives and cement consumption was varied, the time for getting plastic, intermediate and final strength  was determined. The issue to find the minimum level of cement consumption while producing blocks with density type D600 with strength class B1,5 was set and solved while using cement ÏÖ500D0 190 kg/m3 from city Stariy Oskol.
Summing up results of all carried out tests, OOO “IIC” proceeds to designing of plant for producing cellular concrete wall blocks using vibroimpact gas concrete technology. ÏÁÇ120À line was taken as a basic.
During modernization process the design of dozing unit and mixer were greatly changed in essence. Besides this the unit for preparation of aluminium suspension and programmed vibroimpact platform.


Nomenclature of products and their physical-mechanical properties, which were achieved in real operating conditions and provided with received certificates of conformity you can see below:

Density type

Strength class

Nominal / Actual parameters mm
width  x  height  x  length

B 1.5
375 x 200 x 600
374 ± 1.5 x 198 ± 1 * 599 ± 3
B 1.2
B 2
300 ÷ 200 ÷ 600
299 ± 1.5 x 198 ± 1 * 599 ± 3
B 2
B 2,5
300 ÷ 188 ÷ 600
299 ± 1.5 x 198 ± 1 * 699 ± 3

Design thermal conduction factor ? at equilibrium moisture content 4-6 % for products with density type D500 is 0.11Wt/ (m *K).

Engineering metrics of products, produced with OOO “IIC” are represented in several certificates of Russian Federation. Wall cellular-concrete blocks are unique building material, which possesses as sufficient density, either good heat-insulating qualities. Such blocks are produced out of porous concrete of D500 density type, B1.5 compression strength class. Such strength is enough to construction of 2 floors high bearing walls. Massive and light wall blocks with width 375 mm allow to brick single-layer outside enclosing constructions which possess high level of thermal protection and low level of air permeability. At the same time, additional thermo-insulation is not necessary for them. Resistance to thermal transfer of such walls with finishing is equal Rtr=3.64 m2 kW. Blocks 300 mm width are commonly used in building of single-layer outside walls of public buildings and constructions. Resistance to thermal transfer of such walls with finishing is equal Rtr=2.89 m2 kW.

At present time OOO “IIC” team, having summed up long-term experience of designing and producing of special equipment , proceeds to work on the second tendency – creation of high automated factory with annual capacity of 150 thousand m3 of products, produced from cellular concrete using prospective vibroimpact gas concrete technology. Start-up of such factory is planned to take place already in 2008.

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