The workshop of the ZHBI plant with a capacity of 30 thousand m ³ per year - AR

Contents

Introduction

1. Choice of Production Technology

2. Calculation of material requirements

3. Calculation of material warehouses and required process equipment

3.1 Calculation of cement warehouse

3.2 Calculation of aggregate warehouses

3.3. Calculation of Finished Goods Warehouse

4. Rebar Shop

5. Calculation of concrete mixing shop

6. Molding of articles

8. Plant Master Plan

9. Quality control of liquor production

10. Labor protection, safety measures, production sanitation and fire-prevention actions

List of literature used

Graphic part:

Sheet 1 - Shop plan at elevation 0.000 m, section 1-1, section 2-2;

Sheet 2 - Plot Plan

Introduction

Reinforced concrete compared to other building materials appeared relatively recently and almost simultaneously in Europe and America. However, by now it has become the most widespread in construction, has its own history and its outstanding figures.

Reinforced concrete consists of concrete and steel reinforcement, rationally located in structures for perceiving tensile, and in some cases - compressive forces. Concrete, being an artificial stone, resists compression well and is much worse (1020 times) - stretching. This feature of concrete is most unfavorable for bent and stretched elements, widespread in buildings and structures.

Reinforcement (reinforcement) of the stretched zone of bent elements by materials having significantly higher tensile strength than concrete makes it possible to significantly increase their bearing capacity. This material is most often steel, and structures obtained on the basis of rational combination of concrete and steel, provided that their joint work is ensured, are called reinforced concrete .

The main advantages of reinforced concrete, which provides it with wide distribution in construction, include: fire resistance, durability, high mechanical strength, good resistance to seismic and other dynamic effects, the ability to erect structures of a rational shape, low operating costs (compared to wood and metal), good resistance to atmospheric effects, the possibility of using local materials. Energy costs for the production of reinforced concrete structures are significantly lower than metal and stone. Disadvantages of reinforced concrete: high density, high heat and sound conductivity, labor-intensive alterations and amplifications; necessity of holding till strength acquisition, occurrence of cracks due to shrinkage and force effects. Many of these disadvantages can be eliminated by using concrete on porous aggregates, special treatment (steaming, vacuuming, etc.), preliminary stress, etc.

Production of prefabricated reinforced concrete products, as a rule, is organized at specialized enterprises in separate workshops or spans of construction materials plants, at landfills of construction sites or enterprises. The final products of these types of enterprises are reinforced concrete products, and in some cases commercial concrete.

Plants for the production of prefabricated reinforced concrete products include: workshops of the main production, concrete mixing and reinforcement workshops, warehouses of cement, aggregates, reinforcement steel, molds, finished products, various materials, including fuels and lubricants, transformer substation, compressor, laboratory and repair units.

In the course project, the ZHBI plant with a capacity of 30 thousand m3 per year was designed. Nomenclature of manufactured products :

beams rafter 11950х1400х300;

crossbars 11975х520х850 .

4. rebar shop

Reinforced concrete products and structures are reinforced with pre-fabricated welded reinforcement elements in the form of grids, as well as flat and spatial frames. These elements form the main - working, distribution and installation fittings. Auxiliary reinforcement are loops, hooks, retainers, embedded metal parts.

In order to reduce the cost of direct reinforcement of structures, it is necessary that the reinforcement elements have the highest degree of readiness, be as large as possible and do not require any additional pre-assembly operations on site.

Reinforcement is manufactured at the reinforced concrete plants in the reinforcement shop on production lines equipped with high-performance welding and other machines. The manufacturing process should be based on the principle of a single process flow from the preparation of reinforcement steel to the production of the finished product, if possible without intermediate transshipment operations and interoperative storage of blanks and semi-finished products.

Reinforcement frames and grids are manufactured in accordance with working drawings, which indicate the class, steel grade and length of rods, their diameter and number, pitch of rods in longitudinal and transverse directions, places of welding of embedded parts, mounting loops, etc.

The production of reinforcement products provides for the organization of storage of reinforcement steel in warehouses. Reinforcement steel warehouses shall be covered and equipped with crane racks adjacent to the reinforcement shop. High-strength wire and products from it are stored in closed rooms. Reinforcement steel is placed in the warehouse of the plant by grades, profiles, diameters and lots.

Reinforcement steel is transported from the warehouse to the reinforcement workshop using an electric car or car. Reinforcement is delivered internally by bridge cranes, telefers, auto and electric cameras, and manual trolleys.

The layout of the reinforcement shop is determined by the type of products produced and their complexity and can be different. Depending on the type of reinforcement shop, its location with respect to the moulding shop is determined - in the same unit as the moulding shop or in a separate building. If the plant has a limited range of products not exceeding 10 standard sizes, then it is advisable to place the reinforcement workshop together with the molding in one block.

The reinforcement shop blocked with the moulding has three equipment layout diagrams. The first scheme - the equipment is placed in front of the molding units, on the same spans, and in the second scheme - parallel to the molding shop, in a separate span and more often in a separate transverse span adjacent to the ends of the molding span. The third scheme allows installation of equipment along the process flow and eliminates counter movements of reinforcement blanks, which is not always achieved in the first scheme.

Reinforcement shop consists of separation of billet, welding, pre-assembly and manufacturing of embedded parts. These departments perform the following main operations: editing, cutting, bending and butt welding (billet); welding of flat frames and grids; bend grids and frames; preliminary assembly of volumetric frames; manufacturing and metallization of embedded parts; rework of reinforcement articles (welding of reinforcing rods and embedded parts, cutting of individual rods to form holes in meshes, etc.).

