Manual loading lines for polystyrene concrete production

Manual loading lines for polystyrene concrete and foamed concrete blocks’ production 


The company Siberian Construction Technologies designs and completes sets of equipment with manual loading of raw materials for polystyrene concrete production. The set includes:

  • PND-500 Pre-Expander (completed with steam generator);
  • Dryer for polystyrene granules;
  • Ageing bunkers; 
  • Transfer hopper for secondary foaming;
  • Pneumatic system; 
  • Volumetric batcher of polystyrene granules; 
  • Mixer for polystyrene concrete with embedded gerotor pump;  
  • RK-3 Cutting set; 
  • FM-0,84 m3, FM-1,47 m3 moulds for RK-3 Cutting set. 

PND-500 Pre-Expander.

Pre-Expander is designed for polystyrene foaming. For steam supply PGES-50 Steam generator or another source is used. Primary pre-foaming of bead polystyrene is effected by hot water steam in the pre-expander chamber. The pre-expander capacity and therefore density of foamed polystyrene depends on speed (intensity) of raw material supply from the feed hopper to the receiving cone of the screw feeder.  

 


Dryer for polystyrene granules.

The set is designed for drying and oxygenation of previously foamed granules before they go to the ageing bunker. Structurally the drying set consists of electric radiator to warm air and low pressure radial ventilator for transportation of granules to the ageing bunker. The drying set body has butterfly gates to control direction of warmed air flow. 

Air warmed up to +40-50ºС is supplied continuously to the heat treatment chamber. Previously foamed granules fall through loading hatch of the dryer body inside. Granules are exposed to air and heat treatment, which leads to stabilization of the internal pressure and hardening of the granules outer walls. 

After that granules fall inside suction fan and then with the help of air flow are transported to the pneumatic system.


Ageing bunkers and transfer hopper for the secondary foaming.

Ageing bunkers and transfer hopper is a metal frame with a bag from ventile fabric fixed inside. Ageing bunkers are meant for drying and stabilization of pressure in polystyrene granules after foaming process, and also for intermediate storage of granules. Ageing bunkers are connected with each other and with technological parts by pneumatic system. The required number of the ageing bunkers and their total volume depend on the desired output. Overall dimensions and bunkers volume can be different, depending on the characteristics of working space and production output. To control the level of polystyrene granules in the ageing bunker is possible to install sensors or inspection window. The transfer hopper is designed to feed polystyrene granules for secondary foaming after primary foaming and ageing.   


Pneumatic system.

Pneumatic system is a system consisting of air ducts, low pressure radial ventilators and butterfly gates with manual or pneumatic actuator. The pneumatic system is controlled with the help of a separate control unit. The pneumatic system is designed for transportation of foamed polystyrene granules with bulk density from 6 to 50 kg/m³ by air flow between the ageing bunkers and technological parts. The air duct is made from galvanized steel and can be any shape depending on sizes and shape of working space. Design of the butterfly gates is a cylindrical drum made from thin steel plate with two flanges at the ends for joining. Rotating blade is fixed on the body axes. Number and power of the ventilators depend on the ducts length and system productivity. 

The pneumatic system is characterized by simplicity and reliability. The system design does not allow deformation of polystyrene granules during transportation.  


Volumetric batcher of polystyrene granules.

Batcher is a bunker provided with volume sensor and shutter with pneumatic actuator. Foamed polystyrene with the help of pneumatic system ventilator goes to the bunker through a throat in the upper cap. When the bunker is full with granules feeding automatically stops. The bunker is unloaded through the shutter which opens and closes with the help of the pneumatic actuator.





Mixer for polystyrene concrete with embedded gerotor pump.

Mixers are represented by installations of «RS-1000» series. These installations are designed for preparation and transportation of polystyrene concrete and foam concrete mix of different density to a place of laying. The installation consists of the followed main components which are easily serviceable and are mounted on a frame: 

  • Mixer (volume 1000 liters);  
  • Gerotor pump;  
  • Remote control;  
  • Gear motor (Italy).

Mixing mechanism of the installation consists of two oppositely directed screws. This fact provides high quality mixing of mix components.  
The gerotor pump feeds mixture to the place of laying. The mixture can be supplied up to 100* meters horizontally and up to 20* meters vertically.

Note:
* Feed range is defined having two knees at an angle 90° plasticity of solution at 13 cm, according to GOST 5802-86.
   When plasticity of solution changes, pump capacity and feed range change correspondingly.  




RK-3 Cutting set.

RK-3 Cutting Set is universal and it is meant for vertical sawing foamed concrete, polystyrene concrete or gas concrete into blocks of given sizes. Cutting technology make it possible to avoid the use of expensive battery molds and to achieve high accuracy of blocks’ sizes and quality of their surface. Use of the cutting set excludes a number of manual operations; increases labor capacity and reduce staff workers (to service the set only 1 person is needed). The cutting technology provides to manufacture products with geometric fidelity of ± 1 mm and product’s surface quality which meets necessary standards. This fact allows making settings using special types of glue and significantly increases thermal efficiency of exterior walls. 

The cutting set consists of the outfeed table for a mass and vertical band saw which divides the mass into blocks of given sizes.  

 


FM-0,84 m3, FM-1,47 m3 Moulds.

For pouring and forming of mass FM-0,84 m3 and FM-1,47 m3 moulds are used. Size of mass for sawing is 1198*598*295 mm (or other sizes).  

 
     

Operating principle of the set of equipment:Water and chemical admixtures are loaded into the mixing installation. After that cement is loaded. The solution is mixed for 1-2 min. Then foamed polystyrene is loaded from the volumetric batcher to the mixer. Mixture is stirred for 3-5 min. The operator performs visual inspection of volume and homogeneity of the mixture. Ready polystyrene concrete mixture with the help of the gerotor pump through resin mud channel is evenly poured into moulds. Before pouring the mixture the moulds are lubricated with release compositions. After pouring the moulds with mass are exposed with heat treatment. Process of thermal treatment is performed according to the process procedure. Use of thermal treatment allows to speed up process of stripping strength gain, as well as to get polystyrene concrete with higher strength characteristics. Then the moulds are dismantled. After dismantle, mass meant for sawing with gripper and with the help of telpher or other hoist is installed on the outfeed table. Then actuator of band saw is starts. The operator moves the band saw machine and saws off block of required size. Then the machine returns to its original position. Ready blocks are taken from the outfeed table, stacked on pallets and wrapped with wrap tape. The pallets with polystyrene concrete blocks are kept in the storage area for finished product till they get 70 % of strength and max 25 % of selling humidity. Storage temperature of finished product should be min +150С. The pallets with blocks are installed in 2-3 layers. Required space is calculated on the basis of daily productivity.

Advantages:

High quality of mixture stirring. Mixing mechanism of the installation consists of two oppositely directed screws. This fact provides high quality mixing of mix components.

High profitability. Low cost of the set allows organizing highly profitable business with short payback period.  

Quality of products. The products manufactured by our numerous clients are certified. We invite you to get to know our products and confirm its advantages.  

Purchasing the set of equipment you also get:

  • High reliability of equipment, all separate elements of the set are made with strength and power assurance;
  • Schemes for individual processing of the moulds;  
  • Operating procedure for polystyrene concrete manufacturing;  
  • Recommendations how to use products;  
  • GOSTs necessary for manufacturing;  
  • Free training on working factory;  
  • After-sales service, technologist’s consulting;  
  • Technologist’s visit for start-up of the line, proportioning, development of processing methods for products manufactures, and also staff training (paid separately).