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    EMACO GROLimestone

    EMACO GROUP

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    EMACO GROUP

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    EMACO GROUP

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    EMACO GROUP

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    Machines,

    Equipment andAutomation Production of Building Materials

    EMACO GROUP

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    Which machine for which block?

    At a glance

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    Efficient Production

    3

    Our range

    Over 300 experts are bound by one objective: the design and construction of machines optimised for the users success.

    LASCO model KSP-1250 calcium silicate block press. The development of the double-

    acting compaction, hydraulically driven KSP press series has made possible the production

    of large-format calcium silicate blocks and wall elements of excellent quality.

    LASCO, a independent medium-

    sized company with over 140 yearsof experience in mechanical

    engineering is a leading supplier of

    technology to the forming industry.

    We have been offering special

    solutions for the manufacture of

    building materials and ceramics

    for some decades now.

    We are known worldwide for the

    manufacture of highly efficient

    equipment for the production of

    calcium silicate (sandlime) blocksand blocks with aggregates

    containing silicate. Our

    comprehensive solutions in this

    field range from double-acting

    (KSP) and single-acting (KSE)

    compacting presses through dies,

    wear parts and automation

    equipment to filler block

    production equipment and

    complete turnkey production

    factories.

    LASCO combines internationallyrecognized competence in

    development, design and

    production with highest standards

    of quality (DIN EN ISO 9001:2000)

    and the flexibility of an

    independent, medium-sized

    enterprise.

    Personal service and maximum

    possible proximity to our

    customers is supported by a global

    network of representatives, servicecentres and agents in over 60

    countries.

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    berzeugend wirtschaftlichLASCO Technology Converts them to Best Form.

    5

    Sandlime blocks

    CS manufacturing process

    The material flow starts with the

    filling of the silos with sand, lime

    and, if needed, aggregates

    containing silicate, all of which are

    mixed with water to precise

    proportions and fed to the reactor.

    The sandlime mass remains in the

    reactor until the calcium oxide has

    converted to calcium hydroxide.On expiry of the reaction period

    the mixture is fed to the presses

    that mould the blocks.

    After pressing, the green blocks

    are stacked on hardening wagons

    by programmable stacking

    equipment and transferred to a

    conveyer. The stacked green

    blocks are conveyed to autoclaves

    for hardening in a pressurized

    steam environment. The autoclaves

    are designed for either roll in/roll

    out or single entry/exit loading.

    Schematic representation of the construction of calcium silicate block production plant.

    LASCO technology makes possible the production of calcium silicate blocks of all sizes and shapes.

    The complete process is split up

    into stages that are organized fully

    automatically. Personnel are only

    required for process control and

    monitoring purposes.

    . .

    s of all sizeo sizete procesete

    ges that art t r

    atically. Patic .

    quired forqu d r

    monitorini in

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    LASCO-Konzepte...Blocks with Siliceous Aggregates.

    6

    LASCO Solutions

    The production of blocks using

    siliceous aggregates opens up avariety of methods of actively

    contributing to environmental

    protection. Fly ash, for example, a

    result of combustion in coal-fired

    power stations or steel mills can

    be usefully disposed of by mixing

    into such blocks.

    In cooperation with internationally

    known research institutes, LASCO

    has developed processes that allow

    such blocks to be produced withthe largest-possible proportion of

    aggregates having best-possible

    building characteristics. Using

    LASCO presses that have been

    optimised for these tasks fly ash

    blocks can be produced that are

    characterized by high strength and

    exact form and are highly suitable

    for a multiple of tasks in the

    building of multi-storey walls.

    Depending on their chemical

    composition, the proportion of

    aggregate materials to the rawmaterial volume of a block can be

    up to two thirds.

    Excellent sound insulation

    One of the important advantagesof calcium silicate is its excellent

    sound insulation. This is achieved

    because of its high specific

    density of 2.0 kg/dm or more.

    This characteristic is also evident

    in the fly ash block as well,

    which predestines it for use in

    metropolitan areas and residential

    areas close to transit roads.

    Wide range of application

    One of the main advantages ofbuilding blocks with siliceous

    aggregates lies in the fact that

    they can be produced in many

    formats and specifications.

    Individual requirements of design

    and wall structure can be met, as

    well as the pressing of various high

    quality block types, for example,

    hollow blocks or solid blocks.

    Calcium silicate blocks and blocks

    with siliceous aggregates can be

    used for building both the inner

    and outer walls of a house fromthe basement to the roof.

    Building made of blocks containing siliceous aggregates.

    Fly ash blocks from China.

    Coloured sandlime blocks from Russia.

    A

    egategag both thethls of a hof a o

    ent to theen

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    mple, m ,

    ocks. ck

    blo blo

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    ...im Detail

    7

    Perspectives

    Special Building Materials.

    Samples of ancient LASCO-machines for the building material industry (at the beginning of the 20th century).

    The production of fly ash blocks on LASCO KSE presses.

    Concrete block - dry pressing process.

    The development of customer-

    specific solutions for the building

    materials industry has a long line

    of tradition at LASCO. Even at the

    beginning of the twentieth century

    a wide range of products was on

    offer. The first hydraulic press for

    the production of fireproof blocks

    was designed and built around1935.

    Our established technology for the

    production of building materials

    using the dry press process was

    not only suited to the production

    of building materials in the

    sandlime category but also for

    concrete blocks and classical

    ceramic clay bricks.

    In contrast to conventional

    processes, economic advantages as

    well as special features such as

    surface effects and improved

    mechanical characteristics can be

    achieved.

    If you are interested in innovative

    technology that allows theproduction of a specific building

    material with the help of hydraulic

    presses more economically than

    before then you should contact us.

    Our experienced project engineers

    will be only too pleased to advise

    you.

    n innovat n va ows the th specific b s

    the helph

    ore econoore e

    hen you sy u

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    n be b

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    Prozesssteuerungen

    8

    Product Series

    LASCO sandlime block presses in

    the KSP series are, from anengineering point of view, the

    production backbone of the 21st

    century in Germany, just as they

    are in a growing number of

    countries worldwide. These

    machines, first developed at the

    beginning of the 1990s and

    constantly improved in innovative

    details, are the mechanical

    engineering answer to market

    demands for higher speeds and

    efficiency in the building of wallswith higher quality building

    materials.

    Double-acting compaction

    The core aspect of the KSP is the

    double-acting compaction of the

    raw materials from two sides with

    electro-hydraulically driven

    downstroke and upstroke punches.

    Computer-controlled die movementoptimises the formation of the

    pressure cone, ensuring impressive

    homogenous compaction of the

    sandlime mass and uniform

    solidity over the whole of its cross-

    section.

    The punch stroke and the

    compacting forces achieved per

    stroke are measured by measuring

    systems. Control systems correct

    the filling height if necessary toensure that the CS green blocks

    are ejected stroke for stroke with a

    high degree of dimensional

    accuracy and constant

    compaction.

