بتن سبک یونولیتی
وال برد wall board
تاریخچه یونو بتن سبک ((polystyrene concrete
از سال 1971 که تحقیقات برای ساخت مصالح ساختمانی سبک و مقاوم با استفاده از پانل های سیمانی الیاف دار در استرالیا شروع شد تا به امروز بیش از هزاران واحد ساختمانی با استفاده از این پانل ها در روسیه و هندوستان ، چین ، اندونزی ، کانادا ، کویت وعراق و ایران ساخته شده است و تحقیقات زیادی در آزمایشگاه ها و مراکز علمی کشورهای مختلف صورت گرفته تا فرآیند تولیدی برای محلول هموژن و اختلاط بهینه و در نتیجه حصول بهترین نتیجه، بدست آید.
این شرکت دانش بنیان در راستای حمایت از تولید ملی و بومی سازی فناوری های جدید و به روز در صنعتی سازی ساختمان و ساختمان های پیش ساخته بتنی سبک دارای استاندارد های سطح بالای عایق حراراتی و آکوستیک از سال 89 تاسیس شد و با تحقیقات گسترده با تیم R&D خود متشکل از نخبگان دانشگاهی به تولید بتن های سبک متخلخل و ساخت ماشین آلات تمام اتوماتیک آن، در حوزه مکانیکال پرداخت.
لذا در راستای دستیابی به تکنولوژی روز، مورد استفاده در اروپا در زمینه ساخت بتن متخلخل کامپوزیتی اقدام به بومی سازی کامل و تولید یونو بتن سبک polystyrene concrete با تکنولوژی pc lc پرداخت. سپس به طراحی خط تولید تمام اتوماتیک یونو بتن سبک جهت تولید انبوه "بلوک یونو بتن سبک polystyrene concrete blocks" و محصول ویژه "پانل درای وال یونو بتن pc panel" با قابلیت نصب پوسته گچ برگ یا فایبر سمنت روی آن با سبد 4 نوع محصول برای کاربردهای مختلف تحت یک فرآیند تولید پرداخت.
این تکنولوژی تحت ثبت اختراع ملی به شماره 51024 در اداره ثبت شرکت ها و مالکیت صنعتی، ثبت شده و جزو طرح های برتر بنیاد ملی نخبگان و معاونت علمی ریاست جمهوری بوده و تحت مالکیت فکری و معنوی این شرکت دانش بنیان می باشد.
یونو بتن سبک polystyrene concrete یک ماده کامپوزیت است که متشکل از سیمان پرتلند و پودر سیلیس یا fly ashو پر کننده یونولیت EPS خروجی از خط تولید یونولیت و دو نوع ادتیو یا افزودنی پودری و مایع، است. این بتن کامپوزیتی با کنترل مقدار اجزای آن، در تیپ ها و دانسیته های مختلف از D400 تا D1200 تولید می شود که به صورت اتوماتیک با سیستم کنترل بچینگ plc، قابل برنامه ریزی در تابلو کنترل مانیتورینگ دستگاه، می باشد.
پانل های pc panelدارای خصوصیات بالای عایق حرارتی و صوتی بوده و در حالیکه سبک ، محکم و نازک می باشند از فشردگی بالایی برخوردارند و در برابر رطوبت ، یخ زدگی و حریق نیز مقاوم می باشد. یونو بتن توسط مرکز تحقیقات ساختمان و مسکن مورد آزمایش و تایید قرار گرفته و بعنوان یک پارتیشن جدید معرفی گردیده است. ضمنا دیوار فوق مورد تایید محیط زیست بوده و هیچ نوع موادی که برای انسان مضر باشد در آن وجود نداشته و مناسب برای محیط های داخلی ساختمان می باشد.
