What Is Modular Concrete?
The concrete mixing station is mainly composed of 5 major systems, such as the mixing host, the material weighing system, the material conveying system, the material storage system and the control system, and other auxiliary facilities. Compared with the aggregate measurement of the station, the aggregate measurement of the building is reduced by four intermediate links, and the material is measured vertically, which saves the measurement time and therefore greatly improves the production efficiency.
- Volume: 400L
- Weighing range: 0 560 kg
- Weighing accuracy: ± 1%
- Concrete mixing station is a joint device used for centralized mixing of concrete, also known as concrete precast yard. Due to its
- Generally speaking, concrete mixing stations are divided into two categories: fixed mixing stations and mobile mixing stations. This is also the classification that many manufacturers first distinguish during production. Most of the fixed mixing stations also adopt a modular easy-to-splice design, which is mainly used in large-scale commercial concrete manufacturers or concrete component related manufacturers. It can be used in large-scale engineering construction. The characteristics are strong production capacity, stable work and anti-interference Sex is good. The mobile mixing station is towed by a towing unit, which has good mobility and makes production more flexible. It is generally used for various small and medium-sized temporary construction projects and can be rented for own use.
- According to usage, it can be divided into commercial concrete mixing station and engineering concrete mixing station. The commercial mixing station is a concrete mixing station mainly for commercial purposes. It should have high efficiency and economy, while meeting environmental protection requirements. For self-use, we should consider whether it is consistent with our own project.
- According to the layout process, it is generally divided into first-order and second-order. First-order refers to the one-time lifting of sand and gravel aggregate, cement, etc. to the silo on the roof of the mixing station. Various materials are top-down according to the production process. Carry out, and finally discharge from the ground floor, more common in the mixing building. Such a mixing station is divided into a silo layer, a weighing layer, a stirring layer, and a discharge layer from top to bottom. The mixing efficiency is very high, but the construction is difficult, the demolition is inconvenient, and the investment cost is high. In terms of stage, the aggregate is raised again after weighing the aggregate. Although it takes up a lot of space and the stirring efficiency is slightly lower than the first stage, it is easy to disassemble, low manufacturing cost, easy to install, widely used, and the improved second stage The production capacity of the type mixing station can be comparable to the first order.
- According to the number of mixers, the mixing station can be divided into a single host station and a dual host mixing station. The model name of the dual host mixing station is the 2HZS series concrete mixing station. For example, the 2HZS25 concrete mixing station expresses the meaning of two JS500 mixing hosts. The theoretical productivity of the dual-host mixing station is 2 * 25m³ / h. The dual-host mixing station is a good complement to the same type of mixing station
- According to the weighing method, it can be divided into independent weighing and cumulative weighing methods. Individual weighing will be equipped with a separate weighing unit for each material. After each material is weighed, it will be added to the internal mixer of the mixer. This weighing method High accuracy, but complex design and high cost; cumulative weighing is the addition of all aggregates into a unified hopper, which is more likely to accumulate errors, which is detrimental to the final production, and the more the number of ingredients bins, the more prone to deviations, not suitable For large projects. However, the structural design is simple and the cost is cheap.
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- 1. The performance label of the construction concrete; from this, it is used to choose what kind of mixing machine to use. For water conservancy projects, a forced mixing host must be selected. In addition, the batching station and storage bin should be selected according to the type of concrete that can be stirred.
- 2. The amount of construction concrete and its construction period; use these two parameters to choose how large the mixing station is. Let the total concrete task amount be M; the number of concrete pouring days is T; the number of working hours per day is H; the utilization factor is K, the specification of the mixing station should be selected X = M / (T * H * K), where K is 0.7- 0.9. In the selection, the transportation condition of the finished concrete should also be considered. Such as: direct pumping or vehicle transportation. The volume of the conveying vehicle is also an important basis for determining the type of the mixing station.
- 3. Construction environment and construction object; when choosing to purchase a concrete mixing station, the influence of the construction object and construction environment should be fully considered to ensure smooth construction and construction quality. We recommend that you be prepared for the following situations.
