Moscow 1981.

Printed by decision of the section of the factory technology of concrete and reinforced concrete NTS NIZHB Gosstroy USSR on March 6, 1981

The technology of production of pre-tense reinforced concrete structures with a non-blank method on all redistribution (preparation of concrete mix, preparation of steel stands, laying and tensioning of reinforcement, molding, heat treatment, cutting stripped concrete on products and transportation). Requirements for the quality of finished products.

Preface

In recent years, the Unsopal production of reinforced concrete structures on linear stands has been developed in the USSR, on which the method of continuous molding can be made of a permanent length of the cross section stand: multi-consistency panels of floors, flat and troughting plates, single-layer and three-layer wall panels, etc.

These recommendations are intended for practical use at the collective reinforced concrete factories, where the unpaid production of reinforced concrete structures will be introduced on linear stands equipped with self-propelled molding units and other equipment purchased from Max Roth (Germany) or reproducible in the USSR under license this company, and Also describe the order of the technological process.

The indifference method of production using self-propelled molding units provides special requirements for the quality of concrete mixtures, transporting them to molding units, controlling the continuously moving molding unit, laying and tensioning fittings, heat treatment, platform and transportation of products.

Recommendations are drawn up on the basis of practical verification of the provisions of the technical documentation of the Max Roth's technical documentation in production conditions at the Seversky Plant of the ZhBI, the Glavsredur-Malstroy Mainstroaching of the USSR.

Recommendations Developed by NIIZB Gosstroya USSR (candidates of tech. Sciences S.P. Radoshevich, E.Z. Axelrod, M.V. Muza, V.N. Yarmakovsky, N.N. Kupriyanov) with the participation of the Chief Hosredar Mainstream of the USSR (E. engineers . Varnavsky, S.N. Poish, V.N. Khlybov) and UralpromstroyProektov State Building of the USSR (candidates tehn. Science A.Ya Epp, R.V. Sakayev, T.V. Kuzina, I.V. Filippova, Yu. N. Karnet, Inzh. V.V. Anischenko).

Directorate NIIZB

General provisions

1.1. These recommendations apply to the manufacture of pre-stressed reinforced concrete products with a width of 1.5 m and a height of up to 30 cm (multi-duct panels of overlaps and wall panels) from heavy and lightweight concrete by a non-blank method.

1.3. The peculiarities of the non-blank production under the license of Max Roth are:

multistage continuous molding of hard concrete mixes;

the implementation of the vibration effect on the concrete mixture by the working bodies by contact only with the mixture (surface layered seal);

continuous movement of sealing machines of the machine relative to the placed concrete mix.

The technological line of the indifferent production of preframed reinforced concrete products should have the following set of equipment:

steel stands size 150´ 4 m with oil heating registers under them (technological lines with reproducible in the USSR equipment can have smaller stands);

hydraulic tension devices for group tension of reinforcement and compensation of tension losses when heated stand and reinforcement during heat treatment (group hydraulic machines);

powl HydroComcrate for single reinforcement tension (single hydraulic acid);

self-propelled armature layout with deflecting and cutting devices;

cook holders of wire or spinning reinforcement;

self-propelled forming unit with dispensers bunkers;

carts with thermally insulating bedspreads for coating freshly-appointed concrete strip for the time of heat treatment;

vibratory for cutting of a raw concrete massif;

saws with a diamond disk for cutting hardened concrete;

self-propelled lifting machine with pneumatic producers for removing the stand and transportation of finished products;

machine for cleaning the stand;

the installation for heating the oil (coolant) of the MT-3000 type (the company "Heinz") or non-2500 (Karcher company).

In addition, the technological line should have a special post of sink of the molding unit.

1.4. The molding feature is that the formulating unit made in the form of a portal on which handouts of dispensers are mounted, three steps of sealing vibro elements, movable violations, forming and dividing moving elements, lubrication and plasticization of the stand and controls, moves with smoothly adjustable cable-tension hydraulic device. At the same time, the formulating unit by means of an automatic device lays and pressing the transverse upper rod fittings and aligns the open surface of the product.

1.5. The formulating unit allows by appropriate reference to produce various in the width and thickness of the product. In this case, the total width of the formulated products does not exceed 3.6 m, the height is not more than 30 cm.

1.6. For the manufacture of products, concrete mixtures with rigidity 20 - 40 s (GOST 10181 -81) can be used.

2. Technology of manufacturing reinforced concrete structures by a non-blank method

Requirements for concrete mix

2.1. The molding of crowd panels and solid plates is made from a concrete mix on a dense filler with a design brand of concrete for compressive strength 300 - 500.

2.2. Concrete mixtures with rigidity (25 ± 5) C according to GOST 10181 -81 can be applied to molding multi-retained panels and solid plates (1.0± 0.2) m / min.

2.3. To prepare concrete, it is necessary to use cement with a normal thickness of cement test (NGTST) not more than 27%. The use of cements with greater NGST can lead to a violation of the ratio between sand and cement and, therefore, to the poor formility of the mixture.

2.4. Sand must comply with the requirements of GOST 10268-70. The presence in the sand grains of more than 10 mm is not allowed.