طرح توجیهی اقتصادی و برآورد هزینه یک خط تولید بتن سبک گازیAAC با برند اروپایی تقریبا 50 برابر خط تولید تمام اتوماتیک یونو بتن سبک با ظرفیت مشابه است. یونو بتن سبک محصولی است که هم اکنون در اروپا در سطح وسیع استفاده می شود و از مزایای آن جذب آب بسیار پایین تر از بتن سبک گازی و سطح عایق بالاتر به علت استفاده از فناوری ترکیبی پلی استایرن و بتن متخلخل است. قابل ذکر است این خط تولید دارای توجیه فنی و اقتصادی بسیار مناسب برای دارندگان خط تولید یونولیت می باشد.
همانطور که تصاویر گویا است درصد وزنی جذب آب هپلکس 70% نسبت به وزن نمونه خشک آن است که کاربرد این محصول را در شرایط و مکان های تحت رطوبت محدود می کند و همچنین درصد چسبندگی ملات به آن نیز پایین می آید ولی در یونو بتن سبک جذب آب 15% حجمی می باشد و هیچ محدودیتی در کاربرد های با رطوبت بالا و چسبندگی ملات ندارد.
Description and basic properties of polystyrene concrete
from siberian Constructing Technologies
Polystyrene (STATE STANDARD R 51263-99) is a composite material consisting of Portland cement and its varieties, silica aggregate (silica sand or fly ash from thermal power station), a porous filler (foamed polystyrene granules)and modifying agents (setting accelerators, plasticizers, etc.)When we control the ratio of the components in the mixture we can get different brands of polystyrene on the indices of the average density in the dry state from D150 to D600. As a result we get both constructional and insulation material.
Due to good thermophysical properties of polystyrene this material can be used as an independent system of thermal insulation of external walls instead of using the so-called fastened insulation systems, where mineral wool, or a more popular solution – polystyrene is used as lagging.
Polystyrene concrete field of application for objects of housing and industrial construction is extremely wide:
- Production of ready-mixed polystyrene concrete mixtures of different density;
- Monolithic thermal insulation of attic floors and roofs;
- Erection of exterior walls in permanent shuttering for skeleton-type buildings;
- Insulation of external walls and surfaces of reconstructed buildings;
- Monolithic insulation of elements of exterior walls and floors;
- Monolithic exterior and interior walls and partitions;
- Manufacture of light insulation products for the construction of bearing and self-supporting elements (wall blocks, internal partition blocks, etc.).
Polystyrene concrete combines high-quality technical, operational and cost characteristics and is the best alternative to the traditional heat and sound-insulating materials.
Many of Russia's architects, builders and the tenants have appreciated the outstanding properties of polystyrene concretee as the most appropriate modern and promising material for efficient construction.
Manufacturing technique of small-size products of polystyrene concrete
Main technological operations:
- Foaming of polystyrene granules;
- Drying (maturing)of polystyrene granules;
- Batching of raw components;
- Preparation of polystyrene concrete;
- Molding of polystyrene concrete mass;
- Hardening of polystyrene concrete mass;
- Cutting the polystyrene concrete mass into blocks with specified sizes;
- Storage of polystyrene concrete blocks.
- Foaming of polystyrene granules.
The process of foaming of polystyrene granules consists of pre-foaming and drying (maturing of) foamed polystyrene granules. Polystyrene pellets from feed bind bunkers are delivered to the prefoamer by a screw conveyor. Under the influence of water steam polystyrene pellets grow soft and begin to froth. Polystyrene granules become increased in volume and are being replaced by non-foamed granules. Auger blades mix the foamed polystyrene pellets, preventing adhesion and contributing to the uniform movement of the material to the unloading window of the set, with the constant impact of water steam.
