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Automating line of Foam Concrete Production

Automating line of Foam Concrete Production NM-150

1. Automatic cutting machine

In cooperation with the world leader in the sphere of development of production systems foam NEOPOR SYSTEM GmbH company "ALVIKO" developed and successfully implemented an automated production line for foam concrete blocks of non-autoclave hardening.

The first line was launched in autumn of 2004 and continues to operate successfully, producing foam concrete blocks of varying sizes and density. Technology and manufacturing line processes are based on the same principle of rotation forms, which is used in the manufacture of autoclaved foam concrete / aerated concrete. Despite the fact that autoclaves are not included in the equipment, they can be installed if the customer prefers.



Line NM-150 has the following characteristics:

The production capacity

150m ³ / 24, 45.000 m ³ per year in 300 working days

Number of shifts

3

Products’ density

400-1000 kg / m ³

Foams’ sizes

1.540 x 1.640 Forms x 600 mm

The volume of forms

1,51 м³

Volume of blocks (net)

1.44 m ³ (after work of Skimming machine, etc.)

Endings

100% go to the next batching

Block sizes

can be changed (at least 100 mm)

The installed capacity of line

150 kW

Specific electricity consumption

6,8 kW /м³

Steam flow in the tunnel

0,04 kW /м³

Required area

length / width / height 80/24/12 Meters

The delivery includes the following equipment *

  • Screw Conveyors
  • Sand bunker with bottom-feeder
  • Sand elevator
  • Intermediate sand bunker.
  • Sand, cement, waste water dosage
  • Waste mixer
  • Foam generator NEOPOR
  • System of automatic dosage
  • CLC mixer (foam concrete mixer)
  • Vertical doors for tunnels
  • Chain pushers
  • Pushers / intakers
  • Holder of the pallet/trolley
  • Skimming machine
  • Cutting mashine
  • Waste pusher onto the waste return belt conveyor
  • Self-propelled trolley
  • String twisting machine
  • Mould
  • Pallet-trolley
  • Grab (Used to take CLC blocks off pallet-trolley and to put them onto shipping pallets).
  • Lubricant mixer
  • Electrical and Automatic Control System
  • Technical and design documentation
  • In some cases, it is possible to manufacture of the equipment by the customer .

The duration of manufacturing operations:

Filling foam concrete mixer

150 sec.

Mixing time

120 sec.

Submission of the foam

150 sec.

Additional mixing

90 sec.

Filling the forms with the foam concrete mixture

60 sec.

Total time to fill the form

9 minutes 30 sec.

Preparation of Mixing and pouring

5 fills per hour (7.2 m ³ units)

A set of plastic strength in the tunnel

4 hours 30 minutes

The process of cutting

9 minutes (1.44 m ³)

Hardening process in the tunnels

20 hours


The sequence of manufacturing operations

2. Sand elevatorКонвейер пода3. Sand & cement dosage4. CLC mixer (foam concrete mixer)осмеситель

Sand and cement (or cement only) from the preliminary bunkers fall into the metering tank, from which the raw material enters the horizontal foam concrete mixer. Its volume is 2.4 m3. Water is supplied after the uniform mixing of dry components. Next the accurately adjusted the volume of foam comes (a process is controlled by a timer). Dosing and mixing are controls with computer. After additional mixing, foam concrete is ready to be filled in a form that consists of a trolley and cone-shaped cap, its volume is1.51 m3. In contrast to the production of aerated concrete, the forms are filled to the brim. Specially established panel screen let us avoid splashes and bubbles inside the foam concrete massif.

Forms – trolleys are pushed by stepping pushers through the tunnel in which the foam concrete is gaining f plastic strength, sufficient for stripping and cutting into blocks of required sizes. At the exit of the tunnel of plastic strength, the massif must be sufficiently "hard" to be not destroyed by stripping, but rather "soft" to be cut by the strings of the cutting machine.

5.The tunnel, giving plastic strength
6. Holder of the pallet/trolley
7.Cutting machine

The edges of the massif, that are in contact with the form, processed with lubricant. Approximately one centimeter from the edges of the massif is cut and fed to the endings mixer for reuse as a raw material in the following mixing. The blocks stay on the pallet-trolley, that moves into the tunnel of curing to become more solid for storage.

Previous form is returned to the post-assembly of form-trolley. There cleaning and installation of form on a pallet-trolley, returning from a post unloading products, is produced. Each set of blocks (0.9 m3) placed on a wooden pallet and wrapped with plastic film to retain moisture, contributing to further increase the strength of the products.

Production capacity of line is 150 m3 according to work in three shifts (24 hours).

8. Control panel  9. The process of storing on the pallets
10. Labeled products are ready for use


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