The multifunctional concrete mixing complex is equipped with six concrete mixers SICOMA of different volumes with a total productivity of 360 cubic meters of concrete per hour. To prepare a mixture, a strain gauge sensor is used as a weighing instrument, the signal from which through software logic controller SIEMENS processed in a fraction of seconds and issues commands to perform actions actuators(motors, sector valves, shut-off valves with drive). As a result, the dosing bins receive required amount materials calculated in the laboratory. The process of collecting materials is controlled automatically. Mixers are equipped with mixing optimization options concrete mixture. Concrete can be supplied from the concrete mixing complex to seven stationary stations. The plant's own concrete mixing complex fully meets the needs for the production of commercial mixtures and reinforced concrete products.
FBS block manufacturing workshop
DSK Kolovrat has self-propelled forming machines for vibratory pressing of FBS type blocks. Blocks can be produced in a short time in large quantities nomenclature provided for by GOST 13579-78.
formless molding lines
On long stands formless molding lines from TECNOSPAN prestressed reinforced concrete products are manufactured. Today this is the most progressive molding method. It is important that the use of formless technologies improves the environmental performance of the enterprise by approximately an order of magnitude (noise, dust content, etc. are reduced) compared to aggregate production lines. We produce hollow core slabs, piles, columns, crossbars, beams, lintels. All products have a mandatory state Certificate and comply with GOST standards.
technical laboratory
The material is checked for compliance with standards and product quality control is carried out by our laboratory, equipped with high-quality European equipment. Quality control is carried out at all stages - from incoming control of materials to shipment of finished products to the consumer.
Production of a wide range of reinforced concrete products using the formless molding method on long stands
The production of hollow-core flooring slabs, piles, columns, crossbars, beams, lintels, airfield slabs (PAGs), side stones, and fence sections has been mastered on the formless molding lines (LBF). All products undergo design and documentary study in leading specialized design organizations countries.
Patented unique technology production road slabs in full compliance with relevant GOST standards. We are working on documentation for the production of power transmission poles.
The development, production and supply of equipment for formless molding of reinforced concrete products on long stands is one of the priority areas of activity.
Product range
Performance
Formless molding line ST 1500
(6 tracks of 90 meters each, product width - up to 1500 mm)
| Product type | Unit measurements | Performance | ||
| per day | per month | per year (250 days) | ||
| Floor slabs width 1500 mm, height 220 mm |
Linear meters | 540 | 11 340 | 136 000 |
| M 3 | 178 | 3 738 | 44 856 | |
| Floor slab width 1200 mm, height 220mm |
Linear meters | 540 | 11 340 | 136 000 |
| M 3 | 142 | 2 982 | 35 784 | |
| Piles 300 mm x 300 mm |
Linear meters | 2 160 | 45 360 | 544 320 |
| M 3 | 194 | 4 074 | 48 900 | |
| Crossbars 310 mm x 250 mm |
Linear meters | 2 160 | 45 360 | 544 320 |
| M 3 | 194 | 4 074 | 48 900 | |
| Crossbars 400mm x 250mm |
Linear meters | 1 620 | 34 020 | 408 240 |
| M 3 | 162 | 3 402 | 40 824 | |
In total, more than 30 standard sizes of products.
Note: When changing the number, width and length of tracks, performance changes.
Specifications
| Characteristic | LBF-1500 |
| Installed power (minimum), kW *depending on configuration |
200 * |
| Overall dimensions of the workshop (minimum), m | 18 x 90 |
| Height up to the crane's main hook, m | 6 |
| Lifting equipment | |
| Number of overhead cranes, pcs. | 2 |
| Load capacity overhead crane not less, tons | 10 |
Service staff
The number of service personnel is given for one shift
| № | the name of the operation | Number of workers, people |
| 1. | Cleaning and lubricating the path, laying out wire with tension, covering with a protective coating, transferring tension to concrete, removing finished products to the warehouse | 3 |
| 2. | Molding, washing the molding machine | 2 |
| 3. | Cutting | 1 |
| 4. | Overhead crane operation control | 2 |
| Total | 8 | |
Brief description and operating principle
The technological process begins with cleaning one of the molding tracks with a specialized track cleaning machine and spraying lubricant onto it in the form of a fine air dispersion. The average cleaning speed using a special machine is 6 m/min. Cleaning time – 15 minutes. The track is lubricated immediately after cleaning using a backpack pump.
Cleaning and lubricating the track
After this, using a wire laying machine, the reinforcement is unwound from the reels and laid out on the track.
