Select technology penobloka
26.12.2009 в 12:24
Select technology penobloka last decade in Russia and most CIS countries is characterized by the introduction of new regulatory indicators teplozahystu buildings. In this regard, their traditional wall construction materials - bricks and keramzitobetonnyh panels - has become economically unprofitable - has demanded increasing the thickness of walls to 1-1,5 m. The above mentioned products in building wall structures yield more teploeffektivnym place from which one of the most promising is penobloka and articles thereof. Products from penobloka have coefficient of thermal conductivity is 2-3 times lower than in brick or keramzitobetonnyh panels. Result: The walls of penobloka 2-3 times warmer brick while maintaining almost the thickness of the former structures within 400-600 mm. Plus, economic benefit, because the amount of wall structures is reduced by 2-4 times, while improving the coefficient of thermal resistance, which becomes relevant requirements of modern standards in terms of lower cost. Hence the development of production penobloka as an effective building material is one of the most promising areas of industrial materials. In penobloka high insulation performance, and with them he has compared to block prochnostnyye characteristics (compressive strength up to 40 kg/m2), although he concedes on this indicator. This shortcoming is compensated by use of different technological solutions to wall structures: a device frame buildings with interior walls that are, and columns, monolithic zone rigidity, reinforced panels overlap. Especially effective are products penobloka for low-rise building, or frame construction. In addition to evaluation of technical and economic performance of different wall materials and products, you can not write off the comfort of human habitation in the house. Known grading of the comfort offered foreign researchers. According to this grading, first took place in comfort at home with walls made of wood, second - with walls of clay bricks, Third-fourth - home of the walls of penobloka, the sixth to tenth - a wall of ceramic and silica bricks. The walls of the expanded clay lightweight concrete and normal concrete are in last place. Intermediate place in the gradations are mixed with wall wall materials and products. Fully evaluate the effectiveness of the use of different wall materials can not be excluded durability of these materials, environmental safety under normal and extreme conditions. Used as insulation mineral wool under constant teplovlazhnostnyh conditions that change is not always retains its properties over the entire period of the capital buildings, and as a result of the coefficient of thermal resistance structure may change. This increase teplopoter, lowering the temperature on the inner wall surface and the possibility of attack condensate. Observed data foamed polymeric materials also prone to failure over time. As to local fires in residential buildings can not be excluded, should consider the allocation of toxic substances and the formation of internal emptiness when heated sandwich panels with inserts of foam polymers. All this makes even more attractive design to protect from penobloka not consumed, obtained in practice, two basic technologies. First, with entry into a mass of concrete mixing with aluminum powder - concrete technology. Mixture of bloating after pouring concrete in forms. The second uses porizatsyi technical foam material that is obtained when introduced into the mass of foaming agents, - concrete technology. In this case, the process of gaining weight porizovannoy completed in the mixer. Technology of Production of peno and concrete on all manufactured virtually identical and differ only at the stage of preparation porizovannoho solution. Both technologies can be used for curing chamber or Steam-curing autoclaves. VNIYISTROM them. MP Budnykova developed several options komponuvalnyh equipment and solutions for enterprises of various production capacity of wall blocks with penobloka. For curing products can be used Steam-curing chamber or autoclaves. When selecting equipment and developing its capacity utilization rate in all cases accepted for at least 50%. Productivity of unit, component technology line, calculated with the optimum conditions of the equipment. Modern requirements for thermal properties of materials tasked to create facilities that can produce products with a density less than 500 kg/m3 and high accuracy of geometric dimensions. Acquisition of high precision cutting and flat surface product lines to foreign firms "Itonh, Hebel, Verhan" provided use short strings tight, do not change their position when cutting. In the Russian practice of well-established production lines from forming, cutting and autoclave processing of products on the same pallet technology. Cutting array produced Vitim strings that vary in length over the array dimensions. When the amount of solid in terms 1200h3000 mm length strings of 1400 and 3200 mm. Cutting a long array Vitim strings can lead to deterioration of the cutting surface and decrease the accuracy of cutting. At the same time the cutting of forming a pallet to reduce the requirements for an array of strength at cutting. This technology is not required to carry an array of special tray for cutting or canting array of grounds on the lateral surface, as is done on foreign equipment.