The strength of the aggregate should not be 2 times the strength of concrete.

2.6. In order to ensure the requirements for the rigidity of the concrete mixture and the strength of the concrete for calculating and adjusting the composition of the concrete mixture, it is necessary to determine the following characteristics of the raw materials:

for cement

activity R C. , MPa - in each party;

NGN,% - 1 time in shift;

density ρ, g / cm 3 - for each type of cement;

for sand

bulk densityg. , kg / m 3 - 1 time in shift;

standard (rms deviation) grains of more than 5 mm in shift,% - in each batch;

multity module M cr - 1 time in shift;

pollution (defusion),% - 1 time in shift;

natural humidity,% - 1 time in shift;

for rubble

density ρ, g / cm 3 - for each career;

bulk densityg. , kg / m 3 - 1 time in shift;

standard grains of more than 5 mm in shift,% - in each batch;

pollution,% - 1 time per shift;

strength (swept), MPa - in each batch;

natural humidity,% - 1 time in shift.

According to the obtained characteristics, the factory laboratory calculates the composition of the concrete mix, guided by the provisions set forth in PP. - These recommendations.

Sh \u003d u p - 0,015 p · (to + f.), (2)

where to I. f. - grains of greater grains of more than 5 mm in shift, respectively, in crushed stone and sand,%;

U p - the calculated amount of rubble, kg.

In this case, the consumption of mixed sand n cm and mixed crushed ground seems are determined by formulas

(3)

where with I. d.- Accordingly, the amount of sand in crushed stone and rubble in the sand,%;

U cm \u003d sh + p - n see (4)

2.10. Correction of consumption of materials depending on the humidity of the aggregates W, the presence of sand in the crushed stone and rubble in the sand, the activity of cement R C. , NGTST, emptiness rubblea. Conducted if the newly obtained value will differ from the previously used as follows:

W - by ± 0.2%; R is ± 2.5 MPa; NGTST - by ± 0.5%;

a - by ± 1.0; M Kr - by ± 0.1.

2.11. Concrete strength is determined by the results of testing sample cubes molded from the control test of concrete with a prune. The specific pressure of which is 4 · 10 -3 MPa. The volumetric mass of freshly appointed samples should be equal to theoretical (calculated) volumetric mass with the tolerance± 2%. Control cubes are collaborated with the product on the stand.

The test of samples for determining the strength is made in the hot state (3 samples per stand).

2.12. The molding of wall panels and blocks is made from concrete mixes on a porous filler, and concrete is used: structural - brands M150 - M200, structural-heat insulating - M50 - M100 brands and thermal insulation - M15 - M25 brands.

2.13. In the manufacture of structural and heat-insulating light concrete M50 - M100 brands, a mixture of clay gravel fraction 5-10 mm should be used on a bulk density not higher than 500 and fractions 10 - 20 mm brand on bulk density not higher than 400, claymzite sand brand on bulk density not higher 800, satisfying the requirements of GOST 9759-76.

For the manufacture of the thermal insulating layer from a large concrete concrete M15 - M25, it is recommended to use clay gravel fraction 10 - 20 stamps on a bulk density of not more than 350.

In the manufacture of structural ceramzite concrete M150 - M200 brands, it is necessary to use clay gravel fraction 5 - 10 mm brand for strength not lowerH125.

2.14. Convertibility of a concrete mixture for the structural ceramzite concrete should be characterized by rigidity in the range of 20 - 40 s according to GOST 10181 -81.

2.15. The working dosage of materials on the embossing is issued by the factory laboratory at least once again in replacing with a mandatory check of the stiffness of the concrete mix of the first damps.

2.16. Dosing cement, water and aggregates should be carried out according to GOST 7473 -76.

The dosing of clay gravel and porous sand should be produced by a volume-weighting method with the adjustment of the composition of the mixture based on the control of the bulk density of the large porous aggregate and sand in the weight dispenser.

2.17. Preparation of concrete mixture for severe structural and structurally thermal insulation light concrete is recommended in mixers of forced action.

The preparation of concrete mixture for the heat-insulating layer of large concrete concrete should be produced in concrete mixers of gravitational action.

2.18. The duration of mixing of a concrete mixture of a given rigidity is established by the factory laboratory in accordance with GOST 7473 -76 and is observed with accuracy± 0.5 min.

2.19. Monitoring the mixing mode is carried out at least twice in shift.

2.20. The stiffness of the concrete mix coming from each concrete mixer is checked at least three times when molding one stand.

Preparation of stands

2.21. After removal of finished products, the stand is cleaned by movement of the cleaning machine on it, installed on the stand using the crane.

2.22. The cleansing machine can operate in two modes:

"Normal cleaning" - when cleaning the stand without a suction concrete;

"Full brush regimen" - if there is on the stand of the remnants of the suction concrete.

2.23. To clean a large number of residues of raw concrete, a special scraper in the form of a bucket with side walls is placed on the cleaning machine. To clean the hardened concrete having a strong clutch with a bench, use a scraper beam suspended by the machine. The speed of the machine is selected in such a way that the stand is cleared in one pass machine.

