Automated complex for the production of foam concrete
Operating principle and structure
The complex operates as follows. On the touch panel of the operator are set cement dosage, sand, water, and start the production process.
Cement is fed in gravimetric feeder via conveyor from a silo. Upon reaching the desired weight of the cement, the feed in the dispenser is stopped.
Cement Silos – is a warehouse of cement. It is a large metal barrel, set upright on the metal supports. At the bottom of the silo is a cone for cement to better spill out of the silo. Loading of cement silo is done through a pipe or hose, which goes upward to the top of the roof of the silo. Cement through this tube by means of a compressor is supplied by compressed air into the cement silo.
In this process, part of the cement can escape through the top of the silo valve, which is mounted, on the silo roof, so in order not to pollute the environment, it is necessary to install a silo filter that will protect the atmosphere from cement dust. To find out the level of cement in the silo, inside are mounted level sensors, upper and lower, and sometimes put humidity sensors.
Unloading of the cement silo usually occurs through the lower conical part of the silo, into a screw. The screw is a screw conveyor for bulk materials. Transfer of material there is carried out on the principle of the Archimedean screw. The screw goes on the bottom of the silo cone to the weight of cement dispenser installed above the mixer. Upon reaching the desired weight of the cement, the feed into the dispenser is stopped.
The sand is fed by the conveyor belt. After contact with the sand on the tape, turns on the drive of the belt conveyor and sand located on the conveyor belt, moves and poured into the hopper. At a set of a given dose of sand – sand flow into dispenser is stopped.
The bunker for sand. Large bunker serves as a place to store the sand into the bunker sand is fed from an open area with a bulldozer or forklift. Under the hopper is set vibrating screen sifting of sand. At a rash from a vibrating screen, sifted sand gets on the conveyor belt. This conveyor delivers the sand into cement dispenser. Using a bunker for sand will eliminate the manual labor to shovel sand on vibrating screen.
A cement dispenser and the dispenser is hopper a of sand located above strain gauges. The dispenser is equipped with a surface vibrator and electric gate. Weighing takes place by means of strain gauges. The data is displayed on the operator console.
Water is pumped through the mixer via dispenser passage. Water flow is controlled by electrovalves. One click – and precisely specified by the operator the amount of water will be in the tank of the mixer.
Concrete solution is prepared in the turbulence-vibration type mixer. By filling water into the mixer, mixing is activated and weigher gate opens for discharging a dose of cement and sand. After stirring and activation in the mixer ready solution is discharged into the receiving hopper of the pump for the subsequent filing solution in the porizator. The use of two mixers allows continuous solution process.
Turbulent vibrating mixer is designed to activate the cement or cement-sandy solution, and allows the use of cement capacity by 100%. The activation takes place due to high intensity mixing with a vibrating effect on the stirred environment. Turbulence and vibration impact on the solution when other conditions being equal gives strength gain in concrete or foam concrete up to 50%.
Foam. For production of foam is required a stable, uniformly filled with air cells initial foam mixture. Obtaining a stable and high-quality foam material is in the foam generator. By using the foam generator RUSBLOK is possible to prepare foams with a bulk density of 40 to 400 g / l. This parameter is adjusted depending on the desired density of the foam concrete mix (from 300 to 1200 kg / m³) and future brand of cellular concrete. Foam generator that runs on any type of foaming agent.
Foam concrete is produced using porizator.
Preparation Technologies of foam concrete using “porizator” lies in the fact that the cement-sand solution is pre-prepared, separately preparing the foam in the foam generator and then the foam is mixed with the cement-sand mortar in “porizator”.
Only at porizator is possible to obtain ultra-light foam concrete on an industrial scale with improved strength characteristics. Moreover, increases the overall productivity of the plant in several times using the same pumps and mixers, because preparation time is reduced and pumping goes without foam. For example, on the density of D600 performance of porizator is 3 times higher.
The remote control lets you manage all the complex of preparation of concrete and foam concrete mix: weigher, screw conveyors, belt conveyors, pump and water dispenser, pump of foam delivery, concrete mixers, mixer, vibrators hoppers and shutters.
