Production of wall blocks, from non-autoclaved aerated concrete using progressing vibration-impact technology.
For the first time in the world of production of aerated concrete products at OPK, a technological scheme of production for the consolidation of the best domestic(Russian) developments in formation of aerated concrete mixture through vibration and not having analogue among foreign technology for tape type blade cutting of raw massive on the platform of new generation with fast-programmable settings for getting almost any given size of building blocks.
Due to use of a vibration technology, the given technological scheme of production provides: reduction of cement consumption to 150 - 200 kg/1m3 of finished products (using TPP ash and blast furnace slag), decrease in resultant humidity of concrete and shortening the period for finishing product massive before cutting it to the blocks of specified dimensions that significantly reduces the required metal equipment. In addition, the introduction of vibration technology and automated process control of concrete mixture proportioning can produce aerated product in bulk with density of 350-700 kg/m3 to ensure high physical and technical characteristics of the finished products of domestic and international standards. Cutting complex RIF -1 followed by cutting of massive into blocks of specified dimensions with an accuracy of + / -1 - 1,5 mm can be achieved in these building blocks, which makes possible to use masonry adhesive in the construction of not more than 3 mm seam thickness. In this nomenclature of types and sizes of blocks will increase from 27 to 340 that meet the diverse requirements of customers. Rational use of domestic and highly reliable automated imported equipment can significantly reduce the complexity of manufacturing operations and saves energy.
Brief characteristics equipment for autoclaved concrete production
Maximum output- up to 200 m3 of finish goods/day.
Finish products – walling and partition blocks with the average density mark Д500-Д700 with compressive strength В1,5-В3,5 (GOST 21520-89).
Dimensions of a block in a standard complete set is 198x295x598.
Installation of other dimensions is possible.
Massif volume - 1 m3.
Time of one massif filling - about 7 minutes.
Release time for the massif - 3 - 4 hours.
Release time for the cut massif before packing – 12-16 hours.
Established capacity of the equipment - 120kw.
Consumption of water - 60 t/day.
Maintenance staff - 6 persons (without a warehouse site).
Conditions of allocation – premise of shop type at absence of an atmospheric precipitation and temperature not lower than +50С.
The area of workshop not less than 2500м2.
Height in a filling zone is 7,5м.
Height of the rest of the premise not less 3,5м.
Formation, cutting, transportation
Ready mixture through lower neck of mixer is uploaded into metal form. The massif's form consists of two parts: pallet and movable curb. Before filing in with concrete mixture the movable curb is assembled, greased with special oil or interlaid with oily paper and installed on the pallet. After vibroimpact processing the mould filled with concrete mixture is transported to stripping durability. Its period depends on many factors (concrete structure, mark of cement, type of filling material etc) and varies from 3 to 5 hours. In order to assure high strength of the material it is obligatory to obtain temperature regime. Depending on materials used the temperature of 40-500С should be provided at site before massif's cutting (3-4 hours). When the desired strength is achieved the movable curb is disassembled and the pallet with the massif on it moves to the cutting site. The movable curb is being cleaned, greased, installed on the free pallet and moved to filling site to the mixer.
Massif gained the plastic strength is caught by special positioning transporter and moves for cutting. At first the top of the massif (up to 5 mm) and its bottom are being cut out at band-saw machine. Then transverse and longitude cutting into blocks takes place on cutting machine REEF-1. Afterwards the massif cut into blocks is moved into autoclave. After autoclave the cut massif is moved for disassembling. The blocks are laid on transportation pallets, tied up with tape and moved to the warehouse by forklifts. The released pallet is cleaned up, covered with plastic or oil paper and moved back to filling site.
Wiring and installation of electric equipment
By the moment of electric equipment installation all the parts of plant should be properly installed, cabling should be clean and ready. All the cabling distribution cabinets should be at place. The electrical equipment installation is possible only at positive temperature at shop floor (higher than +50С). For the period of electrical equipment works the Customer should provide an electrician, who will maintain the equipment in future, as well as indirect workers.
Installation works and start-up
The result of installation and start-up works considers "dry" trial start, going into operation and training of Customer's staff, production of a trial lot of items with bulk density of 600 kg/m3.Density of 500kg/m3 is gained after certain period of operation after reaching the relevant professional skills by operators and optimization of mixing ratio by the Customer at site. Similar to density of 400kg/m3, if the quality of used raw materials allows.Before going into operation the Customer is obliged to provide the raw materials needed at production site.Before installation and start-up team arrives it is important to make sure that all the industrial platforms are ready and correspond to dimensions set. The water and current application should be provided. It is necessary to have all the elevating mechanisms available. All operations on site preparation and auxiliary equipment installation should be terminated. Installation and start up process does not include preparation of the site, assembly and installation of railways, or any construction works. The parts provided by the Customer are not included into installation as well.Staff which will work at equipment should be at site during all the period of installation and start-up work. The Customer should provide electricians, mechanics and indirect staff.The Customer provides the specialists of OPK company with accommodation, transportation to/from the site for the whole period of installation works. The period of installation and start-up works makes one month.
Installation and start-up works are negotiated separately based on object destination and their cost makes from 10 to 20% of the total cost of equipment.