Fence Element Manufacturing Shop

1 introduction

Current state and prospects of industry development

Concrete, as practice shows, resists compression well and is much worse than stretching, so the inclusion of steel reinforcement in the stretched zone of the elements significantly increases their carrying capacity. Steel has high resistance not only to stretching, but also to compression and its inclusion in concrete in the form of reinforcement of a compressed element significantly increases its carrying capacity.

The prefabricated house building in comparison with the monolithic has a number of advantages, the main of which is the transfer of wet processes of forming and hardening concrete into the room and a decrease in the amount of labor at the construction site. However, the construction of prefabricated reinforced concrete requires huge costs to create its base, increases transportation costs, as well as the inertia of the construction complex. In terms of economy and efficiency, prefabricated reinforced concrete significantly loses its monolith, since a building made of prefabricated reinforced concrete in advance seems to be cut into individual elements that do not fully unite on construction, which sharply reduces the cost-effectiveness of the structure.

Monolithic reinforced concrete products and concretes are used in areas with difficult geological conditions, with increased seismicity, in places where there are no developed road networks, as well as in rural areas.

Also, when selecting concrete and reinforced concrete products for construction, it is necessary to take into account the properties of the material. For example, why build a one-story barn in the village from heavy concrete of high strength? It is much more rational to use cellular concrete with sand filler for these purposes. It will be much cheaper, and why overpay for the same quality.

Scientists in many countries are working on the problem of improving the properties of concrete, developing new additives, finding new technical solutions for installation, etc. At conferences and exhibitions, they exchange experience and show the results achieved. Huge funds are invested in this industry by states and various enterprises. The last decades of the XX century. marked by large changes in the theory of concrete and products based on it. Effective chemical modifiers of binding substances and concretes, active mineral fillers, new technological methods have appeared and gained widespread use. Our ideas about the structure and properties of concrete, the processes of structuring have been enriched, there are possibilities to predict the properties and manage structuring.

A feature of new technologies is the effective impact on the structure of the material at all stages of production. Preparation and selection of materials, design of the composition in accordance with design requirements, preparation of the mixture and moulding of the product, initial holding and setting, subsequent hardening - all these stages are linked into a single complex.

In the domestic industry, one of the significant consumers of fuel and energy is construction, and among its industries are prefabricated reinforced concrete enterprises, of which there are several thousand in the country. An analysis of the work of these enterprises showed that their energy consumption can be significantly reduced. Almost any production has real energy savings reserves. If these reserves are identified and technological processes are organized more rationally, then energy consumption can be reduced by at least 1.5 times. This will give the national economy a huge economic effect.

Concrete, having many remarkable qualities, at the same time belongs to very energy-intensive materials. According to the CSO, 1 cubic meter for production. m. prefabricated reinforced concrete on average consumes 470 thousand kcal; for the production of individual structures at landfills, as well as with imperfect technological processes, this consumption increases to 1 million kcal or more. Considering that the annual demand for energy resources of the prefabricated reinforced concrete industry is approximately 12 million tons of conventional fuel, it becomes clear that even a small percentage of its savings will release a large amount of fuel for other purposes of the national economy. The need for energy resources for the production of 1 cubic metre. m of prefabricated reinforced concrete products does not take into account the energy consumption necessary for the production of concrete components (cement, aggregates) and reinforcement, which are even more energy intensive .

At plants, there are noticeable losses according to 1 cc heating calculations. m of concrete in steel form up to 80 degrees (temperature of isothermal holding) requires approximately 60 thousand kcal. Since heating occurs gradually - at a rate of no more than 20 degrees per hour, this process is inevitably accompanied by a significant release of heat into the environment. With the serviceable equipment necessary for heat treatment of products, these losses reach 150 thousand kcal, which is 22.5 times more useful heat. With faulty or negligently operated equipment, as well as with an unjustifiably overstated heat treatment duration, losses are added to the mandatory (planned) losses, unproductive. They fluctuate very widely and in some plants reach almost 200 thousand kcal per cubic meter. m of concrete. Thus, the total heat losses are several times higher than the amount of heat spent on heating concrete with a mold .