    The moulds are fixed in their

    working position by hydraulic

    Two high-power KSP presses in a calcium silicate block production plant in North Germany.

    The double-acting compaction employed by

    the KSP makes possible the production of

    large-format CS blocks and wall elements

    of impressive quality.

    KSP Engineering Power for Large Blocks and

    with h

    trol str l s

    height if nighat the Cat C

    jected stroec st

    gh degreeree

    accuracya ac

    compaco a

    TT

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    clamping bars. This system

    provides for quick tool changesduring format conversions.

    The flexibility of

    the hydraulic

    controller

    allows blocks of

    different heights to

    be produced by

    altering the filling

    height.

    The double-actingcompaction forces

    are a prerequisite

    for the production

    of building

    materials that

    exceed the

    dimensions of conventional

    standardised block sizes. It was

    Individuell programmiert

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    Product Series

    ...Wall Elements of Impressive Quality.

    Automatic hydraulic KSP 1250 press with

    stacking device in simplified model

    representation.

    only with the introduction ofdouble-acting presses that

    production of formats such as the

    CS Quadro, CS-XL and Wall

    Elements in the required quality

    was possible. At present, these

    formats are the most popular.

    duction of io f

    resses thae

    formats srm s

    , CS-XL a, C -

    ts in the re

    possible.oss .

    rmats arerm e

    G

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    Vielzweckpressen

    10

    Product Series

    The KSP the Backbone of Sandlime Block Production...

    Specificati

    A

    B

    C

    D

    EF

    G

    H

    I

    J

    K

    L

    M

    Maximum bloc

    Press table ope

    Drive power for

    Drive power au

    Filling device (left) and unloading and stacking system (right) for a KSP series building material press.

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    Klassiker mit breitem Eignungsprofil...in the 21st Century.

    11

    Product Series

    KSP 401 KSE 801 KSP 850 KSP 1050 KSP 1250

    [mm] 5000 6050 6350 6655 7020

    [mm] 1250 1250 1250 1250 1250

    [mm] 1510 2100 2680 2680 2880

    [mm] 2680 3015 3590 3335 3410

    ca [mm] 3000 3450 4700 5000 5100ca [mm] 3700 4300 4700 5000 5000

    ca [mm] 3100 3600 3600 3900 3900

    [mm] 6100 6100 6100 6400 6400

    [mm] 5300 5300 5300 6000 6600

    [mm] 4850 4850 4850 5310 5350

    [mm] 3190 3190 3190 3190 3190

    ca [mm] 8600 8600 9600 9600 9600

    ca [mm] 9400 9400 9400 9400 9400

    igh [mm] 250 250 500 500 625

    g width x depth [mm] 826 x 506 826 x 772 826 x 772 1100 x 772 1100 x 772

    ss rams [kW] 2 x 37 2 x 55 2 x 55 2 x 75 2 x 75

    ry drives [kW] 5,5 11 11 11 11

    KSEE

    00

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    Kompetent ausgelegt...for Small Block Formats.

    13

    Product Series

    SpecificationKSE 400 KSE 800 KSE 1250

    A ca [mm] 2850 3600

    B [mm] 1250 1250

    C [mm] 1210 2030D ca [mm] 1700 3450

    E ca [mm] 3500 3500

    F ca [mm] 3500 3500

    G [mm] 6100 6100

    H [mm] 3895 3895

    I [mm] 3000-3525 3000-3525

    J ca [mm] 7500 7900

    K ca [mm] 8500 8500

    Maximum block height [mm] 120 200

    Press table opening width x depth [mm] 650 x 860 576 x 826

    Drive power for the press ram [kW] 55 55

    Drive power auxiliary drive [kW] 5,5 5,5

    Maintechnicaldataindividual

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    Optimal konfiguriert ...

    14

    Product Series

    With the introduction of the PSP

    filler block press, LASCO made afurther decisive contribution to the

    building materials industry. Up to

    70 percent of the labour needed to

    saw wall elements is no longer

    required. In addition, around 5

    percent of raw material is saved

    because of optimised green block

    length and about 35 percent of

    wasted material. The patented die

    system in these special presses,

    based on the LASCO KSP series,

    allow the production of variableblock lengths of 100 to 750 mm.

    To achieve these varying lengths

    the blocks are compacted

    longitudinally. The length can be

    varied by changes in the press

    height. The positioning of the

    punch stroke in the press is

    computer-controlled from the

    interface signal of the elementing

    and configuration software.

    Sliding tool

    In itself unique is LASCOspatented sliding multiform die for

    the PSP with moulds for

    standardised wall thicknesses.

    Only the mould that is in the

    centre at the time of the working

    cycle is filled and pressed. In

    order to produce filler blocks and

    elements of other wall thicknesses,

    the complete die (upper and lower

    punches, press table) is

    hydraulically shifted in a horizontal

    direction. This operation is carriedout fully automatic in a few

    seconds.

    Automatic stacking

    The green blocks are removed from

    the conveyer belt by an industrial

    robot fitted with a newly developed

    vacuum gripper plate. The

    individual vacuum chambers of the

    gripper are automatically

    controlled depending on block

    length.

    Blockwork with wall elements and filler

    blocks.

    Simplified model of the LASCO

    PSP filler block press with

    removal and stacking robot.

    Large format blocks of varying

    length and various wall

    thickness can be produced on

    the filler block press. Sawingwork is reduced to the cutting

    of height, gable angles and

    slits.

    The PSP. Patented Solution for Filler Blocks in Varying lengths.

    ACoftw of s s

    thet

    enti enti

    shifts ift

    . his operais oy automatiu at

    nds.ds.

    AutomaticA a

    The grTh r

    the

    rr

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    ... auch fr kombinierte AufgabenSawing Lines. Easy and Efficient Sawing.

    15

    Product Series

    Model of a modular constructed, fully

    automatic LASCO cutting machine with

    cut-off saw, slitting saw and trimming saw.

    Cut-off saw

    Slitting saw.

    The conveyer and handling system on a

    LASCO cutting machine.

    Finishing

    During the finishing of large-volume calcium silicate blocks and

    plan elements five different saw

    cuts are used. The lions share

    with 70 percent is the cut-off, a

    task that can be eliminated to a

    large extent on a LASCO PSP at

    the production stage.

    Other cuts are the gable angle cuts

    and height cuts, floor plan angle

    cuts and slits. LASCO can offer

    outstanding economical solutionsto all these requirements. They

    can be used either singularly or in

    conjunction with a fully automatic,

    process-integrated cutting

    machine.

    Modular concept

    The cutting machine can be

    flexibly fitted with saws needed for

    production and retrofitted as

    required. It combines modern,

    single saws that have been

    improved by patented LASCOinnovations with intelligent

    elementing and control software

    that interacts directly with the

    design data.

    At the building material

    manufacturer, the building plan is

    separated by a software system

    into its individual walls, in which

    windows, doors, slits, joints to

    other walls, etc. are included.

