1REDESIGN AND MODERNIZATION OF PLANTS MANUFACTURING PRECAST CONCRETE: CHALLENGES AND SOLUTIONS

Vollert: state-of-the-art cost-effective equipment for manufacturing of precast wall blocks out of sound-insulation materials

The PBM Group plant in Malataverne, France, managed to organize efficient manufacturing of high-quality façade components and wall precast blocks out of acoustic materials based on applica-tion of the Vollert tray-rotation system. The Vollert company proved to be a com-petent and reliable partner of precast concrete manufacturers.

ZAO PATRIOT-Engineering: integrated approach to redesign and modernization of home-building factories

Efficient and innovation-based modernization can only be carried out if it em-ploys an integrated approach, which means that the modernization goals and objectives are clearly articulated, ways and means of its realization are outlined and verified and all persons involved in modernization performance have clear understanding of how to carry out specified tasks in the course of their work.

Redesign and modernization mustn’t be protracted for many years; upgrading and replacement of equipment at different stages of production process shall be performed simultaneously to ensure synergetic effect from launching the equip-ment into operation and make it possible to implement best process technologies in the whole production chain, not just in separate segments of the chain. ’

ZAO PATRIOT-Engineering was established in 2010. The company routine is to control operation and modernization of construction companies, members of the PATRIOT Group.

The company business is based on own production facilities created either by reconstruction of existing plants or building of new manufacturing facilities in different regions of Russian Federation including Moscow, Rostov-on-the-Don and others.

CONCRETE PRO: laser projection systems for manufacturing of precast concrete components

New laser projection tools offered by the German Com-pany LAP are a good alternative to traditional electrome-chanical plotters and graph-plotters.

RATEC: innovation-based solutions for concrete-form systems. Creation of genius is always simple

At the crisis and post-crisis times issues of production process flexibility and diversity of pro-ducts acquire special importance for manufacturers of precast concrete components. The use of up-to-date concrete-form systems allows successful technological solutions.

Stanislav ShmelevManaging Director PATRIOT-Engineering

Information

for Professionals2011ОБОРУДОВАНИЕ • МАТЕРИАЛЫ • ТЕХНОЛОГИИ

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CONCRETE — EQUIPMENT • MATERIALS • TECHNOLOGIES

BRIEF LEAD IN THE PUBLISHED MATERIAL Concrete – building material of the 21st century

2011 CONCRETE – EQUIPMENT • MATERIALS • TECHNOLOGIES. ISSUE #1

BZAO SK-Lenstrojdetal: always be a step ahead

Use of modern reinforcement-preparation equipment from the Austrian company EVG in the ZAO Construction Corporation SK-Lenstrojdetal, St. Petersburg, Russia.

ZAO SK-Lenstrojdetal is a major manufacturer of welded metal mesh, metal articles and assemblages for reinforcement of concrete and brick building com-ponents in the North-West of Russia. The company has been manufacturing rein-forcement mesh for 15 years. Arcady Krasnov, CEO of SK-Lenstrojdetal, is descri-bing latest developments and tendencies in this important market segment of concrete reinforcement.

Modern concrete product plant for a micropolitanElematic-made equipment allows organization of efficient and cost-effective manufacturing of precast concrete in medium and small-size cities

Flexibility of production and diversity of products are of major importance for a factory located in a micropolitan. The shift from large-scale to small-

scale production or even custom design is more clearly observed in mid-size or small-size towns that in megacities.

Experience of the ООО Strojindustria KSM proves that in Russia newly established and renovated concrete production plants and integrated homebuilding factories can successfully operate not only in megacities but also in smaller ones and demonstrate production growth even at the time of crisis.

The company core business is manufacture of ferroconcrete goods and components for building of large panel structures and prefabricated homebuilding.