Gradually, there is a tendency to move from low-quality concrete to medium and high-quality. The share of low-quality today accounts for about 17% of the total use of concrete. This is a positive trend, since better concrete is less susceptible to destruction and, accordingly, less requires repair. In recent years, the method of pre-heating concrete mixtures directly in mixers with the help of steam has been widely promoted abroad: aggregates and cement are loaded into the mixer and steam is supplied during their mixing. By heating the concrete mixture, the steam is cooled and condensed. The amount of steam supplied is calculated in such a way that after its complete condensation the water-cement ratio of concrete corresponds to the design one. In the mixer, the concrete mixture is heated to a temperature of not more than 60 degrees, after which it is supplied to the place of molding of articles.

General part

2.1 Feasibility study of the reconstructed workshop

The fence plate production workshop is designed on the basis of Belenergostroy OJSC, located 40 km from the city of Minsk, on the territory of Minsk CHPP-5 (Druzhny village). The company works cost-effectively, constantly updates its material base, conducts active work with customers.

Due to the increase in stability in the country, the pace of construction is increasing, which means the opening of a new workshop is economically profitable.

Water supply and water disposal of the enterprise carries out JSC ZhilkomuslugiSvisloch. Power supply is provided from Minsk CHPP-5. Thermal energy in the form of steam and hot water is generated by its own boiler room. Compressed air is provided from its own separate compressor station of type 4K20A.

Cement comes from the Kostyukovichi cement enterprise in wagonkhoppers by rail. Shcheben - from OJSC Granit, Mikashevichi is also delivered by rail. Sand - from a quarry near Radoshkovichi is delivered by the company's own vehicles. Reinforcement steel is delivered by rail from the Belarusian Metallurgical Plant in Zhlobin, the manufacturer of the additive is Ukraine LLC NPP in Rivne.

Labor force - able-bodied residents of the village of Druzhny and neighboring villages.

The products are shipped to the construction sites of Minsk and Minsk region by railway and road.

Process Part

3.4 Selection of process equipment

The equipment is accepted according to the presented diagram.

A concrete transfer hopper is used to feed the concrete mixture from the concrete mixing shop to the molding shop.

To lay the concrete mixture in the mold, a concrete laying device is used.

The SMZh concrete placer - 69A is applied

Total volume of hoppers, m3 2

Greatest laying width, mm 2000

Hopper feeder belt speed, m/min

large 9

Concrete laying speed, m/min 18

Installed power, kW 7.1

Rail gauge, mm 2810

Overall dimensions, mm:

length 3175

width 4000

height 2785

Weight, kg. 3700

Frame vibration platform is used for compaction of concrete mixture.

The frame VPG1.5h6 vibroplatform is accepted

Maximum load capacity, t 10

Disturbing force, kN 55

Oscillation frequency, Hz 25

Method of attachment of shapes Self-locking

The largest dimensions of the shape, m:

6000 length

width 1500

Installed power, kW 11

Overall dimensions, mm:

length 6700

width 2120

height 600

Weight, kg 3700

Automatic lock-on of SMZh-44 is used for movement of molds

Lifting capacity, t 8

Overall dimensions, mm

Length 3600

Width 2234

Height 1883

Pallet

Length 3530

Width 2730

Maximum height of molded article, mm 350

Weight, kg 910

For transportation operations, a bridge crane of type KM 10 is used.

Lifting capacity, t 10

Span, m 17

Maximum lifting height, m 16

Speed, m/min:

hook lifting 18.9

at trolley movement 45,4

at crane movement 118

Power of motor mechanisms, kW 18,9

Crane weight, t 30

For the export of finished products to the warehouse, self-propelled trolleys SMZh - 151 are used.

Lifting capacity, t 20

Limit range, m 120

Speed of movement, m/min 31.6

Installed power, kW 7.5

Overall dimensions, mm:

Length 7490

Width 2573

Height 1450

Weight, kg 3700

Mold is used to form articles

Overall dimensions, mm:

Length 4000

Width 2550

Height 160

Weight, kg 1700

Trolley of trailer SMZh-154B

Lifting capacity, t 20

Overall dimensions, mm:

Length 6900

Width 2500

Height 780

Gauge, mm 1524

Weight, kg 1700

3.5 Production and quality control of finished products

Various means of identification will be used to ensure traceability in order to enable causal analysis when product inconsistencies are detected in the workshop.

The identification objects will be:

- products - during manufacture, testing, storage, shipment;

- purchased products - during incoming control, production, storage;

- control, measuring and testing equipment - during operation, metrological confirmation of suitability, storage;

- samples and samples of test objects - during incoming control, control during production, final (acceptance) control and testing;

- Product status with respect to monitoring and testing.

