Gypsum board production shop with capacity of 5 mln m per year

Contents

1. Introduction

2. Product characteristics

3.Technical requirements

4. Basic raw materials and their requirements

5.Technological diagram

6.Define Enterprise Performance

7. Operating mode of the enterprise

8. Production program of the enterprise

9. The need of the enterprise in raw materials

10. Selection of process equipment

11. Quality control

12. Safety Technics

13. Literature

2. Introduction.

Builders learned to build a lot and quickly a long time ago, and they can be proud of this today. But time complicates the tasks - you need to build as best, more economical and environmentally friendly as possible, meeting the modern requirements of creating a comfortable habitat.

Every year in Russia, the popularity and scope of such environmentally friendly and excellent quality products as gypsum board, gypsum fiber sheets, dry mixtures based on gypsum binder is growing. Environmental friendliness is not the only advantage of the interiors of the premises finished with this product. Adopting decades-old foreign experience, architects and builders, using the unusual properties of plaster, were able to create unconventional architectural forms of walls, ceilings, transform the built-up space with minimal effort and time.

Gypsum board is a sheet finishing material certified in accordance with the requirements of GOST 626689. They also meet the German standard din 18180. By installing a partition wall or attaching a gcle to a brick or concrete wall or to a ceiling using a frame, you can abandon the "wet" keying, plaster, whitewash - a perfectly even surface of the factory made gcle is already ready for a wallpaper sticker or color. At the same time, gypsum board sheets manufactured at enterprises can be given special properties that meet the requirements of increased moisture resistance or fire resistance. Taking into account these properties, the glass is used in the interiors of showers and bathrooms, toilets, when finishing pools or other rooms exposed to wet air. When finishing rooms with increased fire safety requirements, a fire-resistant nail is used. All varieties and grades of glass retain their main property - the ability to "breathe," maintaining the humidity equilibrium of air due to the content of the main initial component in them - gypsum.

However, there is one area of ​ ​ internal work where the properties of the gypsum board are supplemented by another gypsum-based material - a gypsum fiber sheet. It is these products that are recommended for use in the construction of environmentally friendly and quick-mounting floors. Gvl is stronger than gkl, has high water and fire protection properties. Gwl is a homogeneous environmentally friendly building material made from gypsum grades g4, g5 and fluffed cellulose waste paper. Conventional gypsum fiber sheets are used for finishing rooms with dry and normal humidity conditions, and a special moisture-resistant gwl is used in high humidity conditions. Most preferably, gwl is used for the arrangement of prefabricated bases (dry ties) of the floor, in the arrangement of wall linings with increased requirements for protection against impact. Installation of gwl bases allows you to completely abandon the "wet" processes associated with manual labor in the construction of cement floor ties. The floors thus obtained are ecologically clean, chemically neutral and radiation safe. The experience of using prefabricated floors in Moscow and St. Petersburg showed that they are 200 people/days per thousand m2 of area less labor-intensive compared to the traditional method of flooring. These characteristics open up a wide range of possibilities to spread the technology of erecting prefabricated floors in residential, civil, industrial buildings with dry and normal humidity conditions under conditions of small and moderate mechanical loads .

In accordance with the conclusion of the Research Institute of Construction Physics, obtained on the basis of the results of the tests, gypsum fiber sheets can also be used for wall cladding, installation of frame inter-room partitions, suspended ceilings in residential, civil and public buildings, children's medical and medical institutions. The products are certified in accordance with the requirements of the 5742004035137797 and have a hygienic certificate, a fire safety certificate.

In all cases of using gypsum board and gypsum fiber sheets, complete systems based on them, sealing of seams and joints between individual sheets is recommended to be carried out using dry mixtures. At knauf enterprises in Russia, patches on gypsum astringent are made - fugenfüller and fugenfüllerhydro. They can also be used to glue a nail to an even base, seal cracks and other defects on the nail, fuse flat concrete and porous surfaces, fill the joints of prefabricated reinforced concrete elements. Another dry mixture - glue pearlfix - is intended for work on lining of glass walls, insulating materials and gypsum board combined panels.

Mixtures of fugenfüller and pearlfix feature high water retention and ductility, which saves up to 1015 percent of the binder. Mixtures are recommended for use in any type of finishing work and for any type of base. Mixtures of fugenfüllergs and pearlfixes are offered for installation of gwl.

4. Fire technical characteristics

GVL and GVLV sheets belong to flammability group G1 as per GOST 30244, flammability group B1 as per GOST 30402, smoke-forming capacity group D1 and toxicity group T1 as per GOST 12.1.044.

5. Acceptance Rules

5.1 Each batch of sheets shall be accepted by the technical inspection service of the manufacturer in accordance with the requirements of this standard.

5.2 Sheets shall be accepted in batches. The lot shall consist of sheets of the same type, type of longitudinal edges and dimensions made according to the same technology and of the same materials.

The lot volume is set in the quantity of not more than replacement production of the process line.

5.3 Acceptance control is carried out by carrying out acceptance tests according to the following indicators:

- appearance;

- shape and dimensions;

- weight 1 m2;

- flexural strength;

- surface water absorption (for HVAC sheets).

5.4 Five sheets shall be taken from the batch for acceptance tests by the manufacturer.

The selected sheets are checked for compliance with the requirements of this standard in terms of appearance, shape and size. In the case of positive control results, three sheets out of five tested are used to monitor the remaining indicators.

The batch shall be accepted if all sheets selected for inspection meet the requirements of this standard for the indicators specified in 7.3.