After laying out the required amount of wire (in accordance with the album of working drawings), it is tensioned using a hydraulic tension group. The ends of the wire are fixed in the spinneret holes of the stops using collet clamps. The ends of the wire are cut off with a manual cutting machine and covered with a protective casing, after which the track is ready for shaping. On average, it takes no more than 70 minutes to lay out the reinforcing wire, taking into account the time for threading, upsetting the heads, trimming the ends and tensioning the wire.
Using an overhead crane (with a lifting capacity of at least 10 tons), the forming machine is installed on the rails of the forming track behind the stops at the beginning of the track. The power cable is unwound from the hydraulic cable drum and powered from the workshop 380 V network. The traction cable is unwound from the machine’s traction winch and secured to the anchor at the end of the track.
The ready-made concrete mixture is supplied to the storage hopper of the molding machine using a concrete supply container and an overhead crane. The traction winch and vibrators are turned on. For continuous process When the track is formed, the concrete mixture is supplied to the storage hopper in a timely manner. Average speed of the molding machine during production hollow core slabs– 1.5 m/min; Taking into account the time for installing the machine, we accept 90 minutes. After completing the formation of one track, the forming machine is installed by crane on the washing station and thoroughly washed with the installation high pressure for washing cars from concrete mixture residues. Track with a strip of molded product using a laying trolley protective coating cover with a special covering material and leave for the duration of the heat treatment process.
Heat treatment
The heat treatment process follows the following scheme: 2 hours raising the temperature to 60-65˚C, 8 hours holding, 6 hours cooling.
After the concrete reaches the transfer strength of the product, the covering material is removed, and the tape is examined by factory laboratory workers, who mark the tape into segments of the designed length for subsequent cutting.
After this, a hydraulic stress-relieving unit from 3 cylinders produces a smooth release and transfers the tensile force of the reinforcement to the concrete of the product. Then the reinforcement is cut, this is done using a manual hydraulic group and takes, taking into account the time it takes to install it into working position, no more than 10 minutes.
The cutting of the tape is carried out by a special cross-cutting machine equipped with a high-strength diamond-coated cutting disc.
The cutting machine is installed by crane on the rails at the beginning of the track. The power cable is unwinded from the hydraulic drum and powered from the workshop 380 V network. The required amount of water is poured into the tank. Cutting is carried out by the cutting machine operator in manual or automatic mode. The duration of cutting a hollow core slab with a diamond-coated cutting disc is about 2 minutes. We accept effective length 6mm slabs, from here we get 14 cuts, time for cutting slabs on one path is about 30 minutes; together with the operation of installing the machine and moving it, we take 70 minutes.
The finished slabs are placed on a load trolley by an overhead crane using a technological gripper for transporting the slabs and transported to the finished product warehouse. Side surfaces slabs are marked by quality control department employees in accordance with the established procedure.
After forming each track, the machine is installed on a stand, after which the forming machine and the punch - matrix are obligatory washed. Washing is carried out with a stream of water under a pressure of 180 - 200 atmospheres. This operation takes about 20 minutes.
Washing the forming machine
Price
- Technological equipment – from 25 million rubles (depending on configuration)
- Equipment for technological floors – from 8 million rubles (depending on the configuration)
- Services (installation, commissioning - from 5 million rubles (depending on the scope of work).
The cost specifications on this website are provided for reference purposes.
The commercial offer is presented to the Customer during the negotiation process and is valid for 30 days from the date of its issuance.
You can see the example
Other conditions
The warranty period is 12 months.
OJSC “345 Mechanical Plant” offers to organize a free visit of our specialists to coordinate the placement of LBF-1500 at the Customer’s site.
Other conditions are agreed upon upon conclusion of the contract.
4./2011 VESTNIK _7/202J_MGSU
MODERN TECHNOLOGICAL LINES FOR PRODUCTION OF FLOOR PLATES
MODERN PROCESS LINES FOR THE FLOOR SLABS PRODUCTION
E.C. Romanova, P.D. Kapyrin
E.S. Romanova, P.D. Kapyrin
State Educational Institution of Higher Professional Education MGSU
The article discusses modern technological lines for the production of floor slabs using the formless molding method. The technological process, the composition of the line are analyzed, and the characteristics of the equipment used are indicated.
In the current article the modern process lines for off-formwork slabs production is under investigation. The whole technological process is examined as well as lines composition. The characteristics and qualities of the used equipment are mentioned.
Currently, the key to the success of an enterprise producing concrete products is the production of a wide range of products. Consequently, a modern enterprise, plant, plant needs automated production lines, easily reconfigurable equipment, universal machines, application of energy-saving and energy-efficient technologies.