Drying (maturing) of polystyrene granules
Foamed polystyrene pellets contain up to 10-15% of moisture, besides there is a negative pressure inside the pellets due to condensation of water steam. This may lead to deformation (compression) of foamed polystyrene pellets. Pellet compression dramatically reduces the amount of material and leads to a significant increase in bulk density. That’s why foamed polystyrene granules must be dried to stabilize the internal pressure and hardening of the outer walls of the granules. The use of pneumatic drying and transporting units for foamed polystyrene allows us to quickly and effectively reduce the residual moisture content of the material to 6.3%, while moving the material into maturing bins. Foamed polystyrene pellets remain in the maturing bin about 4-12 hours, depending on the grain size, bulk density and residual moisture. Significant reduction in the exposure time can be achieved by applying the method of pumping granules with heated air flow from on bin to another. In this case maturing time is reduced to 2-3 hours.
Batching of raw components
Ready foamed polystyrene granules from the maturing bin are delivered by the air flow through blast line into the receiver-bin of volume batcher. As the batcher is full, the granules fall into the mixer. Cement and fine-dispersed filler (fly ash) from storage bins by means of screw feeders are in turn fed into the bin of the weigh batcher. When the bin of the batcher is filled with necessary quantity of material the screw feeder turns off. Then the batcher pneumatic flap opens and the material goes to the mixer. Water is poured into special tanks before the shift starts. Recommended mixing water temperature is +40-50 * C.
Preparation of polystyrene concrete
Components of polystyrene concrete (foamed polystyrene granules, cement, inert filler, water, additives) in dosed parts are fed into the mixer. Dosage of the components is determined by the technological regulations of the enterprise. The sequence of loading of the mixture components: Loading of polystyrene component into the working mixer is carried out in the following order. First, the mixer is fed with dosed by volume polystyrene, then water and chemical additives. The mixture is stirred for 1-2 minutes. Then the mixer is loaded with dosed cement (filler) and the mix is stirred for not less than 3 minutes to obtain blended homogeneous porous structure. The total duration of polystyrene concrete preparation process, including the time of loading of components and duration of their mixing must be at least 3-5 minutes. In the process of mixing the components the condition of polystyrene concrete, its plasticity should be visually controlled. Molding of polystyrene mass. It is a process of casting the polystyrene concrete mixture into the pre-greased molds for forming the polystyrene mass.
Hardening of polystyrene mass
The speed of hardening of the polystyrene mass in the molds depends on the following major factors: binder activity, temperature in the room and the presence of thermal processing chamber. Using the chamber allows you to speed up the process of getting demoulding strength, as well as to obtain polystyrene concrete with high strength characteristics. Use of mobile forms with demountable sides allows you to eliminate lifting mechanisms from the process, which in turn reduces the consumption of materials and material costs.
Cutting the mass into polystyrene concrete blocks with target sizes
Cutting the mass into polystyrene concrete wall blocks with target sizes is carried out by using an automated cutting complex. Performance of the complex is 4 - 5 m 3 / h, and during one working shift (12 hours), performance may be 40 - 60 m 3.This is achieved through the features of manufacturing of the cutting complex. The cutting complex is operated by only two people.
Storage of polystyrene concrete blocks
After sawing finished blocks are stacked on a pallet and wrapped in stretch tape. The pallets with polystyrene concrete blocks are kept in stock of finished goods until they have 70% of strength and selling moisture not more than 25% (7-10 days). The temperature must be at least 15 0 C. The pallets with the blocks are set in 2-3 storeys, occupied area is calculated on the basis of daily performance.
Technology of preparation and casting of in-situ polystyrene concrete
Monolithic polystyrene concrete is an effective, environmentally friendly, durable and robust wall material, which is increasingly in demand in the construction market. The developed technology allows production of monolithic polystyrene concrete directly on the construction site and provides transportation of foam concrete mix by gerotor pumps without delamination, and also allows casting of the mixture into the formwork without vibrocompaction. Application of monolithic polystyrene concrete in exterior walls instead of block wall masonry enables to:
- Increase the coefficient of thermotechnical homogeneity and respectively increase by 30% or more wall heat transfer resistance, by excluding masonry joints of heat-conducting cement-sand mortar;
- Reduce labour coefficient of the walling;
- Increase rate of progress of the construction work.