Karelia RepublicBefore November13, 1991 Karelia had the following names: Karelian Autonomous Soviet Socialist

Republic, Karelo-Finnish Soviet Socialist Republic, Karelian Labor Commune.Territory: 180.5 thousand sq. km. (1.06 % of the Russian Federation territory). Population: 684.2

thousand (less than 0.5 % of Russia’s population), urban population share — 76.4 %..

PetrozavodskCapital of Karelia. One of the industrial, scientific, cultural and tourism centers in Russia’s

North-West. Territory: 135 sq. km, population with suburbs: 269.2 thousand.

2CONCRETE PRODUCTS TODAY’S CONCRETE ADMIXTURES — KEY TECHNOLOGICAL SOLUTION IN CONSTRUCTION INDUSTRY

New-generation concrete — concrete with additivesThe chapter retrospec-

tively presents the back-ground of concrete science and technologies. It ack-nowledges that revolutio-nary changes in this sphere of people’s life took place at the turn of the 3rd Mil-lennium; the progress in production of concrete has

been caused mainly by efficient use of additives in the course of concrete preparation. Authors briefly examine principal properties of the new-generation concretes and present basic characteristics from European documents regulating the use of a wide range of materials and substances as additives in concrete production.

Fundamental principles for selection of single or complex addi-tives have been formulated with respect to modern ideas about the additive action mechanisms. Compatibility of additives with cements is emphasized and has been examined from the point of view of their manufacturing efficiency in terms of different tech-

nological solutions. Expediency of calorimetric methods for analy-sis of cement and concrete hardening processes with additives is shown for theoretical studies and for applied research.

The difficulties include determination of concentrations of che-mical, mineral and combined additives at the stages of concrete design and adherence to requirements for concrete proportioning at concrete batching and mixing plants.

Certain technological prospects have been outlined for the new-generation concrete.

Ph. D., D.Sci., Alexander Usherov-MarshakKharkov State Technical University of Civil Engineering and Architecture, Ukraine

Arcady KrasnowManaging Director BZAO SK-Lenstrojdetal,

Michael KickmaierArea Sales Manager EVG, Austria

Heavy-duty mixers from Maschinenfabrik Gustav Eirich GmbH

The EIRICH brand guarantees production of high-quality concrete having special properties and meeting requirements of architects and developers, as the EIRICH company has been employing own concrete-mixing techniques, technologies, expertise and know-how for over a hundred years. The article describes specifics of the EIRICH special mixing technique gua-ranteeing success to the mixing process.

CONCRETE – EQUIPMENT • MATERIALS • TECHNOLOGIES. ISSUE #1 2011

New High Реrformаnсе СоnсretеIn recent years much progress has been observed in the studies of concrete performance, and

concrete also has changed. In 1986 the world research community for the first time formulated the concept of high quality and high performance concrete (HPC), which established basic quality requirements for concretes with anticipated life time of up to 500 years. The emergence of such concretes paved the way for the era of high-rise buildings (skyscrapers) with solid ferroconcrete carcasses, offshore oil platforms, pre-stressed concrete long-span bridges and tunnels connec-ting islands and mainland territories, underground mini-cities, as well as architectural reinforced concrete. The author also briefly reviews data about invention and use of new high performance concretes.

Some aspects of admixture use in concrete production

Today progress of concrete technologies is closely linked with the use of various additives, which allow to significantly change properties of concrete mixtures, as well as properties of har-dened concrete. Of top priority are the additives, which allow to change water content in concrete mixes without changing the mix mobility or to increase the mix mobility without changing water content in the mix.

New modified concrete in modern building practices

Unique building projects in Russia, Ukraine and Belarus de-monstrate the latest developments in the use of concrete having special properties such as high-strength heavy concrete (classes В60… В90), low heat rise and high shrinkage-and-heat resis-tance, ultralow permeability and high resistance to corrosion (for structures without secondary containment in ground waters).

Techmatik: modern technologies in production of building materials

The Techmatik product range includes equipment for vibro-compression used in production of concre-te components (modern high-performance vibro presses, molds for paving blocks and other concrete products), complete lines, concrete mixing stations for production of premixed concrete and technological concrete.