Technologies for the production of reinforced concrete products and structures can be divided into traditional (conveyor, aggregate-flow, cassette) and modern, among which continuous formless molding occupies a special place.
Formless molding as a technology was developed during Soviet Union and was called “combine-flooring technology”. Today the technology is in demand in Russia; with each operating experience, it is improved by our specialists, while the experience of foreign companies is used.
The technological process of the formless molding method is as follows: products are molded on a heated metal floor (about 60°C), reinforced with pre-stressed high-strength wire or strands, the molding machine moves along rails, leaving behind a continuous strip of molded reinforced concrete.
There are three known methods of continuous formless molding: vibration pressing, extrusion and compaction.
Tamping method
The essence of the compaction method is as follows: the forming machine moves on rails, while the concrete mixture in the forming installation is compacted with special hammers. In Fig. 1 shows a diagram of a forming installation for continuous tamping.
Rice. 1 Diagram of a forming installation for continuous molding using the ramming method
The bottom layer of the concrete mixture is placed on the molding tracks from hopper 1 and compacted with a high-frequency vibration compactor 3. The top layer of the concrete mixture is supplied from hopper 2 and is also compacted with a high-frequency compactor 6. Additionally, the surface of the slab is compacted with a shock-vibration tamper. After both surface compactors, stabilizing plates 4 are installed to improve compaction of the concrete mixture. The method is not widely used, since the installation is extremely complex both in operation and maintenance.
Extrusion method
The technological process consists of several successive stages:
1. First, a special track cleaning machine cleans the metal coating, and then lubricates the tracks with oil.
2. The reinforcing ropes that are used for reinforcement are stretched, creating tension.
3. Then the movement of extruder 1 begins (Fig. 2), which leaves behind a strip of molded reinforced concrete 2 (Fig. 2).
Rice. 2 Extruder
4/2011 VESTNIK _4/2011_MGSU
The concrete mixture in the auger extruder is pumped through the holes of the forming equipment in the direction opposite to the movement of the machine. Forming proceeds horizontally, and the forming machine seems to push away from finished product. This ensures uniform compaction in height, making extrusion indispensable when molding large-sized products with a height of more than 500 mm.
4. Then the product undergoes heat treatment - covered thermal insulation material, and the stand itself is heated from below.
5. After the concrete has gained the required strength, the slab is cut to the designed length with a diamond saw with a laser sight, having previously relieved the stress.
6. After sawing, the hollow core slabs are removed from the production line using lifting grips.
The technology makes it possible to produce slabs that are 5-10% lighter than traditional ones. The high compaction of the concrete mixture provided by the augers makes it possible to save about 20 kg of cement per cubic meter of the mixture.
In addition to its advantages, the technology has significant disadvantages:
Operating costs are high. Hard concrete mix is abrasive, which causes wear on the augers
Extrusion equipment is designed for cement and inert materials only of the highest quality (usually M500 grade)
Limited range of products. Extrusion is not intended for molding beams, columns, crossbars, pillars and other small cross-section products.
Vibrocompression method
The vibration pressing method is optimal for the manufacture of any products with a height of no more than 500 mm. The forming machine is equipped with vibrators to compact the concrete mixture. It is reliable and durable, does not contain wearing parts. The range of manufactured products is varied; hollow core flooring slabs, ribbed slabs, beams, crossbars, pillars, lowering piles, lintels, etc. are equally successfully produced. An important advantage of the molding machine is its unpretentiousness to the quality of raw materials and the associated cost-effectiveness. High quality products are achieved by using grade 400 cement, sand and crushed stone of medium quality.
Let's consider modern complex formless production of hollow-core floor slabs (Fig. 3) and describe in detail the technological process.
The production cycle of formless molding contains the following operations: cleaning and lubricating the molding track, laying out reinforcement, tensioning reinforcement, preparing a concrete mixture, molding products, heat treatment, relieving stress from reinforcement, cutting products into pieces of a given length, and exporting finished products.
The complex includes:
Industrial flooring
Slipformer
Concrete aspirator
Multifunctional trolley
Automatic plotter (marking device)
Universal sawing machine
Saw for fresh concrete
Rice. 3 Technological line for the production of prestressed hollow core slabs
Technical characteristics and advantages of manufactured products:
1. High strength characteristics.
2. High accuracy of overall dimensions.
4. Possibility of manufacturing various standard sizes along the length with any pitch.
5. Possibility of producing oblique ends of products (it is possible to make cuts at any angle).
6. The possibility of forming holes in the ceilings for the passage of ventilation and sanitary blocks through the use of shortened slabs, as well as making these holes standard width and position in plan when molding products.