    The elementing software further

    separates these walls into planelements and filling blocks. These

    are then automatically optimised

    with respect to reduction of waste

    and the length of cut, taking all

    relevant parameters into account.

    The control process for the cutting

    machine is generated from these

    data.

    are furthe ar th lls into pl nt l ling blockli

    maticallytic

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    Kaltfliesspressen

    16

    Technology

    Technology has major significance

    for the fulfilment of economic

    objectives. A good reason to

    explain the performance

    characteristics of LASCO presses

    in more detail:

    The drive

    Axial piston-pumps-running in

    load sensing mode provide the

    drive, a technique that increases

    efficiency and the life of thehydraulic system. A reliable

    heating, cooling and filter system

    keeps the hydraulic fluid clean

    and at a constant temperature.

    The press frame

    Visually, the press table, the cross

    beam and the side columns are

    the dominating elements of the

    press frame. These components

    are of a welded and stress-relieved

    design. This means that the filling

    wagons and dies have rigid guides

    in which to carry out their

    constantly cycling operations.

    as human hands. It grips the

    blocks firmly, but carefully, lifts

    them out of the die and sets them

    softly onto the timed conveyer

    band. A pulse generator records

    precisely the position of the

    conveyer belt each time. The

    phased sequences are freely

    programmable according to the

    size of the block.

    The stacking deviceThe blocks are stacked fully

    automatically. Individual stack

    formations are stored in the

    database for every block size to

    ensure that the hardening boiler is

    filled to its maximum each time.

    The height of each hardening

    wagon is sensed before enters the

    stacking device. The aiming

    position of the gripper is

    calculated from wagon height and

    block height. The wagon is moved

    automatically in preset steps.

    The filling device

    Soft approach and braking phases

    coupled with high positioning

    accuracy are the characteristics of

    the LASCO filling wagon. Precisely

    controlled and with exact

    guidance, it ensures homogenous

    filling of the die with the help of

    its separately driven mixer. It can

    be easily emptied using an

    attached filling hopper. The

    hopper, provided with apneumatically controlled flap, is

    located above the filling wagon.

    Integrated sensors regulate

    material feed automatically.

    Conveying technology

    The freshly pressed green blocks

    are susceptible to impact. To

    overcome this problem, LASCO has

    developed a caring conveying

    system for the journey of the

    young green blocks from the die

    into the hardening autoclaves. The

    control electronics make the

    LASCO gripper almost as sensitive

    Hydraulic press drive system.

    Tool.

    LASCO structures the controllers operating menus and screens according to the customers

    needs. This includes selection of language.

    Process-Sure. Operator-Friendly. Low-Maintenance.

    O

    device e

    roach andch d

    ed with hied

    curacy arec a

    he LASChe C

    controlln ol

    uidid

    ii

    e customers c o er

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    berlegen in der GroserieImproved Detail Solutions Improve Efficiency.

    17

    Technology

    The fully automatic stacking system works

    with parameters decided by block size and

    ensures optimum utilisation of the

    hardening autoclaves capacity.

    Proportional valve (regulates gripper force). Block removal.

    Preparing the tool. Gripper.

    Autoclaves.

    The controller

    The complete sequence of

    production is monitored and

    controlled by a programmable logic

    controller. The operating personnel

    merely carry out control and set-up

    functions.

    The LASCO controller has a lot of

    advantages:

    Automatic fill-height regulationaccording to the pressing force.

    Consideration of special filling

    cycles for critical blocks.

    Precise approach from the

    filling and pressing position is

    ensured by hydraulic positioning

    of the punches.

    Shorter cycle times and higher

    block quality provided by an

    integrated wagon and block

    height sensing system.

    No requirement to shift the

    stacking equipment (position-

    sensing of the conveyer).

    Optional Interfacing to a master

    control system.

    Entry of all production data via

    a central operating terminal.

    Detailed monitor display of

    faults and warnings in plain

    text.

    Short setting times by means of

    stored production parameters in

    a database.

    Options

    LASCO offers as an option the

    modernisation, extension ormodification of old plants

    (including competitors plants) and

    the supply of components. These

    include:

    Hardening wagons

    Clamping frames and press

    tables

    Gripper plates for varying block

    sizes

    Hydraulic die installation

    devices

    Heated dies

    Optimised hydraulic press drives

    PLC control systems

    LASCO experts can analyse and

    optimise operational production

    plants. Flexibly, quickly, reliably.

    roductionro

    perating t at t

    monitormo

    s and warnd a

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    Short settSh t t

    storedto

    a da

    GRO

    U

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    Kalibrierpressen

    18

    Overall Solutions

    Control centre in a LASCO CS factory. CS block removal. Storage place.

    A really new factory is more than

    just the sum of current technical

    progress. A new factory rather sets

    standards in automation,

    productivity, and quality

    assurance, logistics - only if

    everything fits, all the details are

    right and all the components

    optimally interact with each other

    is the move to a new sphere of

    performance a success.

    When we develop, plan and build a

    new factory, we at LASCO think

    deeply about the competition that

    our customers are exposed to, now

    and in the future. We have

    accepted this responsibility several

    times as a general contractor for

    the building of turnkey factories;

    factories in which our customers

    show their customers around to

    show them how efficiently new

    calcium silicate blocks can be

    produced.

    If you are planning the leap into

    this new sphere of building

    material performance you will find

    an ideal partner in LASCO. Well

    be only too pleased to advise you.

    Calcium silicate block factory in Germany. Designed, planned, built and handed over as a turnkey operation by LASCO.

    Turnkey Factories.

    Production plants forthe 21st Century

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    Which machine for which block?

    At a glance

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    A

    P

    .

    .

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    C

    RO

    .

    .

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    G

    .

    .

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    O

    ..

    ..

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    EMACO GROUPHIPERPRESS BRICK PLANTSthe equipment of the brick plants producing traditional and antiseismic buildingmaterials...

    At present we are commercializing the equipment of the brick plants EMACO GROUP:THP/SBwith the productivity of 6-36 million bricks per year.

    The plants EMACO GROUP THP/SBwith bilateral compression produce:

    facing bricks with a frame and chamfers along the face perimeter, rock face veneers with chamfers and splays along the face perimeter, sidewalk and road paving materials, facing and inside lining antiseismic bricks.

    Clicking on the brown mark of the plant you will open the page where you can familiarizeyourself with: the sizes of the production facilities, established power, water consumption,the number of the operating personnel, etc. for the plants of different productivity.

    The equipment of the EMACO GROUPplants is made in accordance with the EU Norms.

    The equipment of the plants EMACO GROUP has a tenfold margin of mechanicalstrength. It has a unique design and is made of German steels including THYSSEN steels. Hydraulicstations have unique structures and they are equipped with hydraulic pumps, valves and pipe couplingsPARKER. Power hydraulic cylinders are made of solid steel preforms with a monolithic bottom andstandard stuffing-boxes and compactors HUNGER. The automated palletizers that have a unique designare equipped with mechanical hands KUKA, with six degrees of freedom etc.