2.24. A stand with a small amount of small residues of concrete crumbs is purified by a jet of water supplied from a pressure hose.

Staying and tension of reinforcement

2.25. Stacking reinforcement is made after cleaning the stand. The wire break (strands) is carried out using a self-propelled fitting of reinforcement from three or six builders located behind stands from group hydroevkrats.

The self-propelled armature layout must move along the stand at a speed of 30 m / min.

Fixing the reinforcement in the stops at the ends of the stand is carried out manually.

2.26. A batch fixed on the stand (strands) is pulled up by a single hydraulic acid on the passive end of the stand before obtaining the assembly tension of the reinforcement equal to 90% of the specified force.

The operation is repeated to a set of mounting tension of all reinforcement elements.

2.27. After tensioning of the reinforcement, protective brackets must be installed on the bench in case of the breakdown of reinforcement elements during its final tension.

2.28. The tension of the entire reinforcement package up to 100% of the predetermined efforts is made by a group hydraulicist at the active end of the stand after installation on it and prepare for the operation of the self-propelled forming unit.

The whole process should be carried out in accordance with the instructions of the Max Roth.

Molding

2.29. The forming unit is installed with a crane on the passive end of the stand; The unit is set to the unit, and the power supply cable and the cable of the cable-tensioning system are delivered to the active end of the stand using the reinforcement cart truck and fasten to the electrical and bracket of the special stop, located behind group hydraulic machines.

2.30. Adjustment and adjustment of the forming unit are carried out on the basis of instructions for servicing the forming unit included in the technical documentation for the equipment supplied by the manufacturer, as well as according to these recommendations.

2.31. Hollow-formers must be installed in such a way that the distance from the stand surface to the lower edge of the back of the hollows corresponded to the projective in the product, and in the front part it was 2 mm in the front. The back of the sides and separation partitions must be installed by 1 mm above the stand, and the front is 2 mm.

2.32. The vibrationovers of the 1st stage are set according to the base thickness of the manufactured panels. The front part of the planks based on rubber shock absorbers must be set to 5 mm higher than the rear part. At the same time, the rear part of the vibrationovers of the 1st stage must be lowered by 5 mm from the lower surface of the hollow-forming agents.

2.33. The 2nd stages are installed in such a way that the rear part of them is at a distance of 5 mm above the hollows.

The angle of inclination of the vibrationovers is chosen depending on the thickness of the panel and the consistency of the concrete mix.

2.34.Mehhanic, the flexible device for consuming transverse reinforcement must be installed in the lower position 10 mm above the top mark of the artwork. The reference mark is the rear part of the 3rd stage vibration vessels or the surface of the steel sheet of stands.

2.35. The plates on which the 3rd stage vibration vessels are fixed, should be installed horizontally and rely on rubber shock absorbers. In this case, the working sealing plate in contact with the concrete mixture will take a project oblique position.

2.36. The bunker block with a total capacity of 10 m 3 with an automatic device for loading the concrete mix and supply the mixture to the bunker-dispensers is installed using a bridge crane on the portal of the molding machine and fastened with bolts.

2.37. Before the start of molding, the operation of all three steps of vibration, hollow-formers, sides and separation partitions, the mechanism of automatic supply of the concrete mixture should be checked.

2.38. The rotation of the vibrators of all three seal steps should meet the movement of the molding machine. In case of inconsistency of the direction of rotation, it is necessary to change the phases.

2.39. When adjusting the position of the sides and separation partitions, forming the side edges of the products, it is necessary to eliminate the possibility of contacting the side of the beads with the stand during the molding process. The installation of sides and separation partitions is produced at the highest point of all stands, to determine which the forming unit is sequentially moved along all stands after they are installed before test formation.

2.40. The gap between the 2nd stage vibrationovers and stretched upper reinforcement should be (20± 5) mm.

2.41. Before you begin molding, the unit is established in the initial position at the beginning of the passive end of the stand; The bunker of the automatic loading mechanism is filled with a concrete mixture supplied from the baud with the help of a bridge crane.

2.42. Before you begin molding, install a device for maintaining and fixing intense fittings. Its installation is produced in this position of the forming unit, when the distance between the dispensing bunker of the 1st stage of the seal and the struts of the reinforcement is 100-150 mm. The direction of the wire (strand) must coincide with the direction of the axis of the stand; If necessary, regulate the position of the guide planks.

2.43. In the molding process, the concrete mixture should be supplied to the consumables-dispensers of all three sealing stages in an amount equal to 1/3 of the bunker volume, which provides a permanent subpode necessary for a uniform feeding of a mixture under sealing machines. In the absence of a mixture of the mixture in consumables, the mixture is supplied under sealing organs in insufficient quantity, which leads to undeplication of concrete in products.

2.44. The dosing of the mixture from the consumables is carried out by the chirates placed on the rear wall of the bunkers, using slider levers.

The reciprocating movement of bunkers-dispensers of the 2nd and 3rd steps must be adjusted by 20 - 30 count / min. At the same time, the 3rd stage of the seal should be supplied to such a number of concrete mixture, which would form a small roller before vibrationovers. This requirement is performed by dispensing the mixture of the bunker of the 3rd stage, as well as the permutation of the mechanical device of the ram in height.

