AUTOMATED PRODUCTION LINE
FOR POLYSTYRENE CONCRETE BLOCKS
capacity 100 m3/shift
|Capacity||100 m3/shift (200 m3/day)|
|Power consumption||81 kW/h|
|Water utilisation||~15 tonnes/shift|
|Cement utilisation||~33 tonnes/shift|
|Polystyrene utilisation||~1 tonnes/shift|
|Productions||small wall blocks according to GOST 21520-89, GOST 51263-99|
|Required production facility area||no less 1000 m2|
|The ceiling height at the mixing area||not less than 6 m*|
|The ceiling height at the production area||not less than 3 m*|
|Ambient temperature||not be less than +15oС|
|Required personnel||12 workers, 1 production manager/foreman|
The production lines employ electronic systems to control raw materials loading and dosing in the mixing area. The control systems provide functions for registration and control of raw materials. The mixing area is controlled by one operator. The cutting area has a cutting machine, which is also controlled by one operator. The mould dismantling and block stacking process is automated.
Raw materials are fed to a weigher with strain gauges and a weight controller that allows for accurate dosing.
The high capacity is ensured by an automated system for raw materials loading and dosing as well as by the high rate of mixer filling with water and raw materials. The high-capacity cutting machine ensures high rate of monolith cutting into blocks of a predefined size.
The process automation system ensures high quality of products and guarantees dosing accuracy as well as stable and uniform composition, which allows us to provide high-quality and competitive products.
RAW MATERIALS FOR POLYSTYRENE CONCRETE PRODUCTION
- Binder. Portland cement or portland blast furnace slug cement of M-400 and M-300 grades under GOST 10178 isused as a binder.
- Aggregate. Granulated polystyrene expanded once or ceveral times serves as an aggregate.
- Mixing water. The water meets requirements of GOST 23732.
- Mould release agent. SDF mould release agents or other antiadhesive agents are used to ensure efficient mould removal.
- Silica component* It is used to manufacture high-density polystyryne concrete.
- Chemical additives. Chemical additives (air-entraining, plasticizing, hardening regulators) must meet the requirements of GOST 24211.
BRIEF DESCRIPTION OF TECHNOLOGICAL PROCESS
1. Preparation of polystyrene mixture
The raw material (polystyrene beads) is fed into the intake hopper of the prefoaming device, then with the help of the screw conveyor it is fed into the prefoaming chamber. Polystyrene beads are expanded for the first time in the prefoaming chamber with the help of water steam generated in the steam generator. After expansion, the polystyrene is sent into the granule drying conveyor for reducing their humidity and aerating. After drying, the granules are transported with the help of the pneumatic conveyor system into aging hoppers. The second or multiple (if required) expansion of polystyrene granules is performed in the same way as the first expansion.
Adding water into the mixer
Water is dosed with the help of electronic water doser. The mixing section operator sets the required water quantity on the control panel and starts the mixer loading cycle.
Loading the mixer with raw materials
Weight batchers are loaded with raw materials (cement and siliceous component, if used) with the help of the weight controller, the same as loading the expanded polystyrene into the volume batcher. Cement is loaded with the help of the screw conveyor, while polystyrene is loaded with the help of the pneumatic conveyor system. Then, the cement is unloaded from the batcher into the mixer, the preparation is mixed for 2-3 minutes until it is homogeneous. When it is ready, the chemical additive batcher doses the air-entrapping additive, then the polystyrene is fed into the mixer, and the mixture is stirred for 1-2 minutes. In real time, the operator monitors all the processes going on in the mixing section. If required, the operator can adjust or amend the formula produced, the mixing time and other technological parameters on the control panel. The equipment can be operated both in automatic and manual mode.
2. Moulding a block
The ready mixture is emptied through the mixer valve into the 0.85 cu. m mould. The mould is filled at once. The mould is made up of the base and removable, interchangeable walls. Before casting, the mould is lubricated and transported to the mixing section where the casting is done.
3. Block ageing
After casting, the mould is transported along the railway to the ageing section, where the block is kept until it gets strength enough for removing the walls. The strength enough for removing the walls can be gained within 4 to 7 hours and depends on polystyrene density, cement activity, temperature, etc.
4. Dismantling moulds and cutting massives
After the massif has gained the required strength, the mould containing the massif is transferred to the dismantling machine along the railways, the mould base is held fixed on the railway. Then, the four mould walls are removed and lifted with the gripple. After mould dismantling, the mould base and the massif are transferred to the cutting section. The free walls are then mantled onto a free base, which is on the adjacent railway. The mantled mould is sent to the pouring section. The massif is cut into blocks of pre-set dimensions with АRК-004 cutting unit. At the cutting section, there are two separate consecutive modules for vertical and horizontal cutting of the massif.
The mould base is held fixed with a gripple at the vertical module, while the operator launches the vertical module. Moving along the guides, the module cuts the massif in a vertical plane and trims it on both ends. After vertical cutting, the mould base with the massif is transferred to the horizontal module area, is held fixed with a gripple, after which it is cut in a horizontal plane into the blocks of pre-set dimensions, as well as the bottom layer and the top are cut away.