    Brick plants EMACO GROUPmanufacture materials of European and/ or E.U. standards.

    The machinery of the plants EMACO GROUPcan be supplied in different types of assembling:

    complete (automated production), medium (semiautomated production),

    minimal (great part of the production is manual).

    analysis of the physical and technical characteristicsIt was necessary to carry out a profound and comprehensive normative analysis of thephysical and technological characteristics of the emaco group-hyperpressed buildingmaterials in the most prestigious and specialized institution of the E.U....

    investigationsintheVNIISTROM(Building

    MaterialsResearchInstitute)oftheE.U.

    In 1990 in the E.U. Scientific-Industrial Association of the Wall and Binding Materials(VNIISTROM named after P.L. Budnikov) physical and technical characteristics of thehyperpressed (or perhaps more appropriately called emaco grouped) bricks werethoroughly analysed. The bricks were made of the compression mixture of the followingcomposition:

    limestone shellrock screenings 84%(limestone natural strength is 30 kg/cm);

    gray portland cement 7%(portland cement type 300 (30));

    potable water 8%;

    The results of the analysis of the physical and technical properties of the solidhyperpressed brick and its brickworkare listed below :

    resistance (according to the State Standard GOST 379-79):According to resistance and bend, the bricks correspond to the type 250;

    is manu

    icalro oun a

    racteristicg ous an

    oing T

    ic pumpe orms

    ate parees o r

    o Europ

    supp ies

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    density (of the dry brick):2,19 g/cm3 0,19 g/cm3 higher than the density of the silicate brick;

    water absorption (according to the State Standard GOST 7025-78 ):Water absorption: 4,7 4,8%, less than that of the ceramic and silicate brick

    heat conductivity (according to the State Standard GOST 7076-87 ):Heat conductivity: 1,08 1,09 V/m K-grade, higher than that of the ceramic brick, similar to thesilicate brick ;

    structure (microscopic and X -ray phase analysis):A porous brick, with isolated pores, the size of big pores: 0,2 0,3 mm, of the small ones: 0,03 0,07 mm; the main phase is calcite; the average size of the basic mass of the grains is: 0,1 0,3mm.

    The durability of the solid brickwas estimated and the following results were received:

    frost resistance (according to the State Standard GOST 7025-78 facing wall materials) :It is determined that a brick made of the limestone screenings has resisted 150 cycles of thealternate freezing and defrosting without losing its weight and without visual damages. Frostresistance of this brick is characterized by the type FRN 150. Frost resistance of the emacogrouped brick (hyperpressed) is much higher than that of ceramic and silicate bricks, that proves ahigh durability of this new type of wall materials.

    resistance to the alternate moistening and drying (complex test run in the climatic chamberFEUTRON moistening, freezing, defrosting and drying 50 cycles):It is established that the loss of weight of the brick made of limestone screenings did not exceed1%, water absorption practically did not change, the change in the compression resistance did notexceed 12% of the initial values. Hyperpressed brick has a high resistance to the alternate freezingand defrosting, moistening and drying, that proves its high durability.

    atmosphere resistance (after 50 cycles of complex impacts in the chamber FEUTRON thecarbonization of the bricks in the environment of 100% carbonic acid gas concentration during 3days):It was found out that a hyperpressed brick is highly resistant to the complex impact, that provesits high durability.

    Physical and technical characteristics of the brickwork of solid brickwith cement-and-sand mortar ofthree types, including: resistance, deformability and a deformation module were analysed. The main briefconclusions:

    Emaco grouped brick can be used for the brickwork of the suporting construction of the buildingswith dry, normal and humid explotation conditions, including outside and inside walls of the livingroms, basements and socles.

    The Compressing resistance of the hyperpressed brickwork corresponds to the requirements SniP11-22-81, for ceramic and silicate bricks.

    The above cited abstracts are from the REPORT ON STUDYING THE PHYSICAL, TECHNICAL ANDCONSTRUCTION CHARACTERISTICS OF THE BRICK AND RECOMMENDATIONS FOR ITS USE, which was

    signed on November 29th, 1990 on behalf of VNPO OF WALL AND BINDING MATERIALS, by GeneralDirector Mr. GUDKOV P.V., Research Superviser, Deputy Director General, Doctor of Technical ScienceMr. AHUNDOV A.A., Responsible Officer, Leading Research Assistant, Candidate of Technical Science Mr.HVOSTINKOV S.I.

    Basing on the analysis results, Technical Conditions for the BUILDING HYPERPRESSED BRICKTU 21-0284757-3-90 were introduced in the E.U. for the first time, it was registered in the StateStandard of the E.U. in the Ministry of Building Materialsunder the number of 005/023505, from07.12.1990(see STATE STANDARDS(GOSTs)).

    QualityofthetraditionalEMACOGROUPlaying

    The comparative tests of the adhesion strength of the ceramic and hyperpressed bricks to the cementmortar, run in accordance with the State Standards GOST 24992-81 (Stone constructions. Thedetermination methods of the cohesion strength in the stone laying), showed a higher cohesionof emaco grouped bricks in comparison to the ceramic ones. (see. Construction in the seismic zones,

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    CNiP-7-81, chapter 12.1).

    mortarandceramicbricks mortarandhyperpressedbricks

    It is a well-known fact that the most appropriatemortar for ceramic bricks were calcimine mortars.The cement discovery and its wide use inconstruction, especially as a liquid stone concrete, led to the total replacement ofcalcimine mortars by the cement ones.

    The adhesion of cement mortars to the ceramicbricks is about 1,45 kg/cm2, enough for thelaying of the II category (normal cohesion withmortar is from 1,20 up to 1,80 kg/cm2).

    A modern range of cement mortars is very wide,nevertheless, in the traditional construction inceramic brickwork a simple cement mortarcomposed by: sand, cement and water is

    generally used.

    Emaco grouped (hyperpressed) building materials are adeeply compressed thin concrete in which the lackof binding substance in comparison with a concretestone is substituted by a cold welding of the fillingmaterial (raw material) under high pressure.

    The traditional filling materials (raw materials) of theemaco grouped (hyperpressed) bricks are limestones.Chemical affinity between the mortar elements basedon cement is higher with limestone than with ceramic.

    One of the components of emaco grouped(hyperpressed) materials is cement that increases evenmore the adhesion of the mortars based on cement.

    The increased adhesion of cement mortars to the

    emaco grouped brick is about 2,53 kg/cm2, more thanenough for the I category brickwork (normal cohesionwith the mortar is more than 1,80 kg/cm2).

    BindingstrengthwiththemortarSNIPP781

    In the E.U. Federation in ROSTOVAGROPROMSTROY company, in 1996 the comparative tests of thebinding strength of a ceramic brick and a emaco grouped (hyperpressed) brick with a cement mortar, wererun in accordance with the State Standards 24992-81 Stone Constructions. Methods of strengthdetermination in the stone laying at the age of 14 days. A cement mortar with a strength of 100kg/cm2, at the age of 28 days was used.