7. Production technology ensures strict adherence to specified geometric parameters.
8. Calculated evenly distributed load excluding own weight for the entire range from 400 to 2000 kgf/m2.
Product range
Table 1
Floor slabs 1197 mm wide
Thickness, mm Length, m Weight, kg
120 mm From 2.1 to 6.3 From 565 TO 1700
From 1.8 to 9.6
From 705 to 3790
From 2850 to 5700
Floor slabs 1497 mm wide
From 1.8 to 9.6
From 940 to 5000
From 3700 to 7400
From 7.2 to 14
From 5280 to 10260
Short description and equipment characteristics
1. Industrial flooring (Fig. 4)
Rice. 4 Construction of the technological floor: 1 - threaded rod; 2 - base (foundation); 3 - channel; 4 - reinforcement mesh; 5 - metal-plastic pipe for heating; 6 - concrete screed; 7 - insulation and concrete screed; 8 - metal sheet covering
Concrete base under the technological floor should be perfectly level and have a slight slope to the side sewer drain. The floor is heated by an electric cable or hot water up to a temperature of +60°C. For enterprises that have their own boiler house, it is more profitable to use water heating. In addition, with water heating, the floor heats up faster. A technological floor is a complex engineering structure that must withstand the weight of molded reinforced concrete products. Therefore the thickness metal sheet is 12-14 mm. Due to thermal changes in the length of the metal sheet (up to 10 cm on a hundred-meter track), the sheet is fixed with metal plates with a millimeter gap. Preparation and welding of metal sheets should be carried out at top level, since the cleaner the surface of the sheet is processed, the smoother the ceiling surface of the slab.
2. Slipformer (Fig. 5)
Rice. 5 Slipformer
Forming machine - Slipformer (w=6200kg) - designed for manufacturing hollow slabs. The car is equipped with everything necessary equipment, including accessories such as, electrical cables, cable drum, water container and smoothing device for the top surface - finisher.
Required thickness slab is achieved by replacing the pipe-formwork kit (replacement takes about 1 hour). The electro-hydraulic control of the machine is designed for the work of one operator.
The machine is equipped with four electric drive wheels and a variator, which provides a variety of travel and forming speeds depending on the type of floor slab being manufactured and the concrete mixture used. Typically the speed varies from 1.2 to 1.9 m/min.
The machine is equipped with one stationary front and one hydraulic rear receiving hoppers for concrete mixture. It also features two vibrators with adjustable power. The machine has one hydraulically driven cable drum complete with electric cable (maximum length 220 m). The finisher is equipped with a mounting device and electrical connection.
The pipe-formwork kit is equipped with a hydraulic drive; the side formwork elements are suspended, which ensures good adhesion to the guides. Concrete is fed through a double hopper with two controlled outlets
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manually (the volume of concrete for each socket is 2 cubic meters). There is one galvanized water tank.
The machine is adjusted according to the type of concrete available at the plant.
3. Concrete aspirator (Fig. 6)
Rice. 6 Concrete aspirator
The aspirator is designed to remove uncured (fresh) concrete (w=5000kg, 6000x1820x2840) and is used for cutting profiles in slabs and making slabs with protruding reinforcement. The aspirator can also be used to clean the floor along the guides, as well as between production stands. The electric drive has two forward speeds and two reverse speeds. Low speed is 6.6 m/min, high speed is 42 m/min.
The aspirator includes:
1. One built-in filter and filter housing including:
Filtering surface area of 10 m2
Polyester needle and felt filter with microporous water- and oil-repellent outer layer
Automatic valve that changes bag filters by blowing air every 18 seconds
Waste container under the filter
Concrete separator located in front of the outlet.
2. Suction device in a noise-insulating housing. Maximum air supply - 36 kPa, motor 11 kW.
3. Centrifugal pump and one additional tank for water nozzle.
4. One galvanized water tank with a capacity of 500 liters.
Suction nozzle with built-in manually operated water nozzle and
A spring balancing device attached to the cross member allows for transverse and longitudinal movement. Waste container with a capacity of 1090 l. equipped with two pneumatic sealing valves. The container has a hook that makes it easier to lift, as well as a device for cleaning the container by lifting it. The height-adjustable working platform is designed for cleaning the guides. The aspirator has an eye hook, air compressor with a capacity of 50 liters, electric switch and a control unit with the ability to install up to 4 remote controls.
