Methods for forming wood-concrete blocks
On the composition and we have already written about the proportions for the production of wood-concrete blocks of the mixture in the first part of this article. Today we tell about how to mold and to stamp wood-concrete mixture, as well as pre-engineered storage rules.
Currently, there are several ways of shaping wood-concrete mixtures:
- Manual compacting on the floor of the production premises.
- Manual compacting using vibrostanka.
- Mechanized vibro compacting method.
- Molding on vibrostanke with prigruzami.
Which one is more preferable - depends on the planned production volume.
Consider these methods in detail.
Manual compacting on the floor
The presented method is considered to be the most economical. As a rule, it is used when it is necessary to make the material for the construction of their own home, but sometimes this method is used when opening a new production.
a991ru (User FORUMHOUSE):
If a little money, I would start with the manual ramming (no machine at all), ie: hand ramming plus shaker table or just hand tamper. With the volume of 100-120 cubic meters per month - this is a great option.
The present method involves the following equipment:
- compulsory mixer type or capacity for hand mixing mixture (some use conventional mixers, but their application in practice is not always effective);
- steel molds for the blocks;
- manual ramming (steel);
- flat base on which are mounted forms (base covered with plastic film);
- pallets for storage of finished products.
Immediately after mixing wood-concrete mixture is decomposed according to the forms. Molding is performed in 2-3 stages: the mixture is placed in the mold in layers, each layer must sequentially ram. Before ramming mixture should proshtykovat using narrow forks.
Whichever method you choose molding, special attention should be paid to the design of the molds themselves. Thus, the shape size in length and width corresponds to the size of blocks. The height of the same shape is always larger than a predetermined size. This is done in order to fit into the mold could neutrambovannoy required volume of the mixture. compression ratio varies within the following ranges: from 1.2 to 1.6. In this case it will match the average density of the structural arbolita (700 kg / m³). In other words, if you block height is 37 cm, the minimum height of the form must be 44.5 cm. The form is filled to the top edge, and then the mixture was compacted to a height of the block (the above shape, the higher the density of the output blocks and, accordingly, their higher strength).
Blocks can immediately make universal that in size they could both be equally applicable to the construction of the walls (thickness of 37 cm), and for the construction of partition walls (thickness of 16 cm).
ecodrev (User FORUMHOUSE):
-50h37h16 size. Thanks to all forum this size and make. This unit is universal - for wall and partitions.
The thickness of the wood-concrete wall, protected from moisture ingress (isolated) should be 30 cm. If there is no protection - 37 cm.
Forms for arbolita do so either steel (stainless steel) or wood (with stainless steel paneling). Mold body should consist of two parts, wherein the bottom in such a construction will be omitted.
It connects the two halves by means of metal spikes.
Instead, use a plywood floor plate or flat surface of the concrete floor. The substrate must be covered with polyethylene film. This is done in order to protect the substrate from sticking to the mixture. In addition, for protection of the side and bottom surfaces of the mold from sticking arbolita can apply linoleum or special solutions. But which option is used to protect one of our portal.
Chomba (User FORUMHOUSE):
Long Wise different "chemistry", intended for lubricating metal molds. As a result, taken from food industry waste vegetable oil (at us the price - 650 rubles. 50 liters), we tried. For the second year they use only. It works fine.
Wood-concrete wall forms desirably provided with special clamps (latches).
Actuating during tamping mixture tamping they fix the cover at a position corresponding adjustment unit.
The lid is hammered by using the steel ram which is used to sequentially tamping several layers of wood-concrete mixture.
In manual molding process using multiple forms. Each of them is calculated by 1 or 2 block. This method allows for stripping finished articles like instantaneously (immediately after molding), and after a certain time (10-12 hours after molding). The second option provides a more durable product.
Carry blocks on pallets desirable, 2-3 days after stripping. Stack the blocks on top of each other can only 3-4 days after their manufacture and store the product in three rows (height) is possible only after 6-7 days after the stripping.
Despite the difference in the density of blocks obtained by manual tamping, with the technology of their strength will always meet building standards.
Manual compacting on the vibrating table
This molding method is to use all the tools that are listed in the previous chapter. The only thing that would have to be purchased separately - is itself a vibrating table.
The molding process forms wood-concrete blocks (together with the base covered with polyethylene) are mounted on the surface of the vibrating table. The mold is then filled with a mixture, which immediately proshtykovyvaetsya thin forks. In the next stage of the work is involved vibrostanok. The device is switched on for a short period of time: 10-30 sec. The exact time of the machine is set empirically.
After switching off the machine the mixture compacted with a hand tamper, and the seating of the cover. Formed units together with the base can be removed from the surface of the vibrating table.