    Bindingstrength

    of

    the

    ceramic

    and

    hyperpressed

    bricks

    with

    amortar

    nameexperimental According SNIP P-7-81 (14 days)

    (14 days) (28 days) first category second category

    Ceramic brickof the semi-dry formation

    1,23 kg/cm2 1,60 kg/cm 2 > 1,80 kg/cm2 1,20-1,80 kg/cm 2

    Ceramic brickof the plastic formation

    1,45 kg/cm2 1,88 kg/cm2 > 1,80 kg/cm2 1,20-1,80 kg/cm2

    emaco groupedbrick, smooth

    2,53 kg/cm2 3,28 kg/cm2 > 1,80 kg/cm2 1,20-1,80 kg/cm2

    emaco groupedbrick, with incisions

    2,87 kg/cm2 3,73 kg/cm2 > 1,80 kg/cm2 1,20-1,80 kg/cm2

    Thus, the binding strength of smooth emaco grouped (hyperpressed) bricks to cement mortar is 75%higher than that of the ceramic bricks. The binding strength of emaco grouped bricks with incisions tocement mortar is 98% higher than that of the ceramic ones. Conclusions of theROSTOVAGROPROMSTROY:

    Emaco grouped brick based on shellrock according to the binding characteristics to the motar -2,5 kg/cm2 (at the age of 14 days) can be used for the construction of any buildings in seismiczones including for the I category brickwork.

    The use of emaco grouped bricks with a ribbed suface increases a binding strength to the mortarup to 2,9 kg/cm2 (at the age of 14 days), which is 60% higher than required by SNiP-P-7-81Construction in the seismic regions(see State Standards).

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    raw materials for EMACO GROUP plantsraw materials for EMACO GROUP plants ...

    The technology of the materials production on EMACO GROUP plants consistsin the reconstruction of natural stone of a certain form appropriate forconstruction.

    It means that the raw materials for these plants are primary and/orsecondary products of the processing of the stone itself - mineralwastes.

    Primery products are the products of the mechanical processing of stone,e.g.: sawn blocks, gravel chippings and screenings wastes of stoneragging.

    Secondary productsare those of the stone mechanical + chemical (burning)processing, e.g. slags and cement.

    Raw material components of EMACO GROUPplants are:

    screenings a product of primary (+secondary) processing of stone, cement a product of secondary processing of stone, water a universal agent of chemical reactions.

    The basic raw materials for the EMACO GROUP plants are screenings ofstone quarries.

    screeningsofstonequarries

    In stone quarries(where sawn stone blocks, slabs and gravel chippings are produced) there are lots ofscreenings, that is our basic raw material.

    As a rule (with the exception of dolomite and lime powder), the screenings are not used and form

    dusty mountains, polluting the environment especially in the periods of drought and heavy downpours. Theecology of stone quarries always leaves much to be desired. Thus:

    Stone quarry screenings are basicraw materials for the EMACO GROUP plants.

    Ceramiccrushing

    Quite often, ceramic brick production is accompanied by large quantities of low quality bricksaccumulating in the form of ceramic crushing, and claydite production by big quantities ofscreenings.

    Ceramic crushing (ground) is a raw material for the EMACO GROUP plants.

    Concretecrushing

    During the reconstruction of urban districts or after strong destructions , there is a keen problemconcerning the use of the rests of the buildings and constructions. As a rule, it is either ceramic crushing orconcrete blocks crushing. Lately, concrete crushing has been used more frequently.

    Concrete crushing (ground) ia a raw material for the EMACO GROUP plants.

    Blastfurnaceslags

    Blast-furnace accumulationson the territory of metallurgical industrial complexes often become a realproblem requiring an adequate and economically profitable solution.

    Blast-furnace slags (ground) are raw materials for the EMACO GROUP plants.

    Burntgobpile

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    Gob pile accumulations on the territory of mining and processing complexes often become a realproblem requiring an adequate and economically profitable solution.

    Burnt gob-pile (ground) is a raw material for EMACO GROUP plants.

    SolidashwastesofThermalPowerStations

    Now there are thermal power stations, that every year consume from one to three hectares of fertile

    lands by ash dumps, throwing into them from 200.000 to 600.000 tons of solid ash-slag wastes fromcoal burning.

    Solid ash wastes (ground) are raw materials for EMACO GROUP plants.

    The raw material base of EMACO GROUPplants is endless, varied and accessible, and their technology isecologically clean as it produces neither solid nor liquid nor gaseous wastes and as its raw material, it useswastes of other types of production: stone quarries, large brick plants and claydite plants, mining,processing and metallurgical industrial complexes, thermal power stations, coal heating power stations andmineral wastes of many other plants.

    raw material basemineral industrial wastes: screenings of the production of shellrock, limestone, marl,marble, gaize, granular blast-furnace slags, solid ash wastes from coal combustion etc...

    The least capricious and the most noble raw materials for EMACO GROUP plantsare the stone quarry screenings.Its evidentl that different quarries exploit different stones and different stones havedifferent wastes more or less suitable for our plants.

    Screenings of soft stone quarries

    Soft stones for our technology are the stones with the strength of up to 500 kg/cm,

    however the most favourable are the stones with the strengthof up to 300 kg/cm.The most appropriate, as a basic raw material for EMACO GROUP plants, are thescreenings of the following soft stone quarries:

    shellrock, limestone, dolomite, tuff, marble, marl, some types of gaize.

    The screenings of the above mentioned stones are perfect raw materials for EMACO GROUPplants, inthe following composition:

    soft stone screenings a product of primary processing of stone (85%), cement a product of secondary processing of stone (7%), water a universal agent of chemical reactions (8%).

    Exploiting quarries of the above mentioned stones can be found practically everywhere and theirscreenings are a cheap and easily accessible raw material.

    The preferable building materials based on the soft stone screenings are facing bricks in the supportingwalls.

    Screenings of the hard stone quarries

    In the mountainous regions of the Earth there are large accumulations of hard volcanic rocks, such asgranite, basalt, diorite, gabbrodiorite, siltstone and others as well as hard limestones and marbles,dolomitic limestones, etc.

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    Hard stones for our technology are the stones with the strength of more than 500 kg/cm.

    Screenings of the above mentioned hard stones are a good raw material for EMACO GROUP plants,always mixed with soft stone screenings in the following composition:

    hard stone screenings a product of primary processing of stone (51%), soft stone screenings a product of primary processing of stone (25%), cement a product of secondary processing of stone (12%), water a universal agent of chemical reactions (12%).

    The necessity to use hard stone screenings relates to their huge accumulations due to the impossibilityto utilize them by other technologies, except for the technology of EMACO GROUP plants.