4. Multifunctional trolley (Fig. 7)
Rice. 7 Multifunctional trolley
The trolley (w=2450kg, 3237x1646x2506) runs on battery power and performs the following three functions:
1. Stretching reinforcing ropes and wires along production stands
2. Lubrication of production stands
3. Cleaning of production stands
The machine is equipped with: an anchor plate for fastening cables and fittings, a scraper for cleaning production stands, a spray bottle for applying a lubricant, and a hand brake.
5. Automatic plotter (marking device) (Fig. 8)
Rice. 8 Plotter
The plotter (w = 600 kg, 1600x1750x1220) is designed for automatically marking slabs and drawing drawings on them according to any geometric data made in the EXG format (working speed 24 m/min), for example, cutting angle, cut-out areas and project identification number. The plotter control panel is touch-sensitive. Plate data can be transferred to the plotter using any wearable device -
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for or through a wireless network connection. A laser is used for measurements with an accuracy of ±1 mm.
6. Universal sawing machine (Fig. 9)
Rice. 9 Universal sawing machine
This sawing machine (w=7500kg, 5100x1880x2320) allows you to saw hardened slabs of the required length and at any angle. The machine uses 900-1300 mm discs with diamond cutting edge; discs are designed for sawing slabs with maximum thickness 500 mm. The machine speed is 0-40 m/min. Sawing speed 0-3 m/min, various adjustments available. The cutting speed is set automatically by economically adjusting the power of the saw motor. Cooling water is supplied at a rate of 60 liters per minute. Cutting disc cooled on both sides by jets controlled by a pressure and flow sensor installed in the water supply system. The front nozzles can be easily rotated for quick saw blade changes. The cutting speed is adjustable for optimal performance of the operation.
The sawing machine has the following characteristics:
1. Electric motors for precise movement.
2. The sawing machine is fully automatic.
3. The operator only needs to enter the cutting angle.
4. Manual positioning is performed using a laser beam.
7. Saw for fresh concrete (Fig. 10)
Rice. 10 Saw for fresh concrete
Manually operated saw (m= 650 kg, 2240x1932x1622) for longitudinal cutting of freshly laid concrete mixture to produce slabs of non-standard width, different from those specified in the molding machine. The maximum slab height is 500 mm. Saw blade It has electric drive. To save money, the used diamond blade (1100-1300) can be recycled. Positioning and movement of the machine is carried out manually. The saw moves along the stand on rollers and is supplied with power via a cable.
Using this technological process allows:
Provide increased bearing capacity floor slabs (since the reinforcement is carried out using prestressed reinforcement)
Ensure high flatness of the top surface by forcefully smoothing the surface of the slabs
Ensure strict adherence to the specified geometric parameters
Produce slabs with high strength characteristics due to forced compaction of the lower and upper layers of concrete, etc.
We examined modern technological lines for the production of floor slabs. These technologies meet most of the requirements for modern production Concrete products Therefore, they are promising, i.e. their use allows enterprises of efficiency, reinforced concrete, etc. be competitive and fully satisfy customer needs.
Literature
1. Utkin V.L. New technologies in the construction industry. - M.: Russian Publishing House, 2004. - 116 p.
2. http://www.echo-engineering.net/ - equipment manufacturer (Belgium)
3. A. A. Borshchevsky, A. S. Ilyin; Mechanical equipment for production building materials and products. Textbook for universities on special. “The production is building. ed. and structures." - M: Alliance Publishing House, 2009. - 368 pp.: ill.
1. Utkin V. L. New technologies of the building industry. - M: the Russian publishing house, 2004. - 116 with.
2. http://www.echo-engineering.net/ - the manufacturer of the equipment (Belgium)
3. A.A.Borschevsky, A.S.Ilyin; the Mechanical equipment for manufacture of building materials and products. The textbook for high schools on “Pr-in builds. ed. And designs". Publishing house the Alliance, 2009. - 368c.: silt.
Key words: floors, molding, technologies, formwork, equipment, technological lines, slabs
Keywords: overlapping, formation, technologies, a timbering, the equipment, technological lines, plates
Article presented Editorial Board"Vestnik MGSU"
4./2011 VESTNIK _7/202J_MGSU
MODERN TECHNOLOGICAL LINES FOR PRODUCTION OF FLOOR PLATES
MODERN PROCESS LINES FOR THE FLOOR SLABS PRODUCTION
E.C. Romanova, P.D. Kapyrin
E.S. Romanova, P.D. Kapyrin
State Educational Institution of Higher Professional Education MGSU
The article discusses modern technological lines for the production of floor slabs using the formless molding method. The technological process, the composition of the line are analyzed, and the characteristics of the equipment used are indicated.