In developing the new equipment the task of cutting the array into blocks short strings, leaving the array during the entire process on your pallet. To make a cut on your own in terms of optimal pallet filled autoclave and cut short strings, took an array of height 1200, width 600 and length 3000 mm. For Russia adopted a number of parametric plant capacity from 10 to 100 thousand m3 per year. For plants with capacity of 10-20 thousand m3 per year production line was designed with a capacity of approximately 1 m3 estate, factories 20-50 thousand m3 per year - lines up an array of about 2 m3 and for plants with capacity of 50-100 thousand m3 per year - up from an array of 2 m3 and 3 m3 technologies were designed for autoclave concrete form with a width of 600 mm and height of the array 1000, 1200 mm. It is known that the use of concrete technology bubble of gas spuchuyut array, and its
strength along and transverse directions spuchennya vary. Difference in strength along and transverse directions spuchennya is 20-25%. Virtually all modern production lines that use concrete technology, concrete is considered property, and cutting the array into blocks produced so that the product length was oriented along the direction spuchennya. In the form of a width of 600 mm in a horizontal arrangement of blocks, this condition is not fulfilled, because the foundation was laid on the principle of technology gaining penobloka by typing in a mixture of technical foams. Received isotropic foam, and orientation to the cutting of blocks is not important. Concrete technology, however, demanding quality raw materials and to get quality products when used to destroy the activity of 70%. The principal feature of applied technology - preparation in the mixer with a
mixture of cement, ground sand, water and destroy further introduction to the technical foams obtained in Foam generators. By changing the composition of the mixture and amount of foam is introduced, developed on the line you may receive products with density from 300 to 1000 kg/m3. To gain blocks of wall density 500 kg/m3 were handpicked concrete, providing for 4-5 hours set an array of plastic strength, enough for her that rozpalubyla and cutting products that cut across and along the axis of the form string, whose length exceeds the width of the array at 100-150 mm on each side. Cutting was carried smooth strings diameter 0,6-0,8 mm. The technological scheme of production of cement and lime with the cost of bunkers coming one after the filler dry, sandy sludge - sludge in the bottle, water is supplied directly to the mixer through the flowmeter. Weight installed on the line, the combined control system that provides capture the required number of raw materials and unloading hoppers to the mixer for a given program. Foam generators in the technology used to obtain stable foam as necessary, so after determining the actual performance Foam generators for obtaining the required concrete density of foam, which is given, determined by the time it works. Dry materials, sand and water slurry loaded in the mixer and peremishuvalysya then filed the foam to the mixer. Dimensions mixer chosen so that the batch size equal to the volume form. The volume form is 2.3 m3, respectively, in line mixer using a volume 3.0 m3. Mixer test showed that the ratio of output value 0,7-0,8 concrete is on its volume, and volume of 3.0 m3 mixer provides the maximum amount of filling out the form 2.3 m3. With mixer mass poured concrete hauler truck in which commercials mixture of forms. Exposure time for stabilization of the forms before they are placed in the cutting termostatovanyh cells, opening during the pouring of concrete and extraction of form from the pallet array. Exposure Time array of forms, depending on the composition of concrete and additives used is 3-6 hours. Forms used on the line, with fixed and consist of a frame, which hinges are attached to the board and which installed a removable tray. This longitudinal sides open on hinges, and the cross - the levers that provide ploskoparalelne vidsovuvannya sides of the array. Sucker capture are in the gap between the cross sides and hearth and capture pallet on the bottom. The design eliminates the capture of its collision with an array of parts and related damage to the surface of the array. Disclosure Forms or produced manually or by using pnevmoprivoda. Pallet, which extracts the form of an array mounted on the carriage of cutting complex. Carriage is moved from its original position on the