Reconstruction of factories ZHBI in minifactories for maloetazhnogo buildings

The industry of precast concrete created in the USSR in fiftieth — the seventieth years, on volumes of production had no equal in the world. It has allowed to carry out huge volumes of housing and industrial building.
However orientation to cheap housing accommodation has led to that its quality has appeared unsatisfactory both from items of the today’s consumer, and from an item of the state which is compelled to bear expenses under the population grant, first of all, on housing accommodation heating, in separate regons components to third of budget.

Teplopoteri because of "cold" walls, poor quality of windows, bad warming of overlappings, etc. in 2—4 times exceed similar teplopoteri in houses foreign proektirovki for close climatic zones. And if the problem of "warm" windows, overlappings, ladder marches can be decided without basic changes in a building design walls require separate decisions. As is known, the basic variant of walls in Russia are single-layered panel (block) nesushche-heat-shielding walls from keramzitobetona with volume weight 1400—1600 kg/cubic metres

Such walls have the bearing ability, allowing building of many-storeyed buildings, however, at economically expedient thickness of walls they do not meet requests of norms on a heat-shielding.

Use for walls of the cellular concrete, all extending the last years, only partially solves heat-shielding problems. So, at a thickness of walls of 60 sm, that, in our opinion, is on border of admissible thickness, the cellular concrete which volume weight does not exceed 600 kg/cubic metres Prochnostnyie of the characteristic of such material should be used skeleton uses allow building of buildings not above two floors, or.

The mass decision of a design of a wall abroad — the three-layer wall including bearing layer, usually, from heavy concrete, a heater from expanded polystyrene and a finishing layer — arhbeton.

Transition to issue of such panels at factories ZHBI requires not only reorganisations of technological process, but also significant investments on manufacturing of new park of forms.

In essence, in any case reconstruction of the enterprises of the precast concrete which technological level corresponds to 70-80 years is necessary.

Reconstruction can be made in various directions and entirely depends from potrebnoy in region of the nomenclature of designs, and optimum orientation on maloetazhnoe building (except, maybe, factories ZHBI of Moscow and S.-Petersburg), in our opinion, is.

It is known, that maloetazhnyie, including individual houses — the basic direction of housing construction abroad.

In Russia — maloetazhnoe building with system of the bank mortgage and the state grants can become the basic direction of an exit of the country from system crisis.

By concept working out maloetazhnogo buildings should be decided as the general questions — cost reductions of production and, first of all, stenovyih materials; the maximum failure of use power-intensive and dalneprivoznyih materials; failure of armature use in the majority of items for walls, partitions, the bases, overlappings, a roof; workings out of the listed products, allowing beskranovyiy installation — and are conducted concrete workings out within the limits of the offered concept.

Development maloetazhnogo housing constructions at the present stage has put forward a problem of system engineering of the building, the consumers focused on various categories and considering:
  • The features of an investment policy stipulating necessity of decentralisation, decrease in absolute value and payback time kapvlozheniy, reinvestment cycle minimisation;
  • Change of a pattern of consumption of the raw materials, connected with sharp rise in price power-intensive and dalneprivoznyih materials (cement, artificial porous fillers, high-quality fillers of firm breeds);
  • Limitation of an infrastructure of a building complex in many regions of Russia and the necessity of realisation connected with it as mechanised, and completely manual installation of buildings;
  • Change of the standard documentation and, first of all, toughening of requests to protecting designs.

As in available housing formation the increasing role will be played by personal means of citizens, the major problem is stabilisation and dwelling depreciation that can be reached, first of all, at the expense of depreciation of construction materials and items and a possibility of realisation of the basic volume of civil and erection works by own forces of builders.

In NPTS «Estroyteh» system "THERMOBLOCK" is developed for building maloetazhnyih apartment houses from the fine-grained concrete which distinctive features are:
  • Use as a unique filler for concrete of the cheapest local material — building sand or industrial wastes replacing it;
  • Possibility of realisation of a wide spectrum architecturally-planirovochnyh decisions, including stage-by-stage building of dwelling by several generations;
  • Application of the unified nomenclature of the modular items including over 80 % (on volume of a completed building) the cheap piece not reinforced items and supplying possibility as mechanised, and completely manual installation;
  • Inclusion in structure of the complete set of items of elements of an accomplishment of territory and an architectural finishing of buildings;
  • Use vibropressovaniya as base technology for production of all nomenclature melkoshtuchnyih items; — a possibility of the organisation of production of complete listed products in the conditions of the small productions characterised by a low capital intensity and fast (6—12 months) a recoupment.

The nomenclature of the concrete items produced vibropressovaniem is developed: base blocks, base pillows, blocks of outside walls (thermoblocks), blocks of internal walls and partitions, blocks of overlappings, a tile, items for an accomplishment and furnish (a detail of fencings, trotuarnaya a tile, gazonnyiy a border, plates and blocks finishing). Besides, in the nomenclature are included produced on traditional technology with consolidation of cement-sandy mixes on vibroploschadke the reinforced items: plates of overlappings, crosspieces, L-shaped beams of overlappings for manual installation of buildings, steps.

Feature vibropressovaniya is possibility of manufacturing of items without forms, and also use of ordinary career (river) sand without preliminary processing — sinks, fraktsionirovaniya, drying, including, and the small sand which usually are not applied in production of concrete.

Indicated above an item are produced of sandy concrete with various degree porizatsii:
  • Especially dense vibropressovannyih (a tile, accomplishment and furnish elements, a thermoblock cover);
  • Pressed from lean mixes with regulated vozduhovovlecheniem (blocks of internal walls, partitions and overlappings);
  • From moderately rigid mixes formed on vibroploschadke without prigruza (beams, panels of overlappings, crosspieces, steps);
  • mineralizovannoy cement technical the foams (MT), including to 95 % of involved air (plitnyiy a heater, thermoblock filling);

Sand — a unique filler in sandy concrete — is the cheapest and everywhere widespread construction material. Cost of sand ex works for the majority of regions of Russia in 2—3 times below cost of rubble of firm breeds and at 5-10 time below cost keramzitovogo gravel.