In the current article the modern process lines for off-formwork slabs production is under investigation. The whole technological process is examined as well as lines composition. The characteristics and qualities of the used equipment are mentioned.
Currently, the key to the success of an enterprise producing concrete products is the production of a wide range of products. Consequently, a modern enterprise, plant, plant needs automated technological lines, easily reconfigurable equipment, universal machines, and the use of energy-saving and energy-efficient technologies.
Technologies for the production of reinforced concrete products and structures can be divided into traditional (conveyor, aggregate-flow, cassette) and modern, among which continuous formless molding occupies a special place.
Formless forming as a technology was developed during the Soviet Union and was called “combine-deck technology.” Today the technology is in demand in Russia; with each operating experience, it is improved by our specialists, while the experience of foreign companies is used.
The technological process of the formless molding method is as follows: products are molded on a heated metal floor (about 60°C), reinforced with pre-stressed high-strength wire or strands, the molding machine moves along rails, leaving behind a continuous strip of molded reinforced concrete.
There are three known methods of continuous formless molding: vibration pressing, extrusion and compaction.
Tamping method
The essence of the compaction method is as follows: the forming machine moves on rails, while the concrete mixture in the forming installation is compacted with special hammers. In Fig. 1 shows a diagram of a forming installation for continuous tamping.
Rice. 1 Diagram of a forming installation for continuous molding using the ramming method
The bottom layer of the concrete mixture is placed on the molding tracks from hopper 1 and compacted with a high-frequency vibration compactor 3. The top layer of the concrete mixture is supplied from hopper 2 and is also compacted with a high-frequency compactor 6. Additionally, the surface of the slab is compacted with a shock-vibration tamper. After both surface compactors, stabilizing plates 4 are installed to improve compaction of the concrete mixture. The method is not widely used, since the installation is extremely complex both in operation and maintenance.
Extrusion method
The technological process consists of several successive stages:
1. First, a special track cleaning machine cleans the metal coating, and then lubricates the tracks with oil.
2. The reinforcing ropes that are used for reinforcement are stretched, creating tension.
3. Then the movement of extruder 1 begins (Fig. 2), which leaves behind a strip of molded reinforced concrete 2 (Fig. 2).
Rice. 2 Extruder
4/2011 VESTNIK _4/2011_MGSU
The concrete mixture in the auger extruder is pumped through the holes of the forming equipment in the direction opposite to the movement of the machine. Molding proceeds horizontally, and the molding machine seems to push away from the finished product. This ensures uniform compaction in height, making extrusion indispensable when molding large-sized products with a height of more than 500 mm.
4. Then the product undergoes heat treatment - it is covered with heat-insulating material, and the stand itself is heated from below.
5. After the concrete has gained the required strength, the slab is cut to the designed length with a diamond saw with a laser sight, having previously relieved the stress.
6. After sawing, the hollow core slabs are removed from the production line using lifting grips.
The technology makes it possible to produce slabs that are 5-10% lighter than traditional ones. The high compaction of the concrete mixture provided by the augers makes it possible to save about 20 kg of cement per cubic meter of the mixture.
In addition to its advantages, the technology has significant disadvantages:
Operating costs are high. Hard concrete mix is abrasive, which causes wear on the augers
Extrusion equipment is designed for cement and inert materials only of the highest quality (usually M500 grade)
Limited range of products. Extrusion is not intended for molding beams, columns, crossbars, pillars and other small cross-section products.
Vibrocompression method
The vibration pressing method is optimal for the manufacture of any products with a height of no more than 500 mm. The forming machine is equipped with vibrators to compact the concrete mixture. It is reliable and durable, does not contain wearing parts. The range of manufactured products is varied; hollow core flooring slabs, ribbed slabs, beams, crossbars, pillars, lowering piles, lintels, etc. are equally successfully produced. An important advantage of the molding machine is its unpretentiousness to the quality of raw materials and the associated cost-effectiveness. High quality products are achieved by using grade 400 cement, sand and crushed stone of medium quality.
Let us consider a modern complex for the formless production of hollow-core floor slabs (Fig. 3) and describe in detail the technological process.
The production cycle of formless molding contains the following operations: cleaning and lubricating the molding track, laying out reinforcement, tensioning reinforcement, preparing a concrete mixture, molding products, heat treatment, relieving stress from reinforcement, cutting products into pieces of a given length, and exporting finished products.