If unsatisfactory control results are obtained for at least one of the indicators specified in 7.3, repeated tests are carried out for this indicator, for which twice the number of sheets from the same batch is taken.

If the results of the repeated tests meet the requirements of this standard, the batch shall be accepted. If they do not satisfy, the batch is not subject to acceptance.

5.5 In case of non-compliance of a batch of sheets with the requirements of this standard in terms of appearance, shape and size, it is allowed to re-present it for inspection after disassembly.

5.6 A batch of HVAC sheets that does not comply with the requirements of this standard for surface water absorption can be accepted as a batch of HVAC sheets, if for all other indicators it meets the requirements of this standard for the specified sheets.

The product shall be re-labelled as specified in the accompanying document.

5.7 The manufacturer shall perform periodic tests of sheets to determine the hardness of the face at least once a quarter. Three sheets were taken from the batch for the test.

If unsatisfactory test results are obtained, the hardness of the face of each batch of sheets should be checked.

When positive test results are obtained, the five successive batches are again subjected to periodic tests.

The results of the periodic tests shall apply to all shipped batches of sheets until the following periodic tests are carried out.

5.8 For the value of specific effective activity of natural Aeff radionuclides in gypsum fiber sheets, the value of Aeff is taken in gypsum binder (gypsum stone) used for making sheets. This value is set based on the quality document of the supplier of gypsum binder (gypsum stone). In the absence of data on the Aeff value in the gypsum binder (gypsum stone) used, sheet tests for this indicator should be carried out at least once a year in accredited test laboratories and each time when changing the supplier of gypsum binder (gypsum stone).

5.9 Fire-fighting characteristics are determined during production, as well as during changes in the composition of the products, which can lead to changes in fire-fighting characteristics.

5.10 For inspection, sheets shall be selected by random selection from different batch locations.

5.11 During testing of sheets by the consumer, inspection and certification tests, the sampling volume and evaluation of control results are carried out in accordance with the requirements of section 4, using control methods.

5.12 The manufacturer shall accompany each batch of sheets or part thereof supplied to one address with a quality document indicating:

- manufacturer's name, trademark and address;

- name and symbol of sheets;

- batch number and date of manufacture;

- number of sheets in square meters and (or) in pieces;

- sign of conformity when delivering certified products (if provided for by the certification system);

- stamp and signature of the head of the technical control service;

- designation of this standard.

6. Transportation and storage

6.1 Sheets shall be transported by all modes of transport in accordance with the rules for the carriage of goods in force on this mode of transport and the requirements of other documentation approved in accordance with the established procedure.

6.2 Sheets are transported in packaged form.

Transport bags are formed from sheets of the same type, such as longitudinal edges and sizes using pallets or liners, which are made from wood, gypsum fiber sheets and other materials. Steel tape according to GOST 3560 or synthetic tape is used as bandages. Transportation bags can also be packed in polyethylene shrink film according to GOST 25951 or in polyethylene film according to GOST 10354.

The number of bindings, their section, dimensions of linings and pallets are set in the process regulations of the manufacturer.

In agreement with the consumer, it is allowed to transport sheets in unpacketed form (without binding or packaging in film).

6.3 Dimensions of packages shall not exceed by length 4100 mm, width 1300 mm, height 800 mm; package weight must not be more than 3000 kg.

6.4 When carried in open rail or road vehicles, the packages shall be protected against humidification.

6.5 Sheets shall be stored in rooms with dry and normal humidity modes separately by types and sizes.

6.6 Storage of sheets at the manufacturer shall be carried out in accordance with 5.5 and the process regulations approved in accordance with the established procedure, in compliance with the requirements of safety and safety of products.

6.7 Transport packages of sheets during storage at the consumer can be installed on top of each other in stacks in accordance with safety regulations. At the same time, the total height of the stack should not exceed 3.5 m.

6.8 During loading and unloading, transportation and warehousing and other works, impact on sheets is not allowed.

7. Guidelines for application

7.1 When applying sheets, be guided by the design documentation approved in accordance with the established procedure.

7.2 GVL sheets are used in buildings and rooms with dry and normal humidity modes in accordance with SNiP II3.

7.3 HVAC sheets are used in buildings and rooms with dry, normal and wet humidity modes in accordance with SNiP II3.

When using GVLV sheets in buildings and rooms with wet humidity mode, exhaust ventilation shall be provided to ensure standard air exchange in accordance with SNiP 2.04.05, SNiP 2.08.01, SNiP 2.08.02, SNiP 2.09.04.

6.Define enterprise performance.

The following approach is used for analytical assessment of requirements for partitioning materials in Perm Krai:

Based on the typical layout of the most mass apartments, when building an average apartment with an area of ​ ​ 54 m 2, 9 m partitions are required, with a ceiling height of 2.5 m. This will be 22.5 m 2, so if you still lay out the floor in 2 layers, and plus 2 partitions, then this will be 153 m 2.

Therefore, on 1m2 areas of the apartment you need to use

153m2/54m2 = 2.83 m2 GVL.

According to the presidential program, at least 2.5 million m of 2 housing should be built in the Perm Territory. 2,500,000· 2.83 = 7,075,000 m 2 GVL will be required in the construction of 2.5 million m 2 of housing

According to the State Statistics Committee of Russia for 2007, the production of wall materials in the Perm Territory amounted to 126 million conditional bricks or 2.1 million m of 2 housing. This means that 2100000· 2.83 = 5943000 m 2 of wall materials was spent on the GVL. We get that in the Perm Territory in 2007 there was a shortage of partitions in the amount of 1132,000 m 2 or 377333 pct of GVL.

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