- 4. When the construction site requires a large amount of pouring at one time, high quality requirements, and there is no mixing station nearby, it is best to choose two smaller mixing stations, or one master and one pair of dual-machine preparation. .
- 5. When the traffic on the construction site is inconvenient and maintenance personnel need to spend a lot of time in and out of the construction site, it is better to choose a two-machine station with the same smaller specifications, or prepare enough spare parts to ensure the construction progress smoothly.
- 6. When the construction sites are scattered, but the distance between the construction sites is not too far, the transportation radius of the concrete mixer truck does not exceed half an hour, and the dump truck does not exceed 10 minutes. It is best to use multi-station centralized mixing to improve the utilization rate of the mixing station and the economic benefits of construction.
- 7. Operators' quality; Generally speaking, the small mixing station has a simpler structure and a simpler control system, so it has lower requirements for operation and maintenance personnel. The larger stations have complex structures and high levels of automation, so they also place high demands on operators. So you should consider this factor in addition to the previous factors when you buy a mixing plant.
- 8. Formulation selection; In general, manufacturers have mature product formulations, such as specifications, quantities, and varieties. You can ask your special requirements when ordering products. We will try our best to meet your requirements. However, when buying products, do not be greedy for everything, this will cause unnecessary waste in economy. In addition, when purchasing products, in addition to referring to the prices of different manufacturers, special attention should be paid to the preparation lists of different manufacturers. In addition to the above-mentioned specifications, varieties and quantities, the most important is the manufacturer of the accessory. In summary, you can always choose the model that is most suitable for you. When choosing a model, don't pursue the best, but pursue the most suitable and meet your needs, because this choice is the most economical and effective.
- 1. Travel speed of access road: 24 km / h, calculated by taking round-trip distance of 24 km as an example.
- 2. Loading time of mixing truck: HZS120 machine 1/6 hours / car, HZS90 machine 7/30 / hour.
- 3. Unloading time of mixing truck: 5 minutes.
- 4. Every time a car is delivered: HZS120 takes 1.25 hours and HZS90 takes 1.32 hours.
- The number of vehicles that can be transported within 5 or 6 hours: HZS120 machine 6 × 1 / 1.255 (car), HZS90 machine 6 × 1 / 1.324 (car).
- 320 m3 of beam pouring concrete is completed in 6 or 6 hours, and the number of vehicles to be transported: 320 × 1 / 6.550 (cars).
- 7. The mixing tanker should be equipped with a certain empty tank rate due to the access road. HZS120 mixer station, the main machine capacity is 2m3, it should be equipped with a 9m3 mixer transport truck, in order to load 4 coils. The transportation distance is about 12KM, and the beam irrigation of 320 m3 can be completed within 6 hours. It should be equipped with a 10 ~ 11 concrete mixer truck.
- 8. The mainframe capacity of the HZS90 mixer station is 1.5 m3, and an 8 m3 concrete mixer transport truck should be equipped to accommodate 5 coils. HZS90 + HZS120 mixer station, should be equipped with 8m3 mixer transport truck, in order to load 4 coils. With a transport distance of 12KM, the beam pouring concrete 320 m3 can be completed within 6 hours, and 13 ~ 14 concrete mixing transport vehicles should be equipped.
- The concrete mixing station is mainly composed of 5 major systems: material storage system, material weighing system, material transportation system, mixing system, powder storage system, powder transportation system, powder measurement system, water and admixture measurement system and control system. And other ancillary facilities.
- The concrete mixing station is divided into four parts: sand and gravel feed, powder (cement, fly ash, expansion agent, etc.) feed, water and admixture feed, transmission mixing and storage. After the mixer control system is powered on, it enters the man-machine dialogue operation interface, and the system initializes the processing, including the formula number, concrete level, slump, production volume, etc. Each bin and weighing hopper are tested according to the weighing , Output empty or full signal, prompt the operator to determine whether to start the stirring control program. Start the sand and stone belt motor to feed the metering hopper; open the butterfly valve of the fly ash and cement tank; start the screw machine motor to transport the fly ash and cement to the metering hopper; open the control valve of the water tank and admixture tank to make water and external The agent flows into the metering hopper. Open the measuring bucket after the measurement meets the set requirements
- 1. According to its structure, it can be divided into mobile mixing station and fixed mixing building. The construction site is suitable for mobile mixing stations.