The identification will be carried out by the personnel in accordance with the instructions on working professions, job descriptions in the following ways:

- products during production - a plate indicating the type of produced products, a passport (accompanying document) - by the workers of the workshop;

- products in the process of transportation, testing - labeling on products, label (label), stamp, etc., in accordance with the current TNPA workers of the workshop, OTC, CL;

- products in the process of storage, shipment (batches of products) - quality document in accordance with TNPA TOC employees;

- samples and samples of test objects during incoming control, control during production, final (acceptance) control and testing - acts of sampling, label, etc. - TSC employees.

Traceability of manufactured products from purchased raw materials to finished products is provided according to the following records:

- logs on accounting of incoming raw materials and materials;

- warehouse accounting cards;

- internal movement consignment note;

- incoming control logs;

- journals on accounting of production output, refinement of non-conforming products;

- specifications for shipment of products, etc.

Quality control of products should be carried out through incoming control of materials and products coming to the enterprise, operational control of all production processes, acceptance control of finished products and periodic tests. Required types of control and testing, periodicity, methods and executors are defined by process documentation, TNAP, incoming control diagrams.

Input, operational and acceptance control, as well as periodic tests, shall be carried out by test units (complexes) certified (accredited) in the established manner.

Quality indicators of incoming materials and components during incoming inspection should be established on the basis of quality documents (passport, certificate), as well as control tests.

Type, periodicity and procedure of incoming control are established by process documents.

During operational control, compliance of process parameters of production processes, as well as quality indicators of products with standards (specifications), working drawings and process documentation is determined.

The scope, organization, periodicity and methods of operational control should be regulated in the process documentation depending on the type of products produced.

Acceptance control is final and is carried out after the production of products before they are delivered to the finished product warehouse. During acceptance of the products, compliance of the appearance, shape and dimensions of the products with the requirements of the working drawings, technical standards is established. In addition, the correct reinforcement of the products, the location of embedded parts and the size of the protective layer, as well as the actual strength of concrete in the finished products, must be checked.

The products can be sent to the consumer only in case of positive results of all tests provided by the TNPA and issuing a Technical passport signed by the head of the OTC or another authorized employee of the OTC.

Periodic tests are also carried out on a series of samples made from a concrete mixture of working composition, that is, they are transferred to a test complex that is not in the enterprise.

In the event that the products, including those purchased, do not meet or may not meet the established requirements, the procedure for managing non-conforming products is carried out, which includes:

- detection of non-conformity;

- identification of non-conformance;

- insulation;

- registration of non-conformance;

- making a decision;

- analysis of reasons for production of non-conforming products;

- development of corrective and preventive actions.

The procedure for managing non-conforming products is described in the relevant organization standard, in which:

- personnel responsibility is determined at each stage of management of non-conforming products;

- The authority to decide on non-conforming products is defined, which may be as follows:

The products shall be reworked;

The products are considered unsuitable;

- the procedure of re-verification (verification) is established for the modified (corrected) products to confirm compliance with the established requirements;

- A form has been established for keeping records on the nature of inconsistencies and subsequent actions taken .

Instrumentation & Process Automation

5.1 Value of Automation in Improving Product Quality

Automation is also among the measures for the development of new progressive technological processes, on its basis high-performance technological equipment is designed, which carries out working and auxiliary processes without direct human participation.

One of the main laws of the development of technology at the present stage is that automation penetrates into all branches of technology, into all links of the production process, causing qualitative changes in them, revealing previously unprecedented opportunities for increasing labor productivity, improving quality and increasing production, and facilitating working conditions. However, there are still a number of problems on which the acceleration of the development of automation tools depends.

Product developers and equipment creators do not have a single methodology, methods for analyzing the degree of readiness of products for automated production, methods for analyzing lines, their equipment with control and automatic control are not sufficiently covered.

The development of automation at the present stage is characterized by a shift in the center of gravity of mass development to mass production, which forms the main part of the engineering industry. Another characteristic feature of modern automation is the expansion of the arsenal of technical means and, as a result, the multivariability of solving problems of automation of production processes.

Automation requires different methods in the field of technology, new

approach to machine and product design than mechanized production system; it requires a rethinking of all elements of previous production, the introduction of a mass-flow method for the manufacture of technologically homogeneous products .