2.45. The molding of products should be carried out continuously throughout the stand without stopping the molding unit. The molding speed, depending on the stiffness of the mixture and the height of the formable product, should be seal experimentally and can be taken equal to 0.5 - 2.0 m / min.

When molding multi-console panels made of concrete mixes rigidity (25± 5) C is recommended speed (1.0± 0.2) m / min. When molding three-layer wall panels 250 - 300 mm thick from concrete mixtures with rigidity 20 - 40 C, a speed of 1.0 - 1.5 m / min is recommended.

The total duration of the molding of the strip of the stand 150 m should not exceed 3 hours, and the strength of the sample-cubes molded at the beginning of concreting before heat treatment should not exceed 0.5 MPa.

2.46. When molding multilayer panels made of ceramzitobetone, the back of the vibrationovers of the 1st stage is set according to the drawing of the product above the stand surface at a distance equal to the thickness of the lower structural layer of the product; The bunker-dispenser sewer should be installed at 100 - 120 mm above the bottom structural layer.

2.47. The rear part of the 2nd stage vibrationovers is set above the predetermined thermal insulating layer by 10 mm, and the bunker-dispenser is 50 to 60 mm.

At the same time, the vibrators of the 2nd seal stage must be disabled.

2.48. The back of the 3rd stage vibration vessels is installed above the stand surface at a distance equal to the thickness of the product, and the bunker-dispenser is 100-120 mm above the surface of the product.

2.49. The processing of the OE-2 lubricant bench and plasticization of the lower layer of the concrete mixture is carried out using special devices installed in the front of the molding unit.

2.50. Before the end of the molding for 2 m to the edge of the stand, it is necessary to remove the planks of the guide devices of the reinforcement. The concrete mix should be supplied to the bunker of the boot device and the consumables are evenly with such a calculation so that it is completely consumed by the end of the molding.

2.51. After the molding is completed, the unit is moved close to the tightening rope to the rotary device, the movement of it stops and all the functional assemblies of the unit are disconnected.

2.52. At the end of the molding on each booth, the forming unit was washed with a stream of high pressure water on a specially equipped sink.

After the work shift, the general washing of the forming unit is produced. Before this, it is advisable to dismantle the 2nd and 3rd stages of the seal. Mechanical impact (climbing) is prohibited. All mechanisms and motors before washing must be covered.

Defects of molding and their elimination

2.53. Wire opening (strand). It should be checked if any of the three coal seal stages do not come in contact. Otherwise, the wire can overlook it and break into the compacted concrete.

2.54. Violation of the clutch strands with concrete or deviation from the project position. It is necessary to check whether the wire (strands) and the vibrationovers of the 2nd stage are not in contact and does not fall into the concrete mixture of the fraction fraction more than 10 mm.

2.55. Roughness of the upper surface of the panels and transverse cracks. It is recommended to check the consistency of the consistency of the concrete mixture of the required, as well as the correspondence of the required velocities for the molding and dosing of the concrete mix for the 3rd stage of the seal.

2.56. Cracks on the bottom surface of the panels. It is necessary to check the angle of inclination when installing the vibrationovers of the 1st stage. In the case of a large angle of inclination, the horizontal component in the movement of the working body increases and can lead to the breaking of the continuity (exceeds the adhesion force of the concrete mixture with the bench).

It is necessary to check the position of the vibrationovers of the 1st stage relative to the voids. With incorrect installation of them, the hollows will destroy the already compacted base of the panels.

2.57. Formation of cracks on the side edges of the panels. It is recommended to check the speed of moving the sides and separation elements and, if necessary, adjust it.

It should be checked if the boards and separation elements with a stand come into contact.

2.58. Insufficient sealing walls between voids. You should check the dosage of the concrete mix in the 2nd stage of the seal. It is recommended to check the angle of inclination of the 2nd stage vibrationovers and their work.

2.59. When checking the work of vibrationovers, you must make sure that all the vibrators are working.

The amplitude of the oscillations of seals must be:

for the 1st stage - 0.9 - 1.0 mm;

for the 2nd stage - 0.7 - 0.8 mm;

for the 3rd stage - 0.3 - 0.35 mm.

Heat treatment

2.60. During the molding period, the oil, heated in an oil-heating unit up to 100 ° C and circulating in the bench registers, provides the temperature of the steel sheets of a stand at least 20 ° C.

2.61. At the end of the molding and coating of freshly-appointed concrete, the heat-insulating coating temperature of the oil for 7 hours is raised to 170 - 200 ° C, which provides a stand temperature of about 90 ° C, and concrete is heated to 65 - 70 ° C.

Concrete temperature control during the heat treatment period is carried out according to the temperature schedules of the oil temperature in the system and the temperature of the concrete based on the temperature of the oil temperature on the oil heating setting.