While the horizontal module is in action, the next massif is fed into the vertical module area. So, two massifs are being cut at the same time, which ensures the line high throughput.
5. Stacking blocks onto pallets, packing, and storing
The mould base with the massif cut is transferred to the block stacking unit. The mould base is held fixed on the railway. Then, half of the massif cut is stacked on a pallet with the help of a gripple. In order to complete the pallet, eight blocks are placed manually. Then, the second half of the massif is stacked, as well as the eight blocks manually (depending on their dimensions). The pallet with blocks is wrapped with a stretching film.
6. Block heat and moisture treatmen
Depending on the climatic zone and type of the material manufactured, the blocks stacked onto pallets can gain the grade strength at the final product warehouse or during heat and moisture treatment. Block heat and moisture treatment is required for accelerating strength gain in the blocks. The heat and moisture treatment means that the blocks are cured in the chamber over 8 to 12 hours at the temperature of +40 to 60оС. The heat and moisture treatment mode also depends on the material density, cement activity and is defined by the customer for each certain type of products manufactured.
7. Recycling cutting waste
Wile cutting, the block is trimmed on both sides and the top crust is cut off. A good idea is to crash that cutting waste with DG-1 Crasher. The Crasher will enable you to grind polystyrene concrete cuttings up to the size of 0 to 30 mm. The ground material can be used as bulk insulation for insulating roofs, attics, floors, etc. The use of this crasher will make your production nearly waste-free.
The area of raw materials storage, preparation, and loading
|1||Cement screw conveyor (L = 6 m*, gear motor (Italy), N = 4 kW)||2|
The area of expanding polystyrene
|1||PND-500 Pre-expander (N – 3,3 kW)||1|
|2||PAR-50 Steam generator (N – 35 kW, 50 kg/h)||1|
|3||Conveyor for drying EPS granules (N – 3 kW)||1|
|4||EPS granules ageing hopper 40 m3||10|
|5||Pneumatic transport system (N – 4,5 kW)||1|
The area of mixing
|2||Electronic control system (including water batcher + booster pump)||2|
|3||Cement weigh batcher (strain sensors, pneumatic shutter, weighing capacity range to 1000 kg)||2|
|4||EPS volumetric batcher 1,0 m3 (level sensor, pneumatic shutter)||2|
|5||Polystyrene concrete mixer RSG -900 (N – 5,5 kW)||2|
|6||C200LB40 Compressor (8-10 atm., 500 l/min)||1|
|7||Gerotor pump GN-10 (N – 7,5 kW)||1|
The area of block cutting
|1||ARK-004 Automatic cutting complex for vertical and horizontal sawing of mass (N – 19,5 kW)||2|
|2||Mould for filling FM-0,85 m3 (V – 0,85 m3).||118|
|4||Complex for dismantling of moulds (N = 2.0 kW)||1|
|5||Complex for stacking blocks onto pallets (N = 2.5 kW)||1|
The area of recycling cutting waste
|1||Crusher DG-1 (N – 4,5 kW)||1|
MATERIAL CONSUMPTION* PER 1 m3 OF POLYSTYRENE CONCRETE D-450
|Cement (М 400, М 300), kg||330|
|Air-entraining additive, kg||0,2-1,0|
|Chemical additive, kg||**|
* The recipes are adjusted to take into account the properties of raw materials chosen by the customer.
** The type and amount of the admixtures are determined on the concrete design phase.
To reduce customer’s expenditures, the line is supplied without cement silo, sand hopper, and railings for mould transportation. The customer is provided with drawings for separate manufacturing of these units.
Besides, the customer is also responsible for water heating up to +35... +40 °C and for arrangement of steam curing chambers. Operating the line in 2 shifts requires additional mould foundations.
The warranty period for the supplied equipment is 12 months. Components of each piece of equipment are listed in the contract, equipment data sheet, and the Delivery and Acceptance Certificate.
Specialists of Siberian Constructing Technologies (SCT) design the layout of equipment in the customer’s production facility. The equipment is installed according to the layout by and at the expense of the customer. The customer is provided with equipment layout (drawings) for corresponding rooms and detailed illustrated instructions for installation.
After the customer completes equipment installation and connection, SCT performs the following works:• equipment commissioning;
• design of polysterene concrete;
• optimisation of the production technology;
• customer’s personnel training.
The customer covers all expenses for SCT personnel transportation and allocation for the period of the works. Technology optimisation includes optimisation of concrete composition based on the raw materials provided by the customer. SCT provides support services.
After equipment commissioning the customer is provided with technical documentation, including:• technical regulations for productions;
• process flow diagram;
• job descriptions;
• safety instructions;
TERMS OF DELIVERYThe cost is specified for EXW-Novosibirsk (Russia) and does not include the cost of customs clearance and shipment. The equipment manufacture time: from 30 working days from the advance payment receipt.
TERMS OF PAYMENT
Payment 1—70% of the contract value within 5 days from the date the contract is signed.
Payment 2—30% of the contract value within 5 days from the date a confirmation is received that the equipment is ready for shipment.