- 2. According to different operation forms, it can be divided into two types: periodic and continuous. The periodic feeding and discharging system is performed cyclically according to a certain period. Continuous feed and discharge are performed continuously. The cyclic type is currently commonly used.
- 3. According to the different process layout, it can be divided into two types: single-stage and double-stage.
- The single-stage lifts materials such as sand, stone, cement, etc. to the top silo at one time, and various materials are weighed, proportioned, and stirred according to the process until they are made into concrete and loaded for transportation. The mixing floor is divided into a silo layer, a weighing layer, a stirring layer and a bottom layer from top to bottom. The single-stage process flow is reasonable and the productivity is high, but it requires a high factory, so the investment is large. Generally, this type is used in mixing buildings.
- The storage bins and mixing equipment of the two-stage material are substantially at the same level. The aggregate is lifted and sent to the storage bin, and the aggregate weighing and separate weighing are carried out under the storage bin, and then it is sent to the mixer by a lifting bucket or a belt conveyor for stirring. Because the material needs to be upgraded twice, the productivity is low, but it can reduce the height of the complete set of equipment, facilitate disassembly and assembly, and reduce investment. Generally, this type is used in mixing stations. [3]
- The concrete version of the floor scale software is mainly a measurement management software for concrete mixing station enterprises in the procurement of raw materials, sales of finished concrete and sales of asphalt mixtures. Contains: Convenient functions of intra-day accumulation, intra-month accumulation, quick conversion of tonnage, and instant statistics. Can print purchase scale, sales scale, separate two sets of serial numbers. Sales can print both concrete scale scales with square volume and asphalt scale scales with tonnage [2]
- Mixer for commercial concrete mixing equipment
- Forced mixers have good mixing quality, strong overload capacity, no unloading, high production efficiency, and can adapt to concrete mixing with various performances. Commercial concrete mixing equipment generally adopts forced mixers. However, its structure is more complicated and the use cost is higher. The forced mixer is divided into two types: double horizontal shaft, single horizontal shaft, single vertical shaft and planetary type. Due to the good mixing performance, high production efficiency, good adaptability, outstanding structural characteristics and good reliability, the double horizontal shaft mixer is very suitable for making Commercial concrete production; single-horizontal and single-shaft mixers have become less and less applied to commercial concrete mixing equipment due to their structural characteristics and adaptability: planetary mixers are also not widely used, and they are more common in imported equipment.
- Electric control system of commercial concrete mixing equipment
- There are various forms of electrical control systems for domestic concrete mixing stations, mainly based on the following three control methods.
- (1) Distributed microcomputer control: This control form was widely used in the design of early mixing stations. The core of the control system is a programmable controller. The upper-level computer is only used for management report printing. The functions and functions of the computer are not obvious. With the widespread application of commercial concrete, the functional requirements of concrete mixing stations are becoming more and more complicated, and the application of this control form is very difficult.
- Centralized computer control: This control form concentrates the computer control and management functions on one computer, the task is relatively heavy, and the statistics of the report data during the production process cannot be synchronized, and the data cannot be statistically measured at any time. The measurement is disturbed by human factors. too much. For example: the compilation of the measurement control program, the accuracy of the signal amplifier and the A / D board will affect the measurement accuracy.
- Centralized dual microcomputer control: This form solves the interference of human factors in measurement. It adopts a dedicated batching control instrument, and separates production control and management functions on two computers without interfering with each other. Production control and report statistics are carried out synchronously, and the management computer can also be used as a production backup machine, providing the same level as the production backup machine. Computer network interface [2]
- Aggregate batching system
- Because the loading of the silo is affected by the auxiliary equipment and the site, the volume of the silo should be selected to be larger.