Time vibration wood-concrete mix - this is one of the decisive factors which determine the quality of the finished blocks. Prolonged vibration leads to a deterioration of product quality.
Stripping can immediately produce, and it is possible later 10-12 hours after molding.
Advantages of forming on the vibrating table consist in the possibility of obtaining a more uniform block inside the structure. The density of the blocks produced during several batches will differ slightly (which is not about the quality of products obtained by conventional manual tamping).
Molding machine at vibropressovalnom
Molding units via vibrostanka requires primary and auxiliary equipment:
- capacity to dilute the chemical. additives;
- measuring tanks for filling cement and filler;
- vibrostanok steel forms;
- Trolley for transporting wood-concrete mixture (if necessary);
- wood or steel pallets for molding (which may be calculated to several blocks);
- Racks and trays for storing blocks.
The present method requires the purchase of a special molding vibrostanka having a rather complex structure (A machine to produce on their own - it is very difficult, and the equipment available on the market often requires processing).
a991ru:
In the market, a huge number of different vibrostankov, but, unfortunately, without changes almost none of them are not suitable for the production of arbolita.
Changes should affect the design vibroplatform and baling machinery. Thus, instead vibroplatform must install vibro-impact unit (to cement vibration did not flow down from the surface of the chip).
VIKTOR 220 (User FORUMHOUSE):
On the vibrator units produce undesirable as cement milk tends downward. For arbolita necessary shock shaking.
If the hand lay-on vibrator similar problem is solved preliminary shtykovaniem, vibrostanka the design does not provide for the implementation of this operation. In addition, if the bale mechanism is actuated by hydraulic (or pneumatic) cylinders, exposed to strong vibrations it quickly breaks down. All these problems arbolita manufacturer has to decide.
Some manufacturers use a variant with a screw press.
ecodrev:
Screw press, I have produced more than 10,000 m3 (over 3 years). Problems unnoticed. I only chain 2 times a year, the engine - 1 every 1.5 years, and the timely replacement of bronze washers (1 per year). I think with the right manufacturing press - working version.
Construction vibropress each manufacturer chooses for themselves.
forming sequence:
- Forms are filled with a mixture of wood-concrete.
- The mixture was subjected to vibro-impact unit (10-15 s).
- Compressing the mixture produced (pressing is carried out either during the vibro-impact mechanism, or after it is turned off).
- The pallet with the finished blocks is transferred to the rack.
Folding blocks on each other, just as in the previous two cases, it is possible not earlier than 3-4 days after manufacture. Storing products in several rows (height) is possible only after a week.
Drying units, in most cases, takes place under the natural (positive) temperature. Additional heat treatment of products, as a rule, is not required.
Advantages in manufacture vibropress blocks consist in the maximum working mechanization and the ability to manufacture blocks with a homogeneous structure.
Vibrating with prigruzami
We now turn to a description of the most common method of molding units, which allows mechanize the process and at the same time to optimize the costs associated with the opening production.
Vibrostanok with prigruzami currently available for purchase on the market and having the presence of the accompanying drawings, it is quite possible to make their own hands (or order the production in the profile production enterprise).
Compact wood-concrete machines prigruzami often designed for the simultaneous molding of only one unit, so prigruzami easily falls in the form of hands.
List of equipment for the production arbolita this method is presented in the previous chapter. Only vibropressovalny machine, in this case, changes to vibrostanok with prigruzami. If you organize the timely switching on and off vibratory, you presented a method of forming will provide robust and reliable units, did not impair the quality of finished at the same instant demoulding products.
forming sequence:
- After filling in the form is activated vibratory work (when filling the mold is performed by mechanized means, the vibration can be included in the process of falling asleep mixture). The duration of vibration of a few seconds and is determined empirically.
- In the next step prigruza lid is lowered into the form. Further vibration activated either simultaneously with molding or after prigruzami lowered into the mold (all depending on the design features of the machine).
- After prigruzami lowered into the mold, the vibration is activated (or continues) without fail.
Anugan (User FORUMHOUSE):
For all in plain language: it is necessary to include vibration as backfilling mixture into a mold, but not to overload mechanisms and are not stratified mixture, the strength of the vibration should be regulated (chastotnikom, eg). Low frequency - in the process of filling, the high frequency - in the instant application to a mixture of upper-prigruza plate. I am doing so.
Well proven method of cyclic prigruza: prigruzami during molding unit rises and falls repeatedly into the mold.
a991ru:
Usually sufficient 3 lifting and lowering cycles prigruza. In this scenario, after flash decompression block practically no internal pressure and rediformatsiya.
Total time of vibration mixture as for previous molding methods must be 10-15 seconds. After compaction is performed shuttering blocks. Folding blocks on each other can be no earlier than 3-4 days after unpacking.