Main technological operations:
- Preparation of polystyrene concrete;
- Laying the monolithic polystyrene concrete;
- Hardening of monolithic foam concrete;
Preparation of polystyrene concrete
Components of polystyrene concrete (foamed polystyrene granules, cement, inert filler, water, additives) in dosed parts are fed into the mixer.
Dosage of the components is determined by the technological regulations of the enterprise.
The sequence of loading of the mixture components:
Loading of polystyrene component into the working mixer is carried out in the following order.
First, the mixer is fed with dosed by volume polystyrene, then water and chemical additives.
The mixture is stirred for 1-2 minutes. Then the mixer is loaded with dosed cement (filler) and the mix is stirred for not less than 3 minutes to obtain blended homogeneous porous structure.
The total duration of polystyrene concrete preparation process, including the time of loading of components and duration of their mixing must be at least 3-5 minutes.
In the process of mixing the components the condition of polystyrene concrete, its plasticity should be visually controlled.
Laying monolithic polystyrene concrete
Is a process of casting a mixture of polystyrene concrete into prepared formwork.
Hardening of monolithic foam
The rate of solidification of monolithic polystyrene concrete depends on the following major factors: binder activity, temperature in the room.
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# |
Item |
Q-ty |
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1 |
Complex of design and technological development on polystyrene concrete production |
1 |
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- process design of the line; - layout arrangements (plan of equipment placement) on customer’s areas); - estimation of company’s work pattern and production plan; - estimation of acceptance and storage site of raw materials and components; - estimation of mixing site; - estimation of foaming area; - equipment selection and specification; - description of polystyrene concrete products’ manufacturing techniques; |
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- Technologist’s visit for compositions selection, development of processing methods for products manufacturing, and also staff training. |
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- Development of individual process regulations of goods’ production. |
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Sector of storage, preparation and feeding of raw materials |
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1 |
Silo for cement storage, 50 t (set of drawings) |
1 |
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List of equipment: |
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Filter |
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Feeding pipeline |
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Ladder |
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Hatch |
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Head guard |
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Aeration system |
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Collector |
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Vibrator |
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Cement shuttle |
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2 |
Cement screw conveyor * (L - 6 m*, gear motor (Italy), N – 4 kW) |
1 |
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3 |
Transfer screw conveyor* (L - 2 m*, reverse, gear motor (Italy), N – 3 kW) |
1 |
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4 |
Water treatment complex (N – 27 kW) |
1 |
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List of equipment: |
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Bin for storage and warming of water (V – 1,0 m3) |
2 |
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Electric boiler (24 kW) |
1 |
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Circulating pump |
1 |
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Water boosting pump |
1 |
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Float switch |
1 |
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Solenoid valve |
1 |
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One-way valve |
1 |
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DV-1700 Electronic water gauge |
1 |
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Control panel |
1 |
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Frame |
1 |
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Switching system |
1 |
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EPS Foaming area |
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1 |
PND-500 Pre-foamer (N – 3,3 kW) |
1 |
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List of equipment: |
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Polystyrene foaming machine |
1 |
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Intake hopper for raw materials |
1 |
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Intake hopper for secondary foaming |
1 |
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Raw material feeding screw |
1 |
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Screw feeding granules for secondary foaming |
1 |
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Frame |
1 |
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Control panel |
1 |
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2 |
PGES-50 Steam generator (N – 40 kW, 50 kg/hr) |
1 |
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3 |
EPS granules drying machine (N – 17 kW) |
1 |
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List of equipment: |
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Drying machine body |
1 |
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Electric calorific installation SFOC-16 |
1 |
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Low pressure radial fan (1,5*3000) |
1 |
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Control panel |
1 |
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4 |