2.62. Isothermal warming is made for 7 hours, while the oil temperature smoothly decreases to 100 ° C.

2.63. Cooling products up to the transmission of voltage to concrete is not allowed [cm. "Guidelines for the thermal processing of concrete and reinforced concrete products" (M., 1974)]. The transfer of compression efforts to concrete is recommended no later than 0.5 hours after the end of isothermia and testing control samples. In this case, the temperature of concrete should be reduced by no more than 15 to 20 ° C relative to the concrete temperature during isothermal warming.

2.64. During heat treatment, the stand and fittings are suspended when elongating the automatic device mounted on group hydraulic machines, due to the triggering of the end switch and the machine for maintaining the force of reinforcement. The response time of the automaton is recommended to be installed using a time relay for 3 minutes.

Cutting products and their transportation

2.65. The tension leave is made by a group hydrodecomk at the active end of the stand with the subsequent trimming of the reinforcement on the passive end of the stand.

2.66. The cutting of the concrete strip on the products of a given length produce a saw with a diamond disk, starting with the passive end of the stand. It is possible to use abrasive discs. The time of one transverse cut of a concrete array of 3.6 m wide - 5 min.

2.67. The products from the stand and the storage of them in the free end of the stand or its continuation produce a self-propelled lifting machine with pneumatic produces.

2.68. Further transportation of products on the export trolley or vehicle produce a bridge crane with a special cross-lifting traverse.

Quality control of finished products

2.69. The quality control of finished products is made by the plant's technical control department based on existing regulatory documents (TU working drawings) and these recommendations.

2.70. The deviation of the size of multi-console panels should not exceed:

in length and width -± 5 mm;

thick - ± 3 mm.

2.71. The thickness of the protective layer of concrete to the working reinforcement should be at least 20 mm.

2.72. Panels must have straight face. In separate panels, the berthsision of the lower or side surface is not more than 3 mm at a length of 2 m and no more than 8 mm over the entire length of the panel.

2.73. On the bottom (ceiling) surface of the panels should not be shells. On the upper and lateral surfaces of the panels, separate fine sinks with a diameter of no more than 10 mm and a depth of 5 mm are allowed.

2.74. Overflows are not allowed in the panels, as well as filling out hollow channels with concrete.

2.75. Panels are available without reinforced ends.

2.76. The appearance of the panels must meet the following requirements:

the bottom (ceiling) surface should be smooth, prepared under the color without additional finishes;

on the lower (ceiling) surface of the panels are not allowed local influx, fat and rusty stains and open air pores with a diameter and a depth of more than 2 mm;

occas and influx are not allowed on the longitudinal lower edges of the panels;

concrete cameras are not allowed along the horizontal edges of the ends of the panels with a depth of more than 10 mm and a length of 50 mm per 1 m panel;

cracks are not allowed, with the exception of shrinking surface widths of no more than 0.1 mm;

the slippage of intense reinforcement is unacceptable.

2.77. Deviations from the design sizes of wall panels should not exceed:

by lenght

for panels up to 9 m long - +5, -10 mm;

for panels longer than 9 m - ± 10 mm;

height and thickness - ± 5 mm.

2.78. The difference between the diagonals of the panels should not exceed:

for panels up to 9 m long - 10 mm;

for panels longer than 9 m - 12 mm.

2.79. Non-stale panels, which is characterized by the magnitude of the greatest deviation of one of the corners of the panel from the plane passing through three angle should not exceed:

for panels longer than 9 m - 10 mm.

2.80. Panels must have straight face. The deviation from the straight line of the real surface profile and the edges of the panel should not exceed 3 mm at a length of 2 m.

On the entire length of the panel, the deviation should not exceed:

for panels up to 9 m long - 6 mm;

for panels longer than 9 and - 10 mm.

2.81. Shells, air pores, local influx and depressions on the surface of the panel intended for the color should not exceed:

in diameter - 3 mm;

at depth - 2 mm.

2.82. Fat and rusty stains on the surface of the products are not allowed.

2.83. Cellites of concrete edges are not allowed in a depth of more than 5 mm on face surfaces and 8 mm - on non-personal, total length more than 50 mm per 1 m panel.

2.84. Cracks in the panels are not allowed, with the exception of local single surface shrinking cracks with a width of no more than 0.2 mm.

2.85. The moisture content of concrete in the panels (in% by weight) should not exceed 15% for concrete on the gravel porous and 20% - for concrete on the porous crushed.

The humidity of concrete in the panels is checked by the manufacturer at least once a month.

Finishing wall panels

2.86. Obtaining the texture of wall panels is carried out using special equipment. Application on the surface of the concrete strip of cement-sand finishing solution and the preparation of the smooth facial surface of the products is carried out with the help of a finishing unit attached to the forming unit and consisting of a mortar bunker and burning bars.

2.87. With decorative relief finishing of products, cement-sand solutions need to be guided by "Instructions for the finishing of the front surfaces of the panels for the outer walls" (EAS 66-89-76).

3. Safety

3.1. At the factory, where the production of precast concrete structures is organized by an indispensable method on linear stands, all work is carried out in accordance with the "Regulations for safety and production sanitation in plants and factory polygons of reinforced concrete products" (M., 1979), as well as head of SNIP III-16-80 "Concrete and reinforced concrete structures".