In accordance with the necessary processes, rebar shop equipment is selected and arranged. The equipment includes:

1) machines for straightening and cutting reinforcement steel, combining all operations for cleaning, straightening and cutting reinforcement steel and its strengthening by drawing; steel electrothermal hardening machines ;

2) machines for cutting rod reinforcement - drive scissors or combined presses;

3) machines for bending individual reinforcement rods and flat grids ;

4) welding equipment - welding arc devices, butt, point and multipoint machines.

Since the production of reinforcement in the workshop is carried out by several flows, then the arrangement of equipment in the workshop is carried out by in-line mechanized lines. Machines and apparatus are installed in strict sequence of technological process. One flow line is created for the manufacture of light reinforcement nets, the second for heavy reinforcement. Between the flow lines along the workshop there is a transport passage with a width of 3.0-3.5 m when transporting fittings with wagons.

Finished reinforcement products are transferred to self-propelled trolleys, which deliver them to the molding stations of reinforced concrete products.

8. plant master plan

The general plan of the plant is a graphic image of all buildings and structures of the ZHBI plant, as well as warehouses, transport and energy facilities, engineering and technical communications, a network for organizing the maintenance and protection of the enterprise, elements of landscaping.

Plot plan of the plant with capacity of 30 thousand m3 per year:

In the main body there are two bench lines for the manufacture of rafters; bench line for making girders. In parallel to the main spans of the main body, a reinforcement workshop is located, which makes it possible to supply reinforcement to these spans using self-propelled trolleys. The concrete mixing shop is attached to the main building. It has one mixer, of which the concrete mixture is fed to the overpasses into the spans of the main body.

The spans of the finished product warehouse are placed perpendicular to the spans of the main body and are equipped with bridge cranes.

Delivery of main raw materials is carried out by railway transport, and export of finished products - by car.

Main technical and economic indicators of the master plan:

- building area 10652m3;

- area of the section 46750m3;

- landscaping area 28208m3;

- building factor 0.23;

These indicators must comply with the requirements of building codes and regulations.

9.1 Concrete Strength Control

The design grade of concrete is determined by testing before destruction of control samples, release and transfer - by testing before destruction of control samples or by non-destructive methods (ultra-sound method; plastic deformation method, including determination of strength by Kashkarov hammer; elastic rebound method; the method of tearing off and the method of chipping the rib of the structure ).

Concrete strength assessment based on test results of control samples and results of tests by non-destructive methods is carried out by static method taking into account actual homogeneity of concrete characterized by coefficient of variation. With high homogeneity of concrete, the standard value of concrete strength adopted during design is provided at an average strength less than normalized. This makes it possible to reduce cement consumption.

Prefabricated reinforced concrete structures are accepted in batches on concrete strength. The batch includes structures made of concrete of the same composition, prepared and laid during, as a rule, one shift or one day, but not more than one week in one technological complex.

When monitoring the strength of concrete according to the sample, at least two samples from different mixes and at least one sample per shift are taken from each batch.

During nondestructive testing, at least 10% of the batch and at least 3 samples shall be monitored. At the same time, the number of controlled areas in the batch should be at least 9.

Acceptance of the batch and sending of prefabricated reinforced concrete products to the consumer is carried out only after testing all samples related to this concrete series, or checking structures representing the batch by non-destructive methods.

To ensure the speed of static control, centralized processing of concrete strength information and output of required strength values using computers using specific calculation programs is advisable.

9.2 Pre-tension control of reinforcement

In the manufacture of prestressed reinforced concrete structures, the reinforcement tension force is measured by a pressure gauge, by the reinforcement transverse bracing force, by the frequency of the reinforcement natural oscillations and by the reinforcement extension.

The pressure gauge measures the force in the process of mechanical tension of the reinforcement with hydraulic jacks, therefore the pressure gauges and hydraulic jacks must be guessed together.

When measuring the reinforcement tension by the transverse bracing force, instruments with and without their own base are used. The tension force is measured after completion. The most common devices were PRD and PRDU.

The reinforcement tension force is also measured by frequency method after completion of reinforcement tension. The most common devices are IP11 type.

Tensile force measurement on reinforcement extension is used to control tensile force in parallel with other methods. The calculation of the controlled elongation value is carried out taking into account the elastoplastic properties of steel in accordance with GOST 2236277.

9.3 Quality control of embedded parts and reinforcement articles

When manufacturing welded frames, grids, embedded parts, geometric dimensions, appearance and quality of welded joints are controlled. The following geometric dimensions are subject to inspection: overall dimensions and the distance between the extreme rods along the length and width of reinforcement products; distances between rods; distances between elements of embedded parts and their mutual position; flatness of embedded parts elements; dimensions of welded joints; dimensions and number of external supports and other defects of welded joints. Additional deviations as per GOST 1092275.

When controlling the appearance, the absence of peeling rust and scale, traces of oil, bitumen, etc. is recorded, some types of visible defects of welded joints.

Reinforcement products and embedded parts are accepted in batches. The lot shall not exceed the number of items manufactured by one welder during one shift and shall consist of items of one type. The batch is accepted according to the results of at least 3 products.

9.4 Acceptance control

Acceptance control of prefabricated reinforced concrete products provides for checking their strength, stiffness and crack resistance and acceptance according to a set of quality indicators, on the basis of which a decision is made on the compliance of the product or batch of products with the requirements of State standards and working drawings.

The results of acceptance control, input and operational control data on quality indicators are recorded in a special log.

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