pretext of cross-cutting position, passing through the installation of the array calibration. On cross-cutting position cuts the string array that varies in the transverse direction. Frequency of double strings of 80 moves per minute. Amplitude regulated from 20 to 60 mm. Depression and recovery frame with strings cross cutting produced electromechanical drive. After cross-cutting to the array lychat stops, bottom bracket with an array of pallet begins to move forward through the string and the longitudinal incision. Availability retaining wall provides a stable position in the horizontal cutting products and to almost completely eliminate the slopes of the exit from the array of strings. Drives complex products get cut from the power frequency converter, which provides speed control of cross and longitudinal cutting, the exact position of the carriage stop cross-cutting and the end position. Scheme of cutting complex eliminates tearing of the array with a longitudinal incision and ensures cutting accuracy within 1 mm. Waste from cutting gather rozbavlyayutsya water and bound shlambasseyn waste. The collected sludge dozuyetsya and goes to the mixer. This is to ensure waste from the cutting array. After cutting trays with an array mounted on tram autoclave. In the shop installed autoclaves 2h19 pm By using small tubs in the autoclave is the height of section 2 ranges in height 1200 mm. Acc autoclave placed in 6 volumes. It turns out that for one cycle in the autoclave zaparyuyetsya 25.9 m3 products. Autoclave filling ratio is around 0.43. Loading and unloading the autoclave is elektroperedavalnym bridge. After zaparky products are removed from the pallet enthusiasm. Delight has a length of 1.5 m, which corresponds to half the length of the array. Line operating experience has shown that the formation of a solid density of 500 kg/m3
is 15-20 minutes, the time exposure to that rozpalubyla is 3-5 hours depending on the mixture composition and temperature in the shop. The quality of concrete blocks was measured in the laboratory: when the density of 480-520 kg/m3 strength of blocks is 25-30 kg/m2. Blocks used in the manufacture of cement M400 D5, ground sand specific surface 1900-2000 cm2 / g, obtained in the form of sludge, lime activity 70-75%. Tests showed that the sand can be used instead of ash and waste from the processing of fine-grained granite. In a similar scheme was developed in line with the capacity 60-80 thousand m3 per year of 3 m3 in volume form, used for the reconstruction Korenevskoho silicate brick plant with transfer it to release products with penobloka. Experience in creating equipment for factories penobloka showed that the autoclave technology and neavtoklavnoho concrete with success can be used similar equipment for shaping and cutting the array. The principal difference is within the concrete, grinding of raw materials and the need to use expensive autoclave
technology penobloka autoclave curing. Because concrete autoclave curing goes much higher quality, its market price is much higher. In neavtoklavnoho concrete market price of 12-50 rub./m3, autoclave curing of high quality - 1500-1600 rub./m3. Profit in the production of the first approximately 330 rub./m3, the production of a second - about 750 rub./m3. Construction Period neavtoklavnoho plant is targeting 0.5 years, autoclave curing - 1.5 years. Since the time of construction and investment at the plant neavtoklavnoho penobloka significantly lower, while the repayment of such enterprise - 1.44 years from start of production. To plant autoclave penobloka it is 3.7 years. Since the profit on higher plant autoclave concrete, the amount of profit is equal to over 5.1 years, and gross profit from sales autoclave penobloka starts exceed revenue from sales penobloka neavtoklavnoho curing. Thus, the selection scheme is necessary to consider the following key indicators: quality requirements for concrete density and strength, the volume of production volumes and investment opportunities. This production neavtoklavnoho penobloka requires less investment, but to make a profit in much smaller quantities than the more expensive factory production autoclave penobloka. When choosing the type of equipment the investor should keep in mind that Russia is an equipment that can get products for quality and accuracy of geometric concrete block size is complaisant products received on imported equipment, which cost several times higher, and the terms of repayment exceed 8-10 years . By Vyacheslav HYLOVICH