    Naturally, the building materials based on the hard stone screenings, have a colossal strength (easilyachieve 750 kg/cm and higher) and their best transformation is the transformation into antiseismic bricks(outside and inside) and sidewalk and road pavers, of the highest strength and erosive resistance.

    Ceramic brick crushing and claydite screenings

    Quite often, ceramic brick production is accompanied by large quantities of low quality bricks accumulatedin the form of ceramic crushing, and claydite production by large quantities of screenings.

    After splitting small ceramic items are a good raw material for EMACO GROUPplants, in the following

    composition:

    small ceramic items a product of primary + secondary processing (60%), soft stone screening a product of primary processing of stone (20%), cement a product of secondary processing of stone (10%), water a universal agent of chemical reactions (10%).

    So, the screenings of claydite production are a good raw material as well.

    The preferable building materials based on ceramic breakage and screenings are both facing bricks andbricks for inner brickwork.

    Rubble piles of destroyed iron concrete buildings

    At the reconstruction of urban districts or after strong destructions there is a keen problem of how to usethe ruins of buildings and constructions.

    The most complicated thing is to separate iron reinforcements and millwork from the rubble of bigconcrete slabs.

    If we solve this problem and can crush concrete rubbles into the fractions of screenings, we can get aperfect raw material for EMACO GROUPplants in the following composition:

    splitted concrete a product of primary and secondary processing of stone (85%), cement a product of the secondary processing of the stone (7%), water a universal agent of chemical reactions (8%).

    This solution is unique as the production of new building materials from ground concrete or bricks can bemade in immediate proximity to the place of new construction.

    Blast-furnace slags

    The accumulation of blast-furnace slags on the territory of metalurgical industrial complexes quite oftenrepresents a real problem which requires an adequate and economically profitable solution.

    Rather often blast-furnace slags contain up to 13-15% of residual iron. A preliminary cleaning of blast-furnace slags from residual iron on the special technological lines is required.

    On the tails of the above mentioned technological lines EMACO GROUPplants are installed.

    When cleaned from the residual iron, the blast-furnace slag is an excellent raw material for EMACO

    GROUPplants, in the following composition:

    ground blast-furnace slag a product of primary and secondary processing (87%), cement a product of secondary processing of stone (5%), water a universal agent of chemical reactions (8%).

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    The preferable building materials based on the purified blast-furnace slag are facing and inside bricks in thesupporting walls as well as sidewalk and road pavers.

    Burntcoal wastes ofmining and processing complexes

    The accumulations of gob piles on the territory of mining and processing complexes frequently become areal problem requiring an adequate and economically profitable solution.

    For the technology of EMACO GROUP plants it is necessary to use old, completely burnt coal refuse (red

    dog).

    After crushing, small coal wastes items are a good raw material for EMACO GROUP plants, in thefollowing composition:

    small coal wastes items a product of primary and secondary processing (60%), soft stone screenings - a product of primary processing of stone (20%), cement a product of secondary processing of stone (10%), water a universal agent of chemical reactions (10%).

    The preferable building materials based on the coal refuse are both facing bricks and bricks for insidebrickwork.

    Solid ash-slag wastes of the Thermal Power Plants.The most efficient heat carrier for Thermal Power stations is coal. Its heating value exceeds the heatingvalue of natural gas more than twice .

    Coal Thermal Power plants have mainly the following wastes:

    carbonic oxide gaseous product of incomplete carbon combustion; 2 carbonic dioxide - gaseous product of complete carbon combustion; volatiles light products of combustion of the dirts with a small quantity of carbon; solid ash-slag wastes products of combustion of dirts not containing carbon.

    As a rule solid ash-slag wastes contain such substances as SiO2 , Al2O3 , CaO , MgO , K2O , Na2O andothers. Among the others, sulfur and its compounds are sometimes present.

    The main part (more than 90%) of it falls at silicon dioxide (SiO2) more than 65% and aluminium dioxide(Al2O3) more than 25%, i.e. at the substances quite appropriate for the technology of EMACO GROUPplants.

    After the coal combustion in the furnace of the electric plant, solid ash-slag wastes are ground up to thegranulometry of screenings and are supplied in pipes by water to the precipitation tanks. The precipitationtanks are artificially dug in the ground tanks, in this case - slag tanks.

    The polluted by many impuruties water gradually oozes into the soil mixing with ground waters and raisingtheir level and the artificial ground reservoirs remain forever filled with ash wastes in the form of fine blackscreenings, dusting and poisoning the atmosphere, soil and rivers.

    It is a real ecological catastrophe for the environment.

    What is the scope of the caused ecological damage?

    Lets speak only about the solid ash wastes.

    Now there are Thermal Power plants which every year consume from one to three hectares of fertilelands by the above mentioned slag tanks, throwing into them from 200.000 up to 600.000 tons of solidash wastes in the form of screenings.

    What is the production cost of this storage for a Thermal Power plant?

    According to the evaluations of the special state institutions of some countries, the cost of such adisposal of solid ash wastes is about 60 euros/ton. 12 36 million euros per year more, as a component

    of the power plant prime cost.

    What should be done? Electric power is vital and coal is the best heat carrier for power plants. Is there anyway out? If there is any, for example in the form of controversial atomic power plants, but it would be inmany years. What should we do now? How can we utilize (completely) these enormous quantities of

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    ecologically damaging and economically expensive wastes?

    The problem of utilizing the solid ash wastes of the power plants is solved by the technology of EMACOGROUPplants.

    The cost of transformation of one ton of solid ash wastes into bricks is 20 euros.

    The cost of the disposal of one ton of solid ash wastes is 60 euros.

    So, to transform each ton of solid ash wastes in our bricks is 40 euros cheaper than to dig them in.

    Thus, if on the output of the solid ash-slag wastes we install a EMACO GROUPplant:

    bricks for inside brickwork are produced (+ profit 10-30 million euros/year); power production cost recedes (+ profit 8 24 million euros/year); never more it will be necessary to dig and fill the precipitation tanks - slag tanks; ecological influence of the plant on the environment markedly improves.

    After crushing, solid ash-slag wastes of the coal combustion are good raw materials for EMACO GROUPplants, in the following composition:

    solid ash-slag wastes a product of primary + secondary processing (70%), soft stone screenings a product of primary processing of stone (20%),

    cement a product of secondary processing of stone (5%), water a universal agent of chemical reactions (5%).

    A natural building material based on the solid ash-slag wastes from coal combustion are bricks for insidebrickwork.

    The raw material base for EMACO GROUPplants is endless, varied and accessible, and their technologyis ecologically clean as it produces neither solid nor liquid nor gaseous wastes, and as its raw material ituses wastes from other types of production: stone quarries, large brick plants and claydite plants, miningand processing and metallurgical industrial complexes, thermal power stations, coal thermal plants andmineral wastes from many other plants.

    composition of the compression mixturecomposition of the compression mixture ...

