Kuch / Schwabe / Palzer Manufacturing of Concrete Products and Precast Elements

Processes and Equipment
1. Auflage 2013
ISBN: 978-3-7640-0557-3
Verlag: Rainer Büchel
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 267 Seiten

Reihe: edition beton

The flexible use of prefabricated concrete products requires a continuously increasing diversity with regard to fresh concrete mix designs and properties, moulding processes, surface finishes and product characteristics. This trend imposes ever-higher requirements on manufacturers of the associated production equipment and on precast plants. The main goal is to implement a flexible production system in all processing stages. The relevant correlations and interactions need to be thoroughly considered and evaluated in order to ensure that concrete products and precast elements are manufactured to the required quality standard. To date, no comprehensive description of these correlations has been published in the relevant literature. This richly illustrated book closes the gap by describing the basic principles of the production processes, the fundamentals of materials, the composition of the concrete mix, and the equipment used for concrete production. Clearly arranged chapters detail the production processes and equipment used to manufacture small concrete products, concrete pipes and manholes, and precast elements. The authors have used their many years of experience in the field of precast technology and their close ties to the industry. Their aim was to integrate modern testing and calculation methods from neighbouring disciplines into precast technology. This includes, for instance, modelling and simulation of the workability behaviour of mixes, implementation of the latest advancements in machine dynamics to the design and engineering of production equipment, and the use of stateof-the-art measuring and automation technology for quality control purposes.

Dr.-Ing. habil. Helmut Kuch was head of the Department of Equipment and Machinery at the University for Architecture and Construction in Weimar from 1984 to 1992. From 1992 to 2007, he was director of the Institut für Fertigteiltechnik und Fertigbau Weimar e. V. (Weimar Institute for Precast Technology and Construction). His work concentrated on the design and dimensioning of equipment for the manufacture of concrete products, with particular emphasis on moulding and compaction and mitigation of noise and vibration. Prof. Dr.-Ing. Jörg-Henry Schwabe completed his studies of mechanical engineering and applied mechanics at the Technical University of Chemnitz with an engineering degree in 1993. Since then, he has been working as a research associate at the Weimar Institute for Precast Technology and Construction. In 2002, he received his doctorate at the Technical University of Chemnitz. His thesis dealt with 'vibrational design of concrete pipe machines'. Since 2006, he has been head of research in the precast technology division of the institute, concentrating on the dynamics of building materials machinery, numerical simulation of machines and processes, and mitigation of noise and vibration. Since 2010 professor for transmission technology and dynamics of machinery at the University of Applied Sciences in Jena. Dr.-Ing. Ulrich Palzer studied process engineering of building materials at the University of Architecture and Construction in Weimar (today Bauhaus University) from 1979 to 1984. From 1984 to 1989, he worked as a research associate at the university and received his doctorate in 1990. In 1990, he became Managing Director of Ritter Verwaltung GmbH and moved on as Managing Director at PBM Projektbau- und Baumanagement GmbH, Weimar, in 1995. Since July 2007, he has been director of the Weimar Institute for Precast Technology and Construction. His work concentrates on building materials research, simulation of processes, and mitigation of noise and vibration in the raw materials industry.

Autoren/Hrsg.

Kuch, Helmut

Schwabe, Jörg-Henry

Palzer, Ulrich

Inhaltsverzeichnis

Foreword
Introduction

1 Basic Principles
1.1 Process Fundamentals
1.1.1 Production Process
1.1.2 Components Determining the Structure of the Production Process
1.1.3 Processes for the Industrial Manufacturing of Concrete Products
1.1.4 Processing Behaviour of Concrete
1.1.5 Process Parameters
1.2 Fundamentals of Materials
1.2.1 Raw Materials for the Production of the Concrete Mix
1.2.2 Concrete Mix Design and Composition
1.2.3 Concrete Properties
1.3 Product Fundamentals
1.3.1 Concrete Products
1.3.2 Requirements Relating to Product Characteristics and
Testing Methods
1.3.3 Evaluation of Conformity
1.4 Fundamentals of Plant and Equipment
1.4.1 Vibration Exciter Systems
1.4.2 Research and Development

2 Production of the Concrete Mix
2.1 Mixing Facilities
2.1.1 Star-shaped Systems
2.1.2 Serial Systems
2.1.3 Tower Systems 7
2.2 Mixers
2.2.1 Pan Mixers
2.2.2 Open-top Mixers
2.3 Quality Control
2.3.1 Assessment of the Mixing Quality
2.3.2 Moisture Measurement
2.3.3 Mixer Control

3 Production of Small Concrete Products Overview
3.2 Block Machines
3.2.1 Technological Line
3.2.2 Configuration of Block Machines
3.2.4 Quality Control
3.3 Egg Layers
3.3.1 Scope of Use
3.3.2 Configuration and Mode of Operation
3.4 Slab Moulding Machines
3.4.1 Scope of Use
3.4.2 Configuration and Mode of Operation
3.5 Production of Concrete Roof Tiles
3.5.1 Casting Process
3.5.2 Extrusion Process
3.5.3 Quality Control
3.6 Finishing and Post-treatment
3.6.1 Finishing of Fresh Products
3.6.2 Finishing of Hardened Products
3.7 Selection Criteria

