Automatic line for autoclaved concrete wall and partition blocks’ production using advanced vibropercussion technologies.
Brief characteristics equipment for autoclaved concrete production
Main equipment is located over the area of 2,5 thousand m2. This enables us to place a plant practically anywhere with pipelines available. E.g, next to the building site, binder production or sand pit.
Relatively small capacity doesn’t require complex infrastructure construction (railway station, cargo rooms, administrative and auxiliary areas, etc.). Necessary raw materials are delivered by road.
Low capital inputs, short site launch date, and high-quality production enable to shorten the payback period to 1,5 years.
Whole autoclaved aerated concrete production global experience present was considered in machinery design. Gas-concrete blocks produced on our line satisfy the strictest global requirements both in physicochemical properties and in geometrical dimensions.
ВAll machinery elements are fully automated. Main console is equipped with touch switchboard; accounting and controlling features are available. Automatic control system is powered by industrial line of world leading Japanese controllers’ such as Mitsubishi and Omron.
-Portlandcement defined in the GOST 31108 and 10178 standards; no added berg meal, burnt clay, trass, glinite, gaize, ashes; containing tricalcium aluminate (С3А) max. 8% by weight. Setting up time: start – no sooner than 2 hours, finish – no later than 4 hours;
-High-basic crozzle, containing СаО 40% min, including free lime 16 % min, SО3 6% max and R2О 3,5% max.;
-Calcium quicklime defined in the GOST 9179 standard, quick and medium slaking lime, with slaking rate 5-25 minutes and containing active СаО + МgО 70% min, dead-burning 2% max.
-Natural materials – quartz sand, containing SiO2 85% min, damp and argillaceous ingredients 3% max, montmorillonitic argillaceous ingredients 1,5% max.;
-After products of manufacturing and power industries: fly ashes of heating and power stations, concentrates, own production (end pieces and cutting waste).
-additives defined in the GOST 24211 standard;
-granulated blast furnace slag defined in the GOST 3476 standard;
-gypsum block defined in the GOST 4013 standard.
-aluminum powder or aluminum powder-based paste.
RAW MATERIAL PREPARATION AND STORAGE STAGE
BINDER (cement, lime) is loaded with pneumatic transport into supply silos from cement bulk trucks or railhead unloader using compressor system.
FILLER (sand) is conveyed into wet-grinding ball drum and afterwards it enters special slurry tank. Prepared water mixture from industrial waste (end pieces and cutting waste) comes therein.
ADDITIVES (liquid) are poured into special containers, where they are mixed with water and brought to required temperature; bulk additives are batched into ball drum with sand.
GAS-FORMING ADMIXTURE (aluminum powder or paste) is loaded into unit for water-base suspension production.
Dry and liquid ingredients mixing comes in several stages.
Monitoring, manufacturing and handling main functions of the installation at all stages of gas-concrete mixture production are performed at plant central control that is situated under the mixing column and next to the platform for mixture casting into molds.
Proportion of ingredients and process of mixing are fully automatically performed and controlled by management computer that is stored with mix formula for production of aerated concrete of required quality.
In real time mode the operator controls the installation working process. If required the operator can adjust or change current formulation, mixing time, temperature conditions and other operational parameters on the main console electronic board or with computer.
Besides the operator can change the operation mode into part manual or manual.
Mass with plastic strength needed is taken to the cutting with special positional conveyor.
At the first stage upper end piece (up to 5 mm) and bottom part are cut off the mass on the special band saw.
The second stage is mass cross-cutting and slitting on the RIF-1 cutter; waste ends fall on the waste conveyor and move to the recycling unit, and blocked-out mass is rolled over to the push-conveyor with transfer trolley for loading into autoclaves.
Autoclaving lasts 12 hours and consists of 4 stages:
- isothermal curing;
-decompression and unloading preparation.
Depending on the mixture formulation, during the isothermal curing temperature is maintained at 180 - 193 С, pressure – 8-13 bar. Autoclaving process control proceeds automatically on the special operating console.
After autoclaved curing stage cut mass is moved to demounting. Blocks are put on the shipping trays, tightened with tape and conveyed to the storage platform or room by means of loaders.