- The volume of a single silo of the mixing station is generally greater than 20m3. If a belt conveyor is used to feed or the concrete ground silo can be larger, it can reduce the area of the stockyard. The volume of a single silo for a mixing building is generally greater than 50m3. The concrete mixing station is generally batched by a batching station. There are two types of structure. The all-steel structure batching station uses ground batching, which is convenient to maintain and easy to drain. The silo is a concrete structure, and the floor is batched. It is convenient to load and easy to maintain heat, but it is difficult to maintain. It can be directly loaded by a loader, bulldozer or dump truck.
- Aggregate lifting system
- Generally, the belt conveyor and the hopper are used for lifting. The belt conveyor has high production efficiency, reliable performance, easy sealing, not easy to be affected by weather, low maintenance cost, but large area. Lifting hoppers are generally only used in mixing plants, with a compact structure and a small footprint, but high maintenance costs and poor reliability. They have been rarely used in large concrete mixing plants. There are also patterned belts and trough belt conveyors. The lifting angle can be greatly increased and the trough belt can be lifted vertically. However, due to its reliability and the problem of rewinding materials, it is generally not used.
- Mixing the main building
- Generally it is fully enclosed, with a centralized dust removal device. In cold areas, the requirements for cold protection in winter construction should also be considered, and the exterior should be insulated. Open mixing stations and simple mixing stations, due to poor environmental performance, new commercial concrete mixing equipment has been rarely seen, and has been banned in some areas.
- Metering system
- The weight measurement method is adopted, which is divided into two forms of cumulative measurement and independent measurement. The accumulative metering structure is simple, easy to maintain, and has a low feeding height, but it cannot control the precision of the meter alone. Independent measurement controls the measurement accuracy separately, the structure is more complicated, the height of loading is increased, and the cost is increased.
- Powder storage and conveying device
- The quantity and size of the powder storage tank should be configured according to the needs, which is generally determined by the type of material and the supply situation. The powder tank should be equipped with a level controller. Powder conveying devices generally have the following two types: simple pneumatic conveying structure, uniform feeding, but long-distance conveying, and difficult to control air pressure; long conveying distance of spiral conveying, easy overall structural arrangement, reliable work, most mixing stations or mixing floors All use spiral conveying.
- Accessories
- The choice of matching parts often determines the reliability of the concrete mixing equipment. Generally, you should choose a well-known brand with high reliability, especially the main parts. For domestic equipment, electronic components, sensors, cement disc valves, and even reducers and lubricating components of mixers are imported components, which are more reliable.
- In short, to buy a good set of commercial concrete mixing equipment requires comprehensive consideration of many factors.
- Safe operation regulations for concrete mixing station
- 1. The installation of the concrete mixing station should be carried out by professionals in accordance with the specifications of the factory, and commissioned under the auspices of technical personnel. Only after all technical performance indicators meet the requirements and are accepted by experience can they be put into production.
- 2. Air compressors, belt conveyors, and concrete mixers and other equipment supporting the mixing station shall implement the provisions of Sections 3.5, 6.8, and 8.2 of this Regulation.
- 3. The inspection items before operation should meet the following requirements:
- (1) There are no foreign objects stuck in the transmission, movement parts, bin doors, bucket doors, rails, etc. of the mixing drum and the supporting mechanisms;
- (2) The oil level of each lubricating oil tank meets the requirements;
- (3) Open the valve to discharge the excess water in the gas-water separator in the gas path system, open the drain plug of the gas cylinder to release the oil-water mixture;
- (4) The wire rope installation and drum winding of the lifting bucket or dragline are correct, the wire rope and pulley meet the requirements, and the brakes of the lifting bucket and dragline are smart and effective;
- (5) The bolts of each part have been tightened, and there is no excessive wear on the inlet and outlet valves, and the tension of each conveyor belt is appropriate and does not deviate;
- (6) All control and display parts of the weighing device work normally, and their accuracy meets the requirements;
- (7) Each electrical device can effectively control the mechanical movement, and there is no obvious damage to each contact point and dynamic and static contacts.