3.2. Special safety regulations during individual technological operations (heating oil, laying and tension of reinforcement on the stand, cutting ready-made products, etc.) are set out in special instructions for carrying out these works contained in technical documentation for equipment and supplied with the equipment factory Producer.

3.3. Special safety regulations should be duplicated on posters in the workshop.

3.4. The personnel entering the plant should undergo a special training course on the technology of work on the stand, pass the offset and take place quarterly briefing.

3.5. When working on an oil heating unit, it is necessary to take into account "Recommendations to reduce the fire hazard of installations with the use of flavored oil-coolant AMT-300" (M., 1967).

Production of non-blank molding on long stands of a wide spectrum of reinforced concrete products

On the lines of indispensable molding (LBF), the production of hollow flooring, piles, columns, bolts, beams, jumpers, plates of aerodrome (pigeons), side stone, fence sections are mastered. All products undergo project and documentary working in the leading profile design organizations of the country.

Patented unique production of road plates in full compliance with profile gtales. In the work - documentation for the production of LEP pillars.

Development, production and supply of equipment for non-blank molding of reinforced concrete products on long stands is one of the priority activities.

Nomenclature of products

Performance

Single-blank molding line ST 1500
(6 tracks 90 meters, product width - up to 1500 mm)

Type of product	Units. Measurements	Performance
		per day	per month	per year (250 days)
Plates of overlapping width 1500 mm, Height 220 mm	Rogue meters	540	11 340	136 000
	M 3.	178	3 738	44 856
Plate of overlaps width 1200 mm, Height 220mm	Rogue meters	540	11 340	136 000
	M 3.	142	2 982	35 784
Pile 300 mm x 300 mm	Rogue meters	2 160	45 360	544 320
	M 3.	194	4 074	48 900
Rigel 310 mm x 250 mm	Rogue meters	2 160	45 360	544 320
	M 3.	194	4 074	48 900
Rigel 400mm x 250mm	Rogue meters	1 620	34 020	408 240
	M 3.	162	3 402	40 824

A total of more than 30 sizes of products.

Note: When the quantity changes, the width and length of the tracks, the performance varies.

Specifications

Characteristic	LBF-1500.
Installed power (minimum), kW * depending on the configuration	200 *
Overall dimensions of the workshop (minimum), m	18 x 90.
Height to nut Crane, m	6
Load lifting equipment
Number of bridge cranes, pcs.	2
Load capacity of bridge crane is not less than, tons	10

Service staff

The number of service personnel is given for one shift

№	the name of the operation	Number of workers, people
1.	Cleaning and lubrication tracks, layout wire with tension, covering with protective coating, voltage transmission to concrete, removal of finished products to the warehouse	3
2.	Molding, sink forming machine	2
3.	Cutting	1
4.	Management of bridge crane	2
TOTAL		8

Brief description and principle of work

The technological process begins with cleaning one of the molding tracks by a specialized machine for cleaning tracks and spraying on her lubricant in the form of a thin air dispersion. The average cleaning speed with a special machine is 6 m / min. Cleaning time - 15 minutes. The lubricant of the track is made immediately after cleaning using the wedding pump.

Cleaning and lubrication tracks

After that, with the help of the wire for laying a wire, the reinforcement is unwinding from the bobbin and lay out on the track.

After laying the required amount of wire (in accordance with the album of the working drawings), it is tension using a hydraulic group for tension. The ends of the wire are fixed in the filter holes of the stops with the help of collet clamps. The ends of the wire are cut off with a manual cutting machine and close the protective casing, after which the track is ready for molding. On average, on the layout of the reinforcing wire, taking into account the time for refueling, landing the heads, cropping the ends and tension of the wire goes no more than 70 minutes.

With the help of a bridge crane (with a carrying capacity of at least 10 tons), the molding machine is installed on the rails of the molding path behind the stops of the track. With the hydraulic drum for the cable, the power cable is unwinding and powered from the 580 V. Cable network. The traction cable is wounded with the traction car winch and fixes behind the anchor anchor at the end of the track.

In the bunker-drive of the molding machine using a capacitance for supplying concrete a bridge crane is supplied by a ready concrete mixture. True winch and vibrators are included. Throughout the continuous process of molding the track in the hopper-drive, a concrete mixture is served in a timely manner. The average speed of the molding machine in the production of hollow plates - 1.5 m / min; Taking into account the time on the installation of the machine we take 90 minutes. After the molding of one track, the molding machine with a crane is set to the post of washing and is thoroughly washed with a high pressure setting for washing machines from the residuals of the concrete mix. The track with a ribbon of the molded product using a trolley for layouts of the protective coating is covered with a special covering material and leave the heat treatment process.

Heat treatment

The process of heat treatment goes according to the following scheme: 2 hours rise temperature up to 60-65 ° C, 8 hours Exposure, 6 hours cooling.
After reaching the concrete, the product of the transfer strength is removed by the observer material, and the tape is examined by the employees of the factory laboratory, which make the ribbon markup on the segments of the design length for subsequent cutting.
After that, the hydraulic block for removing the voltage of 3 cylinders produce a smooth vacation and the transfer of reinforcement tension for concrete products. Then it is cut off the reinforcement, this is done using a manual hydraulic group and occupies, taking into account the time to install it in the working position, not more than 10 minutes.