Operators Touch panel is used to set doses of the components required for the preparation of foam concrete mix, management and control of the process of production foam concrete.
|Accumulation of water tank and storing V = 1000 l. The large volume with small dimensions, the vessel wall prevent the formation of rust, convenient loading and unloading of water, possibility of water heating||2 pcs.|
|water supply pump produced by company Pedrollo, an impeller from a brass alloy and the drive shaft of stainless steel alloy improves reliability. Pump motor power of 1 kW, 380 W., Capacity up to 120 l. / Min.||2 pcs.|
|Dispenser for accurate dosing of water consists of a control panel, solenoid valve, water meter with pulse output. The dose of 1-1000 liters.||2 pcs.|
|Set of hoses and valves for the water supply.||2 pcs.|
|Screw conveyor for feeding cement to the dispenser, model ES, 168 diameter, length = 7.5 m, 3 kW, performance of up to 12 t / h, a tilt angle of 45 degrees.||1 pcs .|
|Two-way Valve rocker with electric power to switch the flow of bulk material from a dispenser in mixers.||1 pcs.|
|Turbo vibro mixer for mixing high intensity cement-sand solution with vibration exposure. Mixer Volume 0.25 m3, operating speed is 600 rev / min., power of 4 kW..||2 pcs.|
|Mounting frame for the dispenser of cement and sand||1 pcs.|
|Weigher for precise dosing of cement supply. Bunker dispenser equipped with a surface vibrator and with electric gate. Weighing takes place by means of strain gauges. The data is displayed on the operator console. The dose of up to 300 kg..||1 pcs.|
|Vibrating screen for sifting of sand. It consists of a vibratory drive (vibrator), frame and screening part, including pallet and screening mesh.||1 pcs.|
|Sand hopper, V = 0,7 m 3 (1000 kg) with the shutter, a vibrator, on the frame.||1 pcs.|
|Belt conveyor for feeding Sand into the dispenser consists of a motor – reducer, a frame, a drive drum, capstan, tape, support for bearing assemblies. Length 8 m, chevron V-belt||1 pcs.|
|Weigher for precise dosing delivery of sand. Bunker dispenser equipped with a surface vibrator and with electric gate. Weighing takes place by means of strain gauges. The data is displayed on the operator console. The dose of up to 300 kg.||1 pcs.|
|The screw (gyratory) mortar with a hopper for feeding sand-cement solution in porizator. Hopper capacity of 500 liters, the power of 5 kW||1 pcs.|
|Porizator of foam concrete mix with a foam generator, capacity up to 15 cubic meters. h., 4 kW, the resulting foam concrete densities range 150-1200kg \ cubic meters.||1 pcs.|
|Set of hoses to supply concrete and foam concrete mix.||1 pcs.|
|General console for the automated management of all devices with the assignment of production recipes of sand-cement solution and foam concrete, with the software.||1 pcs.|
Areas of application of foam concrete and its products
- The produced units from a construction-type heat-insulating foam concrete can be used in load-bearing and self-supporting walls of buildings up to 3 floors inclusive, but not more than 10 m. (According to SRT 501-52-01-2007 “Design and construction of residential and walling public buildings with the use of cellular concrete in Russia “, p.6.2.8.) At the same time block class must not be lower than B2 (p.6.2.10).
- Blocks manufactured from a heat-insulating type of foam concrete can be applied as a heat-insulating walling elements in a tall monolithic housing construction and meet the requirements of SNiP 23-02 and SP 23-101 of the present CS, from the resistance to heat transfer, air permeability and water vapor.
- By their technical characteristics (strength, thermal conductivity, etc.) manufactured products are fully compliant with GOST 52820-83 “Light Concretes. Technical conditions.”
- By their technical characteristics (strength, thermal conductivity, etc.), manufactured products exceed the requirements for materials in claim
Application of included in the delivery innovative equipment, allows to produce foam concrete with new characteristics (lower density, increased strength and improved performance on the thermal conductivity), which will greatly expand the application of foam concrete in monolithic housing construction.
|Density, kg / m3||100||150||200||300||400||500||600||700||800||1000|
|Thermal conductivity in the dry state, W / m ° C||0,041||0,049||0,056||0,072||0,09||0,12||0,14||0,18||0,21||0,29|
|Thermal conductivity at operating conditions A. Mass water saturation, 8% W / m ° C||0,051||0,058||0,065||0,084||0,11||0,13||0,17||0,19||0,26||0,34|
|Thermal conductivity at operating conditions B. Mass water saturation 12%, W / m ° C||0,062||0,069||0,078||0,112||0,135||0,15||0,19||0,21||0,28||0,39|
|Compressive strength, MPa||0,1||0,4||0,6||1,2||1,6||2,1||2,8||3,5||4,1||5,6|