EPS granules ageing hopper 40 m3(set of drawings) |
4 |
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5 |
Pneumatic transport system (N – 3 kW) |
1 |
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List of equipment: |
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Low pressure radial fan (1,5*3000) |
2 |
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Galvanized pipeline |
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Dampers |
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Inserts, bypasses |
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Mixing section |
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1 |
Bridge(set of drawings) |
1 |
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2 |
Electronic control system* |
1 |
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3 |
Cement weigh batcher (weighing capacity range to 1000 kg) |
1 |
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List of equipment: |
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Strain sensors |
4 |
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El. Vibrator EV-320 (N – 0,2 kW) |
1 |
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4 |
EPS volumetric batcher 1,0 m3 |
2 |
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5 |
Polystyrene concrete mixer RSG -900 (with embedded foam generator, N – 5,5 kW) |
2 |
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6 |
C200LB40 Compressor (8-10 atm., 500 l/min) |
1 |
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7 |
Gerotor pump GN-10 (N – 5,5 kW) |
1 |
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Thermal treatment sector Thermal treatment chambers are to be made by a customer according to design |
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Sawing sector |
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1 |
ARK Automatic cutting set for vertical and horizontal sawing of mass with saw bands* (N – 13 kW) |
2 |
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List of equipment: |
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Rail tracks (L – 2,4 m) |
2 |
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Remote control console |
1 |
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2 |
Mould for filling FM-0,85 m3 (V – 0,85 m3) |
94 |
* Final cost is determined after the stage of design in view of a placement
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List of auxiliary equipment and materials (to be purchased by a customer) |
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Special vehicles |
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1 |
Forklift (2-3 tons) |
1 |
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Auxiliary equipment |
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2 |
Ventilation system (supply&exhaust) |
1 |
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3 |
Stocking hydraulic carts |
3 |
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4 |
Household equipment, tools |
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Other |
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Packing equipment and materials |
Consumption per month (25 work days) |
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5 |
Pallets for blocks stacking (reusable), pcs. |
2000 |
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6 |
Machine for strapping with polypropylene type, 2pcs |
--- |
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7 |
Polypropylene string, m |
30000 |
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8 |
Wrap tape, m |
60000 |
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Area of production site required 1000-1200 m2
Ceilings height min 6m
Temperature indoor min +15..+200 С
Electric power required 100-120* kW/hr
Water system required
Staff required – 10 persons, technologist/supervisor – 1 person
Materials consumption*
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Mark by average density |
D 200 |
D 300 |
D 400 |
D 500 |
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Materials consumption |
Cement, t |
1 m3 |
0,2 |
0,25 |
0,35 |
0,4 |
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Shift |
16 |
20 |
28 |
32 |
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EPS, m3 |
1 m3 |
0,6-0,8 |
0,6-0,8 |
0,6-0,8 |
0,6-0,8 |
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Shift |
48-64 |
48-64 |
48-64 |
48-64 |
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Air retaining substance, kg |
1 m3 |
0,25 |
0,2 |
0,15 |
0,12 |
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Shift |
20 |
16 |
12 |
9,6 |
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* Mixes can be corrected in view of the Customer’s raw materials’ peculiar properties
Distinctive feature of automatic Batching Complex is that complex equipment is assembled and installed as single module ready for operation. All complex elements are notable for high reliability and showed themselves to good advantage during operation as parts of automatic production lines.
The complex consists of bridge, 2 section weigh batcher, complex control panel and water metering unit. For polystyrene concrete production complex is additionally equipped with volume batcher of polystyrene foamed granules
Principle of operation is the following: before starting operator selects required density on the control panel. Program memory may have few formulations for different density types of material. You can change density pressing one button. The operator shall press «пуск» (“start”) button. By means of the pump water goes into electronic batcher DV-1700 and then to the mixer. When mixer is full with required amount of water feed automatically stops. By means of screw or belt conveyor raw materials (cement, sand or other) by turn go to the weigh batcher equipped with tensometric sensors (according to rate of application for selected density). When batching is done pneumatic drive opens gate of batcher hopper, and raw materials start unloading to the mixer. During preparation of solution in the mixer, weigh batcher shall be loaded with cement and sand in automatic mode, and when load is completed cycle repeats