The Pioneer in Material Processing ®

Tangible technologies

Research and development in KOBRA Formen GmbH has always focused on pro-ductive efficiency of concrete block molds, which means on increase of the mold wear resistance and life span. Evoline molds can meet any fancy ideas of architects and, on the whole, meet any kind of challenge.

3 FOCUS

German construction science: outward glanceInterviewee: Professor Ulrih Palzer, Director of the IFF Institute in Weimar, Germany

Germany has a number of federal and regional (Land) programs for funding of implementation of research and development findings. Government support is channeled first of all for compensation of structural weaknesses common to small and medium businesses. This is what makes research findings available to small companies not just to big businesses and allows small businesses to keep abreast with latest scientific and technological developments ensuring their competitiveness and proper operation quality.

Special ecologically safe systems and components (which can be put to recycling to the maximum) are developed for construction based of the use of precast concrete. Of top priority is investigation of scientific and technological aspects of precast component and material circulation in construction.

The IFF Institute keeps leading positions in virtual design of building materials, simulation of material treatment processes and engineering of machinery and plant design due to its unique innovation-based equipment.

Ph. D., D.Sci., Vyacheslav FalikmanMoscow State University of Civil Engi-neering (MSUCE), Russia

Ph. D., D. Sci., Grigoriy NesvetaevRostov State Building University, Russia

D. Sci., Semyon KaprielovLaboratorium NIIZHB, Generaldirektor «Master Beton», Russia

Dr.-Ing, Galina KardumyanLaboratorium NIIZHB, Russia

2011 CONCRETE – EQUIPMENT • MATERIALS • TECHNOLOGIES. ISSUE #1

4 PIPES, FITTINGS, CHASE-WALL PARTS

5 PAVEMENT CEMENT CONCRETE

Sewer networks in Russia: time for comprehensive solutions

Interviewee: Sergei Pavlov, Engineering director of the ZAO Lenvodokanalproekt. (SWECO Group)

It happened so that sewage disposal problems relate to different spheres: technical, economic, ecological, legal and property issues have in-termingled forming one solid tangle. Obviously it is possible

to sort them out and tackle each problem separately; how-ever, comprehensive solutions are much more efficient. Today in Russia searching for such integrated solutions lies on ex-perts working in the country’s national-economy sector, the sector of major importance for the land.

strategic partner in modernization of the Malinovsky Reinforced Concrete Plant (MKZHBI), Tula Region

Corrosion and protection of concrete and reinforced concrete parts of waste water disposal and treatment facilities

Examination of sewer networks and practi-ces of their operation shows that sewers are exposed to hazards leading to their rapid and unpredictable destruction. Catastrophic af-tereffects of water-supply and sewer system corrosion need large-scale remediation solu-tions ensuring long life of sewer and water-supply networks, solutions to be found for implementation at the design, building and operation stages.

New prospects for pavement cement concrete in the USA

In the context of road con-struction challenges in Rus-sia, the author examines the impact of the latest develop-ments in concrete production for the US road construction. The article presents data on cements, supplementa-ry cementing materials and additives to concrete. It also examines the role of disperse mineral components (especially microsilica and nano-

microsilica), as well as super plastifying agents, in production of the new-generation concrete. New kinds of concrete are described and best US practi-ces of new technology application in road building and pavement repair are presented for motorways and bridges.

Ph. D., D. Sci., Boris RadovskiyInternet Laboratories, Inc., USA

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The publishing house «Slavutich» (Russia, St.-Petersburg) in collabora-

tion with leading Russian and foreign specialists in the sphere of con-

crete manufacturing prepared the catalogue «Бетон и Железобетон.

Оборудование. Материалы. Технологии». «Concrete and reinforced

concrete. Equipment. Materials. Technologies».

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find new business partners.