The complex includes:
Industrial flooring
Slipformer
Concrete aspirator
Multifunctional trolley
Automatic plotter (marking device)
Universal sawing machine
Fresh concrete saw
Rice. 3 Technological line for the production of prestressed hollow core slabs
Technical characteristics and advantages of manufactured products:
1. High strength characteristics.
2. High accuracy of overall dimensions.
4. Possibility of manufacturing various standard sizes along the length with any pitch.
5. Possibility of producing oblique ends of products (it is possible to make cuts at any angle).
6. The possibility of forming holes in the ceilings for the passage of ventilation and sanitary blocks through the use of shortened slabs, as well as making these holes of a standard width and position in plan when molding products.
7. Production technology ensures strict adherence to the specified geometric parameters.
8. Estimated uniformly distributed load without taking into account its own weight for the entire range from 400 to 2000 kgf/m2.
Product range
Table 1
Floor slabs 1197 mm wide
Thickness, mm Length, m Weight, kg
120 mm From 2.1 to 6.3 From 565 TO 1700
From 1.8 to 9.6
From 705 to 3790
From 2850 to 5700
Floor slabs 1497 mm wide
From 1.8 to 9.6
From 940 to 5000
From 3700 to 7400
From 7.2 to 14
From 5280 to 10260
Brief description and characteristics of the equipment
1. Industrial flooring (Fig. 4)
Rice. 4 Construction of the technological floor: 1 - threaded rod; 2 - base (foundation); 3 - channel; 4 - reinforcing mesh; 5 - metal-plastic pipe for heating; 6 - concrete screed; 7 - insulation and concrete screed; 8 - metal sheet covering
The concrete base under the technological floor must be perfectly level and have a slight slope towards the sewer drain. The floor is heated by electric cable or hot water to a temperature of +60°C. For enterprises that have their own boiler house, it is more profitable to use water heating. In addition, with water heating, the floor heats up faster. A technological floor is a complex engineering structure that must withstand the weight of molded reinforced concrete products. Therefore, the thickness of the metal sheet is 12-14 mm. Due to thermal changes in the length of the metal sheet (up to 10 cm on a hundred-meter track), the sheet is fixed with metal plates with a millimeter gap. The preparation and welding of the metal sheet should be carried out at the highest level, since the cleaner the surface of the sheet is processed, the smoother the ceiling surface of the slab.
2. Slipformer (Fig. 5)
Rice. 5 Slipformer
Forming machine - Slipformer (w=6200kg) - designed for the production of hollow slabs. The machine is equipped with all the necessary equipment, including accessories such as electrical cables, cable drum, water tank and a finishing device for smoothing the top surface.
The required slab thickness is achieved by replacing the pipe-formwork kit (replacement takes about 1 hour). The electro-hydraulic control of the machine is designed for the work of one operator.
The machine is equipped with four electric drive wheels and a variator, which provides a variety of travel and forming speeds depending on the type of floor slab being manufactured and the concrete mixture used. Typically the speed varies from 1.2 to 1.9 m/min.
The machine is equipped with one stationary front and one hydraulic rear receiving hoppers for concrete mixture. It also features two vibrators with adjustable power. The machine has one hydraulically driven cable drum complete with electric cable (maximum length 220 m). The finisher is equipped with a mounting device and electrical connection.
The pipe-formwork kit is equipped with a hydraulic drive; the side formwork elements are suspended, which ensures good adhesion to the guides. Concrete is fed through a double hopper with two controlled outlets
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manually (the volume of concrete for each socket is 2 cubic meters). There is one galvanized water tank.
The machine is adjusted according to the type of concrete available at the plant.
3. Concrete aspirator (Fig. 6)
Rice. 6 Concrete aspirator
The aspirator is designed to remove uncured (fresh) concrete (w=5000kg, 6000x1820x2840) and is used for cutting profiles in slabs and making slabs with protruding reinforcement. The aspirator can also be used to clean the floor along the guides, as well as between production stands. The electric drive has two forward speeds and two reverse speeds. Low speed is 6.6 m/min, high speed is 42 m/min.
The aspirator includes:
1. One built-in filter and filter housing including:
Filtering surface area of 10 m2
Polyester needle and felt filter with microporous water- and oil-repellent outer layer
Automatic valve that changes bag filters by blowing air every 18 seconds
Waste container under the filter
Concrete separator located in front of the outlet.