4 Production of Concrete Pipes and Manholes
4.1 Production Process
4.2 Fabrication of Reinforcement
4.3 Pipe Machines with a Stationary Core
4.4 Pipe Machines with a Rising Core
4.5 Roller-head Process
4.6 Wet-cast Process
4.7 Production of Manhole Rings and Bases
4.8 Curing and Pipe Testing
4.9 Quality Control, Characteristics of Defects
4.9.1 Typical Pipe Defects and their Causes
4.9.2 In-Process Quality Control
4.10 Selection Criteria

5 Production of Precast Elements
5.1 Overview
5.2 Basic Structure of Production Systems
5.3 Carousel Production
5.3.1 Basic Structure
5.3.2 Subsystems
5.3.3 Complete Production Lines using the Carousel Principle
5.4 Stationary Production
5.4.1 Basic Structures
5.4.2 Subsystems
5.4.3 Complete Lines for Stationary Production
5.5 Combined Production
5.6 Curing and Finishing
5.6.1 Curing Systems
5.6.2 Finishing
5.7 Quality Control
5.7.1 Design of Vibration Moulds
5.7.2 In-Process Quality Control
5.8 Selection Criteria

6 Outlook
7 Bibliography
8 Index

Leseproben

Foreword
Concrete is one of the most important building materials of our times. Concrete products and precast elements that are prefabricated on an industrial scale fully utilise the performance potential of concrete whilst offering major benefits with regard to the construction process. The flexible use of prefabricated concrete products results in a continuously increasing diversity with respect to
- fresh concrete mix designs and properties,
- external geometry and design,
- surface finishes in terms of colour and design and
- characteristics of the finished product (quality).
These factors impose corresponding requirements on both the manufacturers of the associated production equipment and its operators, i.e. precast plants.
The main objective is to implement a flexible production system with respect to all four components of the production process, i.e.
- material-related aspects,
- technological processes,
- technical equipment and
- characteristics of the finished product (quality).
These components need to be carefully considered and evaluated to ensure that the concrete products and precast elements are manufactured to the required quality standards.
The relevant literature does not include any comprehensive discussions of these relationships to date.
This book is based not only on the authors' many years of experience gained in the field of precast technology at the Bauhaus University of Weimar and at the Institut für Fertigteiltechnik und Fertigbau Weimar e. V. (Weimar Institute for Precast Technology and Construction), but also on their close ties to the industry.
The authors' aim was to select state-of-the-art testing and calculation methods from neighbouring disciplines and apply them to precast technology. This includes, for instance, modelling and simulation of the workability behaviour of mixes, application of the latest advancements in machine dynamics to the design and engineering of production equipment, and the use of state-of-the-art measuring and automation technology for quality control purposes. In the English translation, the system of mathematical symbols and designations used in the German version was intentionally retained. The same applies to the metric units of measurement used for physical parameters.

Über Autor(innen)

Dr.-Ing. habil. Helmut Kuch was head of the Department of Equipment and Machinery at the University for Architecture and Construction in Weimar from 1984 to 1992. From 1992 to 2007, he was director of the Institut für Fertigteiltechnik und Fertigbau Weimar e. V. (Weimar Institute for Precast Technology and Construction). His work concentrated on the design and dimensioning of equipment for the manufacture of concrete products, with particular emphasis on moulding and compaction and mitigation of noise and vibration.

Prof. Dr.-Ing. Jörg-Henry Schwabe completed his studies of mechanical engineering and applied mechanics at the Technical University of Chemnitz with an engineering degree in 1993. Since then, he has been working as a research associate at the Weimar Institute for Precast Technology and Construction. In 2002, he received his doctorate at the Technical University of Chemnitz. His thesis dealt with "vibrational design of concrete pipe machines". Since 2006, he has been head of research in the precast technology division of the institute, concentrating on the dynamics of building materials machinery, numerical simulation of machines and processes, and mitigation of noise and vibration. Since 2010 professor for transmission technology and dynamics of machinery at the University of Applied Sciences in Jena.

Dr.-Ing. Ulrich Palzer studied process engineering of building materials at the University of Architecture and Construction in Weimar (today Bauhaus University) from 1979 to 1984. From 1984 to 1989, he worked as a research associate at the university and received his doctorate in 1990. In 1990, he became Managing Director of Ritter Verwaltung GmbH and moved on as Managing Director at PBM Projektbau- und Baumanagement GmbH, Weimar, in 1995. Since July 2007, he has been director of the Weimar Institute for Precast Technology and Construction. His work concentrates on building materials research, simulation of processes, and mitigation of noise and vibration in the raw materials industry.