Production lines of a concrete product plant
Based on twenty years' experience, having behind shoulders baggage from more than 400 executed projects in the field of the construction industry, the ELTIKON group of companies accumulated unique experience in system approach to reconstruction of the enterprises for production of precast concrete. Our decisions are based on deep understanding of technology production and about productions of production of concrete goods, good knowledge and continuous studying of the latest western equipment, the advanced trends in the field of automation and information technologies. All this allows us to propose to the Customer deeply worked and most weighed solution. One of characteristic examples of such decision is the reconstruction of the Gomel DSK executed by ELTIKON group of companies (Republic of Belarus).
The purpose of development of this project was modernization of the existing production with replacement of processing equipment for ensuring construction of housing of the modernized series 152M of 70,000 sq.m a year. The new modern processing equipment, both own production of ELTIKON group of companies, and the best global manufacturers providing the best technical and economic indicators (quality of a product, profitability, reliability, etc.) in the conditions of this enterprise was used to achievement of this purpose.
The choice of manufacturing techniques of concrete goods was made on the basis of the required listed products and the outputs on groups of products. All decisions on the choice of technology were agreed with the Customer.
When choosing technology solutions experience of the similar operating enterprises of the Scandinavian countries, Germany, Italy, etc. was considered.
Application of the high-performance automated Vekenmann line (Germany) for production of outside walls and plates of overlappings allowing to reduce labor input of production of products and to increase their quality significantly is provided in the project having reduced honing operations.
Application of an automatic cycle of preparation of concrete mixes on the modern high-precision equipment of production of ELTIKON group of companies allowing to increase quality of concrete mixes to the level of requirements of the European forming equipment is provided.
Supply of concrete is carried out by automatic system of the address delivery integrated into industrial control system of BSTs.
In the project the reliable modern automated equipment of the reinforcing shop allowing to reduce labor input of production, to automate production process is used, it is essential to increase its quality.
The full automation of reception, storage and holiday of fillers of concrete and cement reducing labor input of management of this process is provided.
All technological process of preparation of concrete mixes, beginning from receiving initial materials (fillers, cement) before delivery of mixes to the shop, it is completely automated and has the interconnected structure of management, accounting of data and storages of information.
In the project the automatic control system of heatmoist processing of products in cassette installations reducing labor input and increasing quality of products is applied.
In the project the modern technology of defrosting of inert materials allowing to lower energy consumption is applied and it is essential to increase quality of concrete mixes and products.
For improvement of environment protection and for reuse of the slime water received from residues of concrete mix which are formed in the course of a washing of BSTs concrete mixers, kibbles of address delivery of concrete, concrete placers, auto concrete mixers unit for utilization of liquid production wastes is applied.
Technological part of the present project provided full automation of management of the following productions:
- process on transportation of cement at its unloading from cars hoppers, is completely automated process of delivery of cement from a cement warehouse on BSTs in a complex with a cement overload node. These operations are controlled and controlled by the operator of a warehouse of cement.
- preparations of concrete mixes in BSTs, in a complex with supply of chemical additives from department of preparation of chemical additives, giving of a slime water from unit for utilization of liquid waste, supply of hot water from the modular power station. All process is controlled the operator of BSTs.
- loading process of a warehouse of inert materials in a complex with collection points for fillers from motor transport and from railway cars, and is also completely automated process of delivery of fillers from a warehouse of fillers on BSTs, with management of all path of pipelines in BSTs. This process is controlled the operator of a warehouse of fillers.
- process of control and management of the line of circulation a pallet in workshop in a complex from the gas boiler house for heating of cameras of drying of workshop and the system of address delivery of concrete from BSTs.
All above described control systems are completely interconnected that allows to accelerate process of transfer and exchange of necessary information between various divisions.
In the reinforcing shop process of editing cutting of fittings, production of grids and frameworks, production of brackets and loops on automatic machines is completely automated. Operations of manual welding are excluded to the maximum.
In flight process of thermomoist processing of products in cartridges is automated that excludes overheating of products, fast heating and other factors affecting quality of finished products.
In compressor completely automatic equipment excluding intervention of the person in technological process is installed.
In unit for utilization of liquid waste process of reception and division of waste process is also automated.
On all shops and sites of the plant all manual operations connected with movement of heavy freights installation of large-size elements are made by means of cranes and lifting mechanisms, carts. All labor-consuming operations are carried out by means of the mechanized tool.
The description to photos:
Pic. 1. Reconstruction of a concrete-mixing node, JSC Gomelsky DSK
Pic. 2. A post of the order of concrete mixes in forming workshop, JSC Gomelsky DSK.
Pic. 3. Concrete placer of the line of circulation pallet, JSC Gomelsky DSK.
Pic. 4. Process of molding of concrete goods, JSC Gomelsky DSK.
Pic. 5. The smoothing-down machine tenches of circulation a pallet, JSC Gomelsky DSK.
Pic. 6. System of address delivery of concrete mixes, JSC Gomelsky DSK.
Pic. 7. The transporting kibble of the ADB system, JSC Gomelsky DSK.
Pic. 8. Photos from the Gomel DSK
Pic. 9. Photos from the Gomel DSK
Pic. 10. Forming workshop of production of concrete goods, JSC Gomelsky DSK.
Pic. 11. Cassette installation of production of internal wall panels, JSC Gomelsky DSK.
Pic. 12. Reinforcing workshop, JSC Gomelsky DSK.
Pic. 13. Management system cassette installation, JSC Gomelsky DSK.
Pic. 14. The modular power station for heating and defrosting of inert materials, JSC Gomelsky DSK.
Pic. 15. Unit for processing of liquid production wastes of concrete, JSC Gomelsky DSK.
Pic. 16. Unit for processing of liquid production wastes of concrete, JSC Gomelsky DSK.
Pic. 17. Departments of preparation and storage of chemical additives, JSC Gomelsky DSK.
Pic. 18. Block of tensometric dosers of chemical additives, JSC Gomelsky DSK.