- 4. Qualified sand and stone aggregate shall be prepared according to the technical performance of the mixing station, and those with a particle size exceeding the permitted range shall not be used.
- 5. Each part of the unit should be started gradually. After start-up, the operation of each component and the indication of each instrument should be normal, and the pressure of oil, gas, and water should meet the requirements before starting work.
- 6. During the operation, personnel are strictly prohibited to enter in the storage area and under the lifting bucket.
- 7. Cover the lid of the mixer before starting. During the operation of the machine, it is strictly forbidden to put your hands and feet into the hopper or the mixing drum for exploration.
- 8. When the shovel is stuck by an obstacle, it shall not be forced to pull or pull, or use a shovel to lift a lifting object. During the material pulling process, it is not allowed to perform a swing operation.
- 9. Do not stop the mixer when it is fully loaded. When a failure or power failure occurs, immediately cut off the power, lock the switch box, clear the concrete in the mixer, and then troubleshoot or wait for the power to recover.
- 10. The machinery of the mixing station must not be overloaded; the operation of the motor should be checked. When abnormal sound or excessive temperature rise is found, the machine should be shut down immediately for inspection; when the voltage is too low, it should not be forced to operate.
- 11. Before the mixer stops, it should be unloaded, and then all switches and pipelines should be closed in order. All the cement in the spiral pipe should be conveyed out, and no material should remain in the pipe.
- 12. After the operation, the mixing drum, discharge door and discharge hopper should be cleaned and rinsed with water. At the same time, the additive and its supply system should be rinsed. The knife holder and knife edge of the weighing system should be cleaned and the weighing accuracy should be ensured.
- 13. During the freezing season, the water stored in the water pump, the additive pump, the water tank and the additive tank should be exhausted, and the water pump and the additive pump should be started to run for 1-2 minutes.
- 14. When the mixing station is transferred or deactivated, the materials in the water tank, additive tank, cement, sand, stone storage hopper and weighing hopper should be drained and cleaned. During the transfer, the head of the lever scale should be balanced and the scale rod should be fixed, and the sensor should be unloaded.
- In the concrete production process, a large amount of sewage and wastewater is generated during the equipment cleaning and vehicle cleaning processes. At the same time, waste of resources will cause great harm to the environment. Therefore, the sewage treatment and transformation system in concrete production achieves 100% recovery of its wastewater and reaches zero sewage discharge standards.
- The sewage treatment and transformation system mainly includes a concrete transport fleet's water discharge chute, sand and gravel separator equipment, a sewage sedimentation tank, a sewage tank agitator, a clarification tank, a conveying pump, and a filter press.
- The conventional system has a total of four sewage tanks and three clarifiers. All four sinks are equipped with surface rails and agitators. And the No. 1 pool, No. 2 pool, No. 3 sewage tank are equipped with mud-type water pumps, No. 2 and No. 4 pools are designed with level gauges; you have one sewage-type water pump for each of the 3 clarification pools. The uniform motion of the agitator in the tank ensures uniform water quality in the tank.
- Each pool in the sewage treatment system needs to be arranged in a certain order. Overflow pipes at the lower part of the pool are connected to each other, and pumps at the upper part are connected to each other. When there is insufficient water in the pool, a pump can be used to transport water to keep the water stable. If there is a large amount of water in the pool, it will flow back through the overflow pipe provided in the pool, and the water quality will be clarified during the return flow.
- In the concrete mixing station, a flow channel is designed to connect with the sewage tank, and the rainwater is collected to flow into the pool to ensure the station is tidy and reduce the operating cost. The main station and the vehicle cleaning system are provided with a special flow channel to guide the production sewage to the sewage tank for unified treatment.
- Through the guidance and transformation of the entire drainage in the concrete mixing station, the sewage in the mixing station does not flow out, and the treated sewage is directly supplied to the mixing station and the vehicle for cleaning after inspection. The generated waste can also be used as an aggregate. Achieve zero wastewater treatment [2] .