2. Aspiration device in a noise-insulating housing. Maximum air supply - 36 kPa, motor 11 kW.
3. Centrifugal pump and one additional tank for water nozzle.
4. One galvanized water tank with a capacity of 500 liters.
Suction nozzle with built-in manually operated water nozzle and
A spring balancing device attached to the cross member allows for transverse and longitudinal movement. Waste container with a capacity of 1090 l. equipped with two pneumatic sealing valves. The container has a hook that makes it easier to lift, as well as a device for cleaning the container by lifting it. The height-adjustable working platform is designed for cleaning the guides. The aspirator has an eye hook, an air compressor with a capacity of 50 liters, an electrical switch and a control unit with the ability to install up to 4 remote controls.
4. Multifunctional trolley (Fig. 7)
Rice. 7 Multifunctional trolley
The trolley (w=2450kg, 3237x1646x2506) runs on battery power and performs the following three functions:
1. Stretching reinforcing ropes and wires along production stands
2. Lubrication of production stands
3. Cleaning of production stands
The machine is equipped with: an anchor plate for fastening cables and fittings, a scraper for cleaning production stands, a spray bottle for applying a lubricant, and a hand brake.
5. Automatic plotter (marking device) (Fig. 8)
Rice. 8 Plotter
The plotter (w = 600 kg, 1600x1750x1220) is designed for automatically marking slabs and drawing drawings on them according to any geometric data made in the EXG format (working speed 24 m/min), for example, cutting angle, cut-out areas and project identification number. The plotter control panel is touch-sensitive. Plate data can be transferred to the plotter using any wearable device -
VESTNIK _MGSU
for or through a wireless network connection. A laser is used for measurements with an accuracy of ±1 mm.
6. Universal sawing machine (Fig. 9)
Rice. 9 Universal sawing machine
This sawing machine (w=7500kg, 5100x1880x2320) allows you to saw hardened slabs of the required length and at any angle. The machine uses 900-1300 mm discs with a diamond cutting edge; The discs are designed for cutting slabs with a maximum thickness of 500 mm. The machine speed is 0-40 m/min. Sawing speed 0-3 m/min, various adjustments available. The cutting speed is set automatically by economically adjusting the power of the saw motor. Cooling water is supplied at a rate of 60 liters per minute. The cutting disc is cooled on both sides by jets controlled by a pressure and flow sensor installed in the water supply system. The front nozzles can be easily rotated for quick saw blade changes. The cutting speed is adjustable for optimal performance of the operation.
The sawing machine has the following characteristics:
1. Electric motors for precise movement.
2. The sawing machine is fully automatic.
3. The operator only needs to enter the cutting angle.
4. Manual positioning is performed using a laser beam.
7. Saw for fresh concrete (Fig. 10)
Rice. 10 Saw for fresh concrete
Manually operated saw (m= 650 kg, 2240x1932x1622) for longitudinal cutting of freshly laid concrete mixture to produce slabs of non-standard width, different from those specified in the molding machine. The maximum slab height is 500 mm. The saw blade has an electric drive. To save money, the used diamond blade (1100-1300) can be recycled. Positioning and movement of the machine is carried out manually. The saw moves along the stand on rollers and is supplied with power via a cable.
The use of such a technological process allows:
Provide increased load-bearing capacity of floor slabs (since reinforcement is carried out using prestressed reinforcement)
Ensure high flatness of the top surface by forcefully smoothing the surface of the slabs
Ensure strict adherence to the specified geometric parameters
Produce slabs with high strength characteristics due to forced compaction of the lower and upper layers of concrete, etc.
We examined modern technological lines for the production of floor slabs. These technologies meet most of the requirements for modern production of concrete products. Therefore, they are promising, i.e. their use allows enterprises of efficiency, reinforced concrete, etc. be competitive and fully satisfy customer needs.
Literature
1. Utkin V.L. New technologies in the construction industry. - M.: Russian Publishing House, 2004. - 116 p.
2. http://www.echo-engineering.net/ - equipment manufacturer (Belgium)
3. A. A. Borshchevsky, A. S. Ilyin; Mechanical equipment for the production of building materials and products. Textbook for universities on special. “The production is building. ed. and structures." - M: Alliance Publishing House, 2009. - 368 pp.: ill.
1. Utkin V. L. New technologies of the building industry. - M: the Russian publishing house, 2004. - 116 with.
2. http://www.echo-engineering.net/ - the manufacturer of the equipment (Belgium)
3. A.A.Borschevsky, A.S.Ilyin; the Mechanical equipment for manufacture of building materials and products. The textbook for high schools on “Pr-in builds. ed. And designs". Publishing house the Alliance, 2009. - 368c.: silt.
Key words: floors, molding, technologies, formwork, equipment, technological lines, slabs
Keywords: overlapping, formation, technologies, a timbering, the equipment, technological lines, plates
The article was presented by the Editorial Board of the MGSU Bulletin