Process automation refers to a system approach to a complex task that includes the following interrelated problems:

development of the product technological design and advanced technological process ensuring production flow efficiency and controllability of process parameters and modes;

creation of the latest technological equipment capable of automating operations and communication with APCS (automated process control system);

development of an optimal automatic process and equipment control system:

Thus, complex automation covers the entire production cycle - from the introduction of raw materials (semi-finished products) to the production of a finished product of a given quality.

In relation to the tasks of automation of production processes, automated control is carried out using automated process control systems (APCS), in which the state of the process and technological facility is analyzed using computers. From this it is clear that automated control is carried out with the participation of people, including "decision makers," and the technical means of the control system, including computers, are a powerful tool that repeatedly enhances the capabilities of a person in the complex process of developing and implementing control decisions. Since APCS does not provide automatic control of processes and objects, that is, control without human participation, it can give the impression that the use of automated systems is a step backward compared to automatic control. However, this contradiction is easily explained by considering that automated management provides high-quality and efficient management of complex informal processes and objects, which cannot be achieved automatically. This does not mean, however, that computers cannot be used as components of automatic systems. Computer-based automatic control systems - real-time control systems - are widely implemented in modern manufacturing automation practices.

The highest form of automation is currently implemented with the help of flexible production systems (GPS), which create real prerequisites for the transition to deserted technology, to significantly increase the efficiency of modern industrial production. GPS is designed to provide comprehensive automation of the entire production process, significantly increase labor productivity and quality of manufactured products. The main advantage of GPS is the ability to quickly rebuild to change the range of products produced. This is due to the fact that the re-installation of the production line in the GPS is carried out by software controls with minimal or no changes in the composition of the equipment. Structurally, the GPS is a hierarchical three-level system. At the lower level, automation of the simplest technological operations is carried out using robots and manipulators performing welding, cutting, machining, etc. Automation at this level is based on robotic complexes controlled by microcomputers and microprocessors.

At the second level of the GPS, organizational and technological control is carried out by coordinating the work of modules for processing products, quality control, transport and storage systems. Control at the second level is carried out in the mode of automated dispatcher on the basis of terminal stations for processing technical and economic information, the operation of which is coordinated by the central computer.

At the third level of the GPS, operational and production management is carried out, which implements the functions of weekly and shift-daily planning, accounting and control. The basis of the third level of control is made up of automated systems of technological preparation of production based on mini-computers, which form a single control computing complex connected to the central computer.

Each problem of complex automation is an independent technical area, covering a wide range of specific tasks. In solving these problems, it is necessary to establish a relationship between technical areas, formulate a common goal and achieve mutual understanding between specialists of various technical areas involved in solving these problems.

5.2 Diagram of proposed automation of individual processes

productions

The automation diagram provides:

- automatic temperature control in the chamber

- stabilization of steam pressure in the steam line

- steam flow control

- monitoring and alarm of steam pressure drop

- monitoring and recording of temperature change in the chamber

- automatic ventilation in the chamber at the end of LRW FR cycle

The temperature control system consists of:

1-1, 21, 3-1, 41, 5-1) Copper resistance thermometer

1-2, 22, 3-2, 42, 5-2) Program temperature controller P31 installed on the board

1-3, 23, 3-3, 43, 5-3) Electromagnetic actuator

1-4, 24, 3-4, 44, 5-4) Steam line valve

Steam pressure stabilization system in steam line consists of:

6-1) Pressure takeoff device

6-2) Direct pressure regulator

6-3) Valve on steam line

Steam flow control consists of:

7-1) Diaphragm

7-2) Differential pressure gauge with differential transformer system

7-3) Secondary instrument recording steam flow rate KSD-3

Monitoring and alarm of steam pressure drop consists of:

8-1) Pressure takeoff device

8-2) Electrical contact signal pressure gauge EKM1U, installed in place

8-3) Alarm (siren and signal lamp)

This system is required for timely warning or action in case of drop or absence of pressure in the common line

Control and recording of temperature change in the chamber consists of:

9-1, 92, 9-3, 94, 9-5) Copper resistance thermometer

9-6) KSM-4 multi-point electronic bridge

Automatic ventilation in the chamber consists of:

1-2, 22, 3-2, 42, 5-2) Program temperature controller P31

10-1, 111, 12-1, 131, 14-1) Remote control panel

10-2, 112, 12-2, 132, 14-2) Magnetic starter

10-3, 113, 12-3, 133, 14-3) Fan

The ventilation system, depending on the technology, may or may not be, and the fan may be either individual or group.