A number of new technical decisions is developed for realisation of offered system of building.

One of such workings out is stenovoy the block from sandy concrete — the thermoblock (the patent of the Russian Federation # 2030527), entitled all system of building.

Necessity to supply heat-shielding properties of protecting designs does not allow to produce stenovyie blocks of sandy concrete — a material having low heat-shielding characteristics. Application keramzitobetona, polistirolbetona and other concrete on an easy filler would lead to significant rise in price of items, complication of technological process: to additional warehouses, giving paths to transport of expensive fillers from other areas, etc.

Thus, the primary goal for concept realisation maloetazhnogo buildings in the field of designs is working out stenovogo a material from the sandy concrete answering as requests on bearing ability, and teplotehnicheskim to requests. It is especially essential, that stenovyie and partitions make materials to 70 % of total amount of the concrete items used at building of buildings.

The thermoblock — an item with the standard sizes 390×190x188 the mm, including a cover from high-strength dense sandy concrete and a filler from MT in volume weight of 150-200 kg / cubic m (fig. 1).

The cover is produced vibropressovaniem on the serial home equipment used for manufacturing of blocks SKTS.

On these vibropressah (the base variant «Vibroform-1») is simultaneously produced 5 covers which on a following technological post «on crude» are filled in with MT and after packing are directed to the chamber teplovlazhnostnoy processings.

Items which at volume of 14 litres 13,2 kg weigh are as a result received. For comparison — slot-hole block SKTS-1 similar in the sizes from sandy concrete weighs 27 kg. Bearing functions in the thermoblock are executed by a cover from sandy concrete, heat-shielding — a filler from MT.

Use of MT as a filler allows to exclude application in technology of other base materials except cement and sand.

Division of functions in the block allows to increase, on the one hand, its bearing ability increase of mark of concrete of a cover (for mark of concrete M400 accounts of nine-floor houses from thermoblocks), with other are executed — to increase it teplotehnicheskie characteristics, using easier in comparison with MT fillers, for example, penogips with volume weight 30—50 kg/cubic metres

But also in the offered variant of a wall from thermoblocks have high heat-shielding properties. On this indicator the wall of 38 sm is equivalent in the thickness 142 sm of a bricklaying or 95 sm keramzitobetona and satisfies teplotehnicheskim to requests of norms at temperature of outside air-48°S.

The design of walls from the thermoblocks, containing only lozhkovyie numbers that is supplied with availability of grooves on not obverse side of the thermoblock is developed. These grooves at assemblage in a laying with bandaging on the half-block in the next numbers appear opposite one another. It allows to use for connection of the next numbers of a laying P-shaped elements from armaturnoy a wire, easily loaded in MT (fig. 1).

The laying appears reliably tied up at installation armaturnyih elements through two numbers in the third.

The offered technology represents unique possibilities of furnish of blocks.

Practically without investments, only at the expense of change of the form of a matrix, it is possible to receive relief blocks, blocks with a curvilinear and broken outline of a forward side; use of pigments allows to receive colour blocks, colouring of an outside side of blocks by the colour kolloidno-cement glue, included in a work cycle is possible; reception of the "chipped" invoice of an obverse side of the block practically indistinguishable from a natural granite, limestone is possible at manufacturing of the coupled blocks with their subsequent splitting (the technology and the equipment is developed for splitting). The offered design of the block allows to realise a laying on glutinous structures with the hidden seams and to hide a horizontal seam, special updating of the thermoblock is executed.

The updating of the thermoblock which does not have bridges of a cold at a single-row laying is developed for regions with a hot climate.

The equipment and technology is developed for manufacturing and razlivki mineralizovannoy the foams, including the generator of MT and the system for automatic pouring of the dosed out portions of MT simultaneously in five covers, received post termination a formation cycle.

MT manufacturing includes suspension preparation (cement + water + penoobrazovatel) and saturation by its air under pressure in one unit. The homogeneous composition stable against subsidence which are easily giving in razlivke is as a result received. MT use allows to realise reliable coupling of a filler with a cover also including cement as the knitting.

Table 1.

Material

Durability (concrete mark)

Morozostoykt

Water resistance

Volume weight, kg / cubic m

Vt / ° C The block — a timbering

M400

F200

W6

2300

— Filler — MT

—

—

—

150

0,05

Table 2.

## pp

The name stenovogo a material

The sizes, mm
—
Item cost, rbl.

Cost cubic m of items, rbl.

Volume weight of a material of kg / cubic m

Toschina walls on SNiP, sm

Kt.s

Led to the thermoblock toimost 1 cubic m, rub

Adjusted present value factor

1.

Brick

250×120x65
—
2,2

1100

1700

142

3,74

4100

5,1

2.

Keramzitobeton

390×190x188
—
16,0

1140

1200

95

2,50

2850

3,5

3.

Foam concrete

588×288x200

900

700

74

1,95

1750

2,2

4.

Gazobeton

600×300x200

950

600

60

1,58

1400

1,8

5.

The thermoblock (MT filler)

390×190x188
—
11,2

800

MT 150

38

1,00

800

1,0

In table 1 characteristics of the materials used at manufacturing of thermoblocks, in table 2 — comparative cost stenovyih materials are resulted at a thickness of the walls supplying a heat-shielding required by norms. Source: «the Building expert» #11 (2003)

It is introduced: on November, 27th, 2003

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