    The first stage of the technological process EMACO GROUP is the preparation of thecompression mixture. The Preparation Line (LP), included into the equipment ofEMACO GROUP, plants, automatically prepares the compression mixture of theestablished composition, which depends on the type of the material to be produced.

    The compression mixture for the production of the materials EMACO GROUPconsistsof four components:

    main raw materialthe most suitable raw materials are wastes of stone exploitation: limestone,marl, marble etc. (see raw materials);

    cementPortland cement, whose brand, depending on the requirements to the buildingmaterial to be produced, varies from 300 to 500;

    pigmentcommon mineral pigments or improvised ground rocks of the required colour areused;

    waterto avoid undesirable effects, water should be running, portable.

    Based on our working experience, great importance should be given to the cement quality and the waterpurity.

    According to the compression mixture composition, the building materials EMACO GROUP are devidedinto three large categories: wall, pavingand antiseismic.

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    compressionmixtureforwallmaterials

    The recommended composition of the compression mixture for wallmaterials EMACO GROUPis:

    84% - main raw material (e.g. limestone or dolomite screenings)

    7% - cement type Portland 400 (not less)

    1% - pigment (mineral, e.g., red)

    8% - water (running, portable, without salts)

    compressionmixtureforpavingmaterials

    The recommended composition of the compression mixture for pavingmaterials EMACO GROUPis:

    64% - main raw material (e.g., pebble screenings)

    20% - cement type Portland 400(not less)

    1% - pigment (mineral, e.g., green)

    15% - water (running, portable, without salts)

    compressionmixtureforantiseismicmaterials

    The recommended composition of the compression mixture for antiseismicmaterials EMACO GROUPis:

    75% - main raw material (e.g., limestone or dolomite screenings)

    12% - cement type Portland 400(not less)

    1% - pigment (mineral, e.g., red)

    12% - water (running, portable, without salts)

    Curingoftheformedmaterials

    For curing of the materials formed by the Press, the EMACO GROUPtechnology needs neither kilns, norhigh pressure steam chambers, it needs only a warehouse for 7 days with normal environmental conditionsof living quarters (the most favourable is humid environment).

    In 6-7 days the newly formed materials obtain 50-60% of their strength and can be supplied to theconstructors. These materials obtain their full strength on the 28-29th day, which is perfectly realized inthe brickwork.

    If the above mentioned conditions are met the quality of the building and road materials EMACO GROUPare guaranteed by the Seller, in accordance with the Technical Conditions.

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    emaco group-hyperpressing technologyThe creation of natural stone in the form of traditional and antiseismic buildingmaterials, rock face veneers and sidewalk and road paving stones from fine-dyspersated carbonic minerals without baking and adhesives, by the emacogroup-hyperpressing (bilateral hyperpressing) method...

    The building materials production technology is carried out by the machineryof the EMACO GROUP (THP) plants, which fulfills a emaco group-hyperpressing technological process.

    The production of the materials by reciprocal friction of fine-dyspersatedparticles under high pressure from both sides providing their effective "coldwelding", is called a "emaco group-hyperpressing" method (bilateralhyperpressing).

    Depending on the nature of the substance, its dispersity, value and dynamicsof the development of pressure and other factors, the manufactured materials

    have different physical and technical properties.The building materials production process by the method of unilateralhyperpressing of the compression mixture is significantly activated by addingof binding additives and by hyperpressing of the mixture from two sides.

    The adding of some cement to fine-dyspersated mineral substances, and thenecessary compressing pressure (for the recreation of natural stone) and thedepth of minerals grinding considerably decreases that leads to a considerablecheapening of the equipment and its maintenance.

    The activation of the cement chemical activity with fine-dyspersated mineral environment by bilateralpressing under high pressure predetermines a higher level of homogeneity of the newly formed materials

    both in the process of their formation in the molds and at their curing.Emaco group-hyperpressing technology (bilateral hyperpressing) on the EMACO GROUP (THP) plantsimplies the following stages of the technological process to be made with the compression mixture:

    preparation of the activated compression mixture (preparation lines); formation of the materials (bilateral hydraulic presses); well ordered palletization of the materials (automated palletizer); curing of the newly formed materials (warehouses);

    predetermining both: the composition of the plants equipment, and the proper conditions of themineral raw materialto be used.

    Qualityguarantee

    of

    the

    manufactured

    materials

    The quality of emaco group-hyperpressed building and paving materials is guaranteed under the followingconditions:

    purchase of the equipment in sufficient composition; use of the raw material recommended by the manufacturer; use of the correct composition of the compression mixture; proper curing of the newly formed materials.

    In spite of the evident simplicity of the technological process of the building materialsproduction by the emaco group-hyperpressing method, the quality of these materials directly

    depends on the correct fulfilment of this technological process at each specific plant.

    questions and answers

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    See building materials.

    Determine the plant productivity from the point of view of sales and availability funds.

    The productivity of our plants can be seen on brick plants.

    Determine the productivity from the point of view of investment funds.

    To check the prices and the composition of the plant equipment, please, contact our office Italy.

    The equipment of the plant is offered in "complete", "medium" and "minimal" composition.It is very important to see profitability of the plants and calculate the profitability of the plantin your real conditions.

    Besides, we suggest the Italian State Financing.

    EM

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    EMA O

    R

    UP

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    .

    .

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    ..

    ..

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    Masonry Blocks

    crea e e oo ...

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    Golden SandToodyay CarbonBuff Sunset RedTelfer

    JoondalupGrey Parchment

    100mm Wide Series Full & Half HeightFull Length Three Quarter Half Quarter

    300/P 10.73 600/P 10.74300/P 10.71

    400/P 10.72

    184/T 256/T 400/T 625/T

    Full Length Three Quarter Half Quarter Lintel

    200/P 10.02150/P 10.01 300/P 10.03 300/P 10.04 300/P 10.12

    87/T 115/T 182/T 271/T 188/T

    90 Return Angle 135 Int. Angle 135 Ext. Angle 120 Ext. Angle 120 Int. Angle

    96/P 10.26 72/P 10.135IA 72/P 10.136EA 96/P 10.120EA 72/P 10.122IA

    52/T 76/T 76/T 64/T 84/T

    Full Length Three Quarter Half Closer

    300/P 10.83 400/P 10.84 300/P 10.85 400/P 10.86

    147/T 182/T 285/T 234/T

    Full Length Three Quarter Half Closer Sill Bullnose

    160/P 10.32120/P 10.31 240/P 10.33 192/P 10.36 240/P 10.33S 240/P 10.33R

    66/T 87/T 137/T 107/T 138/T 137/T

    Colours

    The following stock items are available in grey and parchment

    10.01,10.31, 15.01, 15.31, 20.01, and 20.31.

    All other products and colours are made to order.

    Specifically designed blocks can be manufactured to individual

    custom profiles, depending on mould configuration and

    quantity required.