Construction part

6.1 Brief description of the workshop building and its parts

One of the main conditions for industrialization of construction production

reduction of construction time is the maximum typification of prefabricated reinforced concrete structures. The designed workshop will be one storey with a full frame. Based on the design standards, sanitary and technical standards, the overall size of the equipment and its location of the fence plate production workshop, the unified standard span 1 (UTP 1) with overall dimensions is selected: length - 144 m, width - 18 m, height - 12.5 m.

The main elements of the framework are the foundation, columns, crane beams of the coating plates and construction links. Foundations are used separately reinforced concrete, on which columns and foundation beams are supported. Columns are used single-cone solid type with a size of 800 × 400 mm and a height of 10.8 m, and are embedded in "cups," locations at the top of the foundation. The coating consists of the main load-bearing elements: double-pitched reinforced concrete beam, reinforced concrete slab, insulation and steam insulation. As building elements, pre-stressed double-pitched beams with a length of 17960 mm and a height of 1350 mm are used. Reinforced concrete single-rail beams with a length of 11920 mm and a height of 1 m are used for laying crane tracks. Pre-stressed ribbed plates of coatings with a length of 11960 mm, a width of 2980 mm and a height of 450 mm are used as coating plates. For ventilation, holes with a diameter of 7001000 mm are provided in the plates to pass the ventilation shafts, ribbed plates are laid along the upper belt of the rafter beam. Reinforced concrete wall panels are used as the side walls of the workshop. The length of the panel is 11920 mm, the height is 1785 mm. For natural lighting of an industrial building, tape glazing is used. Window openings are filled with glass blocks. The workshop is equipped with a rolling gate less than 4.2 m high. When unlocking the gate, air curtains begin to work. To increase the building stiffness, stiffening diaphragms are provided between the webs along the length of the workshop. Wall panels rest on foundation beams of trapezoidal section, which are laid on upper stage of foundation. A roof is laid along the coating slabs, which consists of a cement sand wall, steam insulation, heat insulation, three layers of ruberoid impregnated with bitumen. The upper layer of bitumen is covered with gravel. Floors in the workshop are made of concrete grades M500. With a shop length of more than 100 m, a temperature-deformation seam is provided, which is located on the drawing of the construction axis. A pavement is provided along the perimeter of the building, which is made of asphalt concrete on a prepared base.

6.2 Industrial aesthetics

Of great importance in improving working conditions is the human environment: the interior of industrial and domestic premises; machines and appliances, working furniture, comfortable workwear, rational and convenient tool, rational light climate, landscaping of workshops and territory. Color painting of the surface of production rooms and process equipment shall be performed in accordance with "Instructions for rational color finish of the surface of production rooms and process equipment of industrial enterprises" and in accordance with the requirements of safety standards as per GOST 12.4.02676.

The color solution of the main surfaces of the production equipment is made complete with the architectural finishing of the rooms taking into account the orientation of the shape and size of the rooms, as well as the peculiarities of the technological process, the conditions of visual work, the nature of lighting. For color finishing of communication equipment and. The following functional colors shall be used for structural elements. Red - stop, prohibition, obvious danger, fire equipment; Yellow or Orange - attention danger; green - security; Blue is information. Pipelines - according to the standards "Identification painting of pipelines of industrial enterprises" and GOST 1420271. To preserve the quality of the colour finish of the equipment, measures should be provided to reduce contamination of the surface of the equipment. The colour finish of the equipment shall be periodically restored. Also in the industrial building and should be provided devices for access to sections of walls, ceilings, which should be painted periodically. Double-pitched beams, floors, window bindings must be painted white. All passageways, driveways, places for storing products should be indicated on the floor of the room with bold white lines. Enclosures of moving parts of machines, mechanisms shall be painted in the main color of this machine or mechanism. Inside the fence is red.

Conclusion

The construction of a workshop for the production of fence slabs is considered advisable, since at present the volume of construction in our Republic is increasing. The products produced will fully comply with the requirements of the RB standards, and the high quality of the products and the relatively low price will make it competitive in the market. In addition, these products meet the requirements of environmentally friendly products.