Cutting the tape is performed by a special machine for transverse cutting plates equipped with a high-strength cut-off disk with diamond spraying.

Cutting machine with a crane is installed on the rails at the beginning of the track. A power cable is corded from the hydraulic drum and is powered by a 380 V.-B cot network. The required amount of water is poured into the tank. Cutting is carried out by the cutting machine operator in manual or automatic mode. The duration of the cutting plate with a cutting disk with a diamond spraying is about 2 minutes. We accept the estimated length of the plate 6mm, from here we get 14 cuts, time for cutting plates on one track - about 30 minutes; Together with the operation of the installation of the machine and its movement take 70 minutes.

Finished plates with a bridge crane using a technological capture for transporting the plates are stacked on the truck and are exported to the warehouse of finished products. The side surfaces of the plates are marked with OTD employees in the prescribed manner.

After the molding of each track, the machine is installed on the stand, after which the mandatory washing of the molding machine and the punch - matrix is \u200b\u200bperformed. Washing is carried out by a jet of water under pressure of 180 - 200 atmospheres. This operation takes about 20 minutes.

Washing the molding machine

Cost

1. Technological equipment - from 25 million rubles (depending on the configuration)
2. Equipment of technological floors - from 8 million rubles (depending on the configuration)
3. Services (installation, commissioning - from 5 million rubles (depending on the composition of the work).

Cost characteristics on this site are referenced.

A commercial offer is exhibited by the Customer, in the negotiation process and indeed within 30 days from the date of its placement.

You can familiarize yourself with the example.

Other conditions

The warranty period is 12 months.

JSC "345 Mechanical Plant" offers free to organize the departure of our specialists to harmonize the placement of LBF-1500 at the customer's site.

The remaining conditions are coordinated at the conclusion of the contract.

State standard GOST 9561-91 Plates of floors of reinforced concrete crowds for buildings and structures. Technical conditions, entered into force on January 1, 1992, provided for three types of multi-consisting plates: stoves Channel PCs with round voids with a diameter of 114 to 180 mm, PG plates with pear-like voids and PB plates made by continuous molding method on long stands. PC overlap plates And PGs found wide use in the practice of construction. Many plants are equipped with metalforms for their production. PC plates of up to 6 meters received the greatest distribution. Some plants produced and currently produce pC overlap plates up to 7 meters long. PG type plates were significantly less frequent. The length of such plates did not exceed 9 meters.

For the production of plates of the PB type, specially complex equipment is needed, which in Russia until 2005 was not produced. Currently, several ZBI plants have mastered the production of PB type plates in Spanish, Finnish, Italian and domestic equipment.

Plates of overlapping reinforced concrete PB is produced by non-absorbing technology due to extrusion, i.e. extruding a compacted concrete mixture on warm stands up to 120 meters long. More recently, the plants produced plates with a width of 1200mm. Today, plates 1000 and 1500 mm width appeared on sale. The presence of different overlapping slabs is significantly reduced by the number of non-defect places on overlap, which, as a rule, has to fill in monolithic sites. In recent years, the thickness of the plates has decreased. The first plates were produced with a thickness of 220 mm and more. Currently you can find lightweight PB plates,the thickness of which is 180, 160 and even 120mm.

Multipurpost plates overlap Reinforced pre-hard high-strength wire-class VP1 with a diameter of 5mm. The equipment allows you to quickly change the number of rods wire in the stove. Due to this, the permissible from 400 to 2400 kg / m2 changes. PB - plates of overlapping, dimensions Which can be changed in 10 cm increments. With the use of plates, you can overlap the spans from 1.3 to 12 meters. Customer Custom reinforcement of the slab overlap - undoubted advantage of PB plates.

For deliveries to the consumer, the slabs of the specified technology of technology is provided by a transverse cutting plate with a high-performance diamond saw. Equipment allows the slab cuts at any angle, while the accuracy of the cut is one degree.

At the request of the customer in the stoves can be provided with a loop, which allows installation plates of overlapping At objects with traditional technological methods without using special traverses.

The technology provides for the possibility of manufacturing plates width 260, 395, 530, 665, 800, 935, 1070 mm. Such plates are produced due to the longitudinal cutting plate of the base size of 1200 mm. The presence of narrow slabs allows you to overlap the premises of any size without the need to cut the plates on the construction site. Narrow plates are available without loops. This must be considered when installing.

PB Upholstery Plates are designed for the device of precast floors in residential, public and industrial buildings with carrier walls, steel or collection-monolithic frame. Plates can be applied in buildings built by approved projects, instead of PC type channels with round emptiness. If the current loads exceed the capabilities of PC plates, PB plates can help you out, but it is necessary to carry out calculation of the slab overlap.

We emphasize once again the advantages and disadvantages of slabs of indoleum molding.

Advantages.