    Masonry Blocks

    0

    U

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    Blockwork Dimensions Chart

    ORMAT SIZE: 400 x 100, 150, 200, 300 x 200 ANUFACTURING SIZE: 390 x 90, 140, 190, 290 x 190

    x W x H (mm) 400 x 100, 150, 200 x 100 x W x H (mm) 390 x 90, 140, 190 x 90

    No. ofBlocks Lengt pen ng

    Heig tNo. ofBlocks Lengt Open ng

    Heig t

    1Coursing Coursing

    1Coursing Coursing

    1 390 410 100 200 151 6090 6110

    11 490 510 151 6190 6210

    11 590 610 15 6290 6310

    13 690 710 16 6390 6410 1600 3200

    2 790 810 200 400 161 6490 6510

    21 890 910 161 6590 6610

    21 990 1010 16 6690 6710

    23 1090 1110 17 6790 6810 1700 3400

    3 1190 1210 300 600 171 6890 6910

    31 1290 1310 171 6990 7010

    31 1390 1410 17 7090 7110

    33 1490 1510 18 7190 7210 1800 3600

    4 1590 1610 00 800 181 7290 7310

    41 1690 1710 181 7390 7410

    41 1790 1810 18 7490 7510

    43 1890 1910 19 7590 7610 1900 3800

    5 1990 2010 500 1000 191 7690 7710

    51 2090 2110 191 7790 7810

    51 2190 2210 19 7890 7910

    53 2290 2310 20 7990 8010 2000 4000

    6 2390 2410 600 1200 201 8090 8110

    61 2490 2510 201 8190 8210

    61 2590 2610 20 8290 8310

    63 2690 2710 21 8390 8410 2100 4200

    7 2790 2810 700 1400 211 8490 8510

    71

    2890 2910 211

    8590 861071 2990 3010 21 8690 8710

    73 3090 3110 22 8790 8810 2200 4400

    8 3190 3210 800 1600 221 8890 8910

    81 3290 3310 221 8990 9010

    81 3390 3410 22 9090 9110

    83 3490 3510 23 9190 9210 2300 4600

    9 3590 3610 900 1800 231 9290 9310

    91 3690 3710 231 9390 9410

    91 3790 3810 23 9490 9510

    93 3890 3910 24 9590 9610 2400 4800

    10 3990 4010 1000 2000 241 9690 9710

    101 4090 4110 241 9790 9810

    101 4190 4210 24 9890 9910103 4290 4310 25 9990 10010 2500 5000

    11 4390 4410 1100 2200 251 10090 10110

    111 4490 4510 251 10190 10210

    111 4590 4610 25 10290 10310

    113 4690 4710 26 10390 10410 2600 5200

    12 4790 4810 1200 2400 261 10490 10510

    121 4890 4910 261 10590 10610

    121 4990 5010 26 10690 10710

    123 5090 5110 27 10790 10810 2700 5400

    13 5190 5210 1300 2600 271 10890 10910

    131 5290 5310 271 10990 11010

    131 5390 5410 27 11090 11110

    133 5490 5510 28 11190 11210 2800 5600

    14 5590 5610 1400 2800 281 11290 11310

    141 5690 5710 281 11390 11410

    141 5790 5810 28 11490 11510

    143 5890 5910 29 11590 11610 2900 5800

    15 5990 6010 1500 3000

    4 0

    7

    1

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    Components of a sand-lime block production plant

    Basic-Data for 1-press plant

    Additional equipment to the press line

    Format: NF 2 40 x 71 x 155 mmTool: 2 rows 8 blocksCycle time: 12,5 s (average capacity per year)Working time: 300 days/year24 hours/dayCapacity: approx. 33.000.000 blocks/year

    510 blocks ^ 1 m

    Components of a sand-lime block production plant

    Technical equipment

    1. Sand receiving bunker

    Length 8 000 mmDepth 3 200 mmHeight 2 650 mmpassable by lorry, with protectionMesh size 100 x 250 mm

    in welded 6 mm sheet steel construction

    2. Bunker discharge conveyor

    Axle distance 8 400 mmConveyor width 800 mmConveying speed 0,4 m/sConveying capacity 270 t/hMotor capacity approx. 11 kW

    3. Conveyor between sand silo and sieving station

    Axle distance 64 900 mmConveyor width 650 mmConveying speed 1,68 m/sConveying capacity 270 t/hMotor capacity approx. 30 kW

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    impact and sliding surface and RACO adjusting unit.

    10. Primary mixer

    equipped with:Mixer RV 23Useable capacity 3 000 l

    Components of a sand-lime block production plant

    Drive plate 2 x 18,5 kWTabulator 90 kWDischarge 4 kW

    Double-chamber silo for different sands

    Dosing system for sandContainer weighing machine for sandDosing system for quick limeContainer weighing machine for quick limeFluid weighing machine

    11. Lime silosCapacity 55 mInternal diameter 2 900 mmCylindrical height 7 600 mm

    conic inclination 60 2 pieces

    equipped with:

    - check opening in the silo cover- breaking cone- filling pipe- filter flange- pressure protection device

    12. Conveyor between mixer house and reaction vesselAxle distance 59 400 mmConveyor width 650 mmMotor capacity 30 kWConveying capacity 270 t/h maxConveying speed 1,68 m/s

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    13. Reacting vesselUseable volume 60 mDiameter 3 300 mm

    Interior coated

    Components of a sand-lime block production plant

    Reactor base discharger

    Diameter 3 300 mmin Zentex constructionSpeed max. 6 min.-1Motor capacity 11 kWSilo height approx. 8 m

    14. Double shaft mixerWidth 1 000 mmLength 4 000 mmCapacity 15 kW

    15. Conveyor between secondary mixer and press

    Axle distance 11 000 mmConveyor width 650 mm

    Motor capacity 3 kWConveying capacity 60 t/h maxConveying speed 0,66 m/s

    16. Pick-out electro-magnetDimensions 1 x b = 618 x 678 mm, h = 204 mmRing screw MI 6Capacity N = 2,5 kWVoltage U = 220 VFrequency f = 50 60 Hz

    Mass m = approx. 350 kg

    17. Transfer platforms

    17.1 Loaded wagon platform (for 5 wagons)Traverse drive 8 kWWagon shift drive 2,2 kW

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    Transmitted to a container from which it is returned to the process through thereacting vessel.

    24.1. Collection conveyor below press

    Axle distance 8 000 mmConveyor width 650 mmConveying speed 0,66 m/sConveying capacity 60 t/hMotor capacity 3 kW

    24.2 Conveyor to spillage conveyor

    Axle distance 13 100 mmConveyor width 650 mm

    Conveying speed 0,66 m/sConveying capacity 60 t/hMotor capacity 3 kW

    24.3 Spillage conveyor to spillage container

    Axle distance 49 935 mmConveyor width 650 mmConveying speed 1,31 m/sConveying capacity 145 t/hMotor capacity 11 kW

    24.4 Spillage container

    Diameter 3 200 mmwith outlet funnel 500 mmSilo height 9 900 mm

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