Now let's talk about weight prigruza. To create a wood-concrete block for compaction ratio (Kup) - 1.27, its surface must apply a force of 0.01 MPa (or 0.1 kg / cm²). To Coop equaled - 1.34, the applied force should reach 0.02 MPa (or 0.2 kg / cm²). These rates are achieved while vibrating, and pressing the mixture. By applying these efforts to the surface of the block, it is possible to obtain articles having structural strength. And knowing the dimensions of the block, you can quickly calculate the required weight prigruza.
For example, block 50h37h16 has a surface area of 1850 cm². To seal such a coefficient block made - 1.34 prigruza weight should be equal to 1850 x 0.2 = 370 kg. If you focus on Coop - 1.27, the need weight - 185 kg.
Anugan:
I intuitively choose the most effective method for the production of shaped blocks 6: vibrovanie with prigruzami pressure - 0.1 * kg / cm2. It uses different frequencies of vibration and the direction of vibration.
forming effectiveness prigruzami repeatedly confirmed in practice and is very popular among modern manufacturers arbolita. As we have said, the simplest machine designed for forming a single unit, you can make yourself. Schematically, the device is as follows:
Its main elements are listed in the table.
The process of manufacturing requires precision, specific knowledge and skills. If you have a desire to try his hand in this matter, the network can find detailed drawings, according to which the machine is manufactured.
We offer you a homemade photo machine.
The design of the mixer
Now we talk a little about the forced type mixers, which are members of our portal Mixing wood-concrete mixture. compulsory mixer type, in contrast to the usual concrete mixer, ideal for mixing arbolita.
The reason is that the light is bad chips mixed in the mixer for heavy concrete mixes.
Kostya mkr1 (User FORUMHOUSE):
The use of such mixers is explained by the fact that the raw material is kneaded light weight, so using gravity rastvoromeshalok to create a mixture of not quite appropriate.
Compulsory mixer consists of a frame, engine, gearbox, the working capacity and working shaft with blades. The mixer as the machine can be purchased on the market, and can be made independently.
Here, for example, what kind of structure offers the user of our portal.
Sherlock Holmes (User FORUMHOUSE):
The three blades are driven mixture left, then three blades are driven right mixture. They are screwed onto the shaft of the blade steel sheet - 12 mm plates with a rubber ply (tires of the truck). Engine power - 5.5 kW.
The calculated momentum of the working shaft mixer in this case correspond approximately 40 rev / min.
As we have said, in the early stages of production will require a minimum of equipment and materials. On the purchase and manufacture of production equipment can wonder if there is a need to increase the production volume.
What kind of equipment is needed for the production of wood-concrete blocks? What he should have a performance? How to use the working space of the room? On these questions, each answer differently. A clear understanding of the painting comes after will be worked out technology guarantees a high-quality and durable blocks.
Check blocks Strength
Tests wood-concrete blocks of the strength should be carried out only after the product is completely dry, that is, reach their constant weight (it needs about 20 days). Most pinpoint arbolita density is possible only in laboratory conditions. In accordance with HF 549-82 test specimens subjected having dimensions 150h150h150 mm.
Arbolit to dry to constant weight, it must be kept in a room with a stable humidity mode. It is also possible to dry outdoors (under cover).
Tensile properties are determined by two major parameters: the resistance to axial compression (prism strength) - Rbk, and resistance to axial tension - Rbtk. Minimal structural strength in this case is arbolita - 21 kgf / cm².
Ecoblocksu (User FORUMHOUSE):
For the construction of one-storey house with a loft or two-storey house is necessary to use a structural arbolit minimum mark strength - M25, which corresponds to the strength class - V1,5 (the minimum compression strength approximately equal to 21 kgf / cm2).
Often contact the laboratory to test the strength - is unprofitable. And the time it would take a lot. Here is a way to test the strength of the invented one of the users of our portal: it is connected a pressure gauge to the conventional hydraulic jacks and set the device to test a homemade installation.
tyjdnfhmj (User FORUMHOUSE):
Outer field - 150 mm. The diameter of the piston of the jack - 35 mm. Pressure gauge went from the high-pressure oxygen reducer - friendly. Readings are taken without a scratch. For example, ravno15 150 kg / cm².
Durability unit is fixed at the beginning of its failure (when the first cracks). When the load increases a smooth way to accurately determine the characteristics of the product.
We recommend a visit to a section for the production of wood-concrete blocks of the experiments took place with maximum efficiency, dedicated discussion of the technological features of the production process. Subject, dedicated manufacturing equipmentHelp to find answers to questions concerning the mechanized devices for manufacturing arbolita. A video clip dedicated walling of wood-concrete blocks, Learn how to properly handle the submissions.
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