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 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

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

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

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

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