1. In comparison with the previously existing technologies, the production of plates of greater bearing capacity, greater length and better quality.
2. The smooth facial slab surface reduces the costs of trimming the ceilings, and the possibility of manufacturing plates without mounting loops reduces costs when the floor covering device.
3. The possibility of transverse cutting plates at any angle allows to overlap the rooms with erkers, curvilinear walls and openings.
4. Technology provides strict adherence to specified geometric parameters.
5. Conducted tests, the fire resistance of RJE 60 plates is confirmed.
6. The use of large-splates expands the possibilities of architects and designers when designing free internal buildings spaces
7. The stability of the strength characteristics guarantees absolutely the same deflection of plates, which eliminates builders from the need to align the ceiling surfaces when installing
8. Thanks to the improved noise insulating characteristics of the slabs, the level of noise effect on adjacent rooms is significantly reduced.
9. PB plates are easier than PC plates by 5-10%., Which allows you to increase the loading of transport and reduce the cost of transportation.

Disadvantages.

The minimum batch of plates with an increased bearing capacity cannot be less than 120 meters along the total length of the plates.

If you decide buy slabs of overlapping, Visit our prices page. Here you will find the main characteristics of the plates and their cost with delivery to the Moscow Ring Road. Cost and conditions for the delivery of plates to your object Check from the manager of our company.

During the construction of individual residential buildings, it is quite common to occur when the use of flood slabs is difficult. This is due, as a rule, with the impossibility of using the crane, the lack of a normal entrance to the construction site, a complex configuration of overlaps. In this case, the task can be solved by applying Marko collection-monolithic floors. Such overlaps are issued by our company since 2009 and used on hundreds of objects. When using overlaps, the marco hollow stove is formed in the running conditions. Such a stove has very high sound insulation and heat saving.

Replace the slabs of overlapping by collecting-monolithic floors can almost always. Often it hinders, according to developers, a higher price of prefabricated floors. Our experience shows - when evaluating the cost of overlapping from plates, developers do not estimate some costs that occur when using plates. To them, first of all, include:

• Device screed on plates for alignment of floor base.
• Anchoring slabs of overlappings.
• The mandatory device of the monolithic belt on the walls of weakly infant materials before mounting the plates.
• The device of monolithic sections between the plates.

Listed work will require additional costs. What? According to our estimates, 1200-1500 rubles per square meter. meter plate. In your case, these costs may be less.

Or more?

It is considered to consider and consider it once again - we can confidently recommend to all developers. Error estimating costs can be very serious if you get a request in Yandex plates of overlapping priceor slabs overlap dimensions Price And so calm down. All processes in the construction are interrelated. And these links must be considered. Including in monetary terms.

Today, the technology of indoor-blank formation of the progress of products received quite a lot of distribution. It has long been known - since the late 1970s, when large-scale all-Union construction of panel houses was carried out. But under the pressure of certain circles, the technology became low-rotation, and in the 1990s almost stopped used in Russia.

Until recently, the main suppliers of equipment for the production of concrete products on non-blank formation technology were three foreign companies that ensured the supply of vibropresses, extruders and splitformers.

Features of the lines of the non-blank formation of the progress

BOF lines are a specialized equipment complex that allows you to carry out the formation of beams, piles, jumpers of road and hollow plates, as well as other progress products for widespread use in various fields of construction. At the same time, the use of BOF is not always economically expedient - this is associated with the technical features of the equipment that is rapidly flawed enough, after which it requires service or expensive overhaul.

The design of the splitphormer used in the formation of the progress on a non-blank technology provides for the installation of vibrators that form the main equipment of the forming machine. The disadvantage of such a design is the need for a long-term high-precision setting, further maintenance also takes a long time.

The mechanism of the work of classical vibropresses is much simpler than the splitphormer, first of all, it consists in gradual sealing of the mixture in front of the forming snap-in. At the same time, the equipment of bov, presents very high requirements for the qualitative composition of the concrete mix. With insufficient quality of the mixture or hit in a mixture of unforeseen fractions, bolts and even small stones, the equipment can produce defective products or in order to fail.

The high quality of the concrete mix and the lack of impurities in it is not the only requirement of production on the technology of the non-blank formation of the progress. Special attention should be paid to systematic equipment maintenance. After each stage of production, it should undergo high-quality cleaning with compliance with regulatory work.

Key drawback - high price

The cost of the production line Bof is significantly higher (on average about 55-65 million rubles) than the organization of production for the means of "classical" technological lines (equipment kit), which the PTC plant offers "turnkey". It is also worth noting the high cost of components to the lines of non-blank molding, besides, all this can be exacerbated by the prolonged delivery time of the necessary components.

Investments in the production of concrete products for non-blank forming technology can be justified only at large enterprises provided by a constant flow of orders, for example, many years of implementation of large infrastructure projects of regional or state importance, where all regulations for the technical operation of this equipment are rigidly complied with.

Of the minuses, it is also worth noting the difficulty of upgrading the BOF line. Production of different types of products of products on such lines is possible with the help of special removable forming snapshots, but to reconfigure the BOF line to another type of production without huge investments is simply not possible. In addition, there are difficulties in the procedure for replacing the snap-in on the splitformer, and the cost of the equipment under the production